Skiwi build

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tryhard
tryhard
222 posts
222 posts
2 Nov 2014 12:40pm
My aim is this build is to recycle as much as I can.I wanted to use the tubes I harvested from my bike but the gauge is only 1.5mm -too thin so I forced on section inside the slightly larger section


tryhard
tryhard
222 posts
222 posts
2 Nov 2014 12:44pm
The next job was to cut a profile in this section which will fit around the bearing assembly.I bought a bimetal hole saw which was 2 mm larger than the headstock (which I have discovered is the correct description) but I think this won't make any difference once it is welded


tryhard
tryhard
222 posts
222 posts
2 Nov 2014 12:46pm
Because I only have the section shown in the previous photo to use,I decided to use an off cut section as a mock up and this is the result


tryhard
tryhard
222 posts
222 posts
3 Nov 2014 3:40pm
tryhard said..
The next job was to cut a profile in this section which will fit around the bearing assembly.I bought a bimetal hole saw which was 2 mm larger than the headstock (which I have discovered is the correct description) but I think this won't make any difference once it is welded




tryhard said..
Because I only have the section shown in the previous photo to use,I decided to use an off cut section as a mock up and this is the result




My next job is to cut down the 75x75 Hollow square section to make the sections attached to the spine.My available tools are my angle grinder with a metal cutting blade,a hacksaw or an oscillating saw. My preference is to use a power tool to avoid RSI.Which one should I use?



tryhard
tryhard
222 posts
222 posts
4 Nov 2014 5:03pm
That was a question for the been there done that group.I would like your advice.While I'm at it you will have noticed the spoked wheel I had planned to use for the front wheel.In other discussions on this forum about wheels etc comments have been made that bicycle wheels are not up to the stresses likely to be inflicted through lateral forces.What advice do you have about that issue?
Test pilot 1
Test pilot 1
WA
1430 posts
WA, 1430 posts
4 Nov 2014 5:51pm
tryhard said..
That was a question for the been there done that group.I would like your advice.While I'm at it you will have noticed the spoked wheel I had planned to use for the front wheel.In other discussions on this forum about wheels etc comments have been made that bicycle wheels are not up to the stresses likely to be inflicted through lateral forces.What advice do you have about that issue?


Use the angle grinder as you would have more control. In fact you could clamp the angle grinder to a bench/table and control your work even more. Bicycle wheels are ok for front wheels as the lateral forces you are referring to normally only occur on the rear wheels.
tryhard
tryhard
222 posts
222 posts
5 Nov 2014 2:04pm
My next question is how do I flatten the mast tube to 50mm? Focussed violence again? And do I need to shape a lip around the top edge or is that not needed?Thanks Testpilot for your tip about the angle grinder.The H&S people would have a fit if they read this.I guess the angle grinder would then be like a table saw
Clemco
Clemco
430 posts
430 posts
6 Nov 2014 6:46am
To flatten the tube to a 50mm wide oval place a 50 x 50 (heavy wall) square section inside the round tube and put it in a large press. I take it down to an engineering workshop to get this done. Usually charge me a few beers.
Hiko
Hiko
1229 posts
1229 posts
6 Nov 2014 2:20pm
A good vice will flatten your tube unless it is exceptionally thick Flaring the top of the tube is kinder to your mast than a
sharp edge If you cut a slot in a piece of metal bar and round the outer edge of the slot you can work around the lip and flare it well
tryhard
tryhard
222 posts
222 posts
11 Nov 2014 8:22am
Other distractions have delayed progress sadly. I have harvested some more bits off the mountain bike which I hope to use.The bits shown in the photo are what the bike seat sat on.My idea is to use the tube for the foot pedal assembly.The control shown will allow the inside tube to slide out so I can adjust the length of the foot pedals to suit vertically challenged pilots


Hiko
Hiko
1229 posts
1229 posts
11 Nov 2014 9:08am



Mast step flattened with vice and flared with slotted bar 60x2mm tube
tryhard
tryhard
222 posts
222 posts
13 Nov 2014 8:23am
Here are the materials for my next sub projects-the mast step and the axle assembly.


tryhard
tryhard
222 posts
222 posts
13 Nov 2014 8:26am
According to Clem's instructions I marked and cut the 75x75 box section on the diagonal from 25mm to 50mm


tryhard
tryhard
222 posts
222 posts
13 Nov 2014 8:27am
And ended up with the 2 halves which I tidied up a bit following my rather brutal surgery


tryhard
tryhard
222 posts
222 posts
13 Nov 2014 8:35am
And the next job is the cut a 45degree bit of the fat ends which are marked as shown.A job for after work tonight.Beats watching telly and day. I think my neighbour has a vise which I can use to flatten the mast step tube down to 50mm.I had thought of another way which was to stick a piece of wood inside the tube and run over it under my truck's front wheel but somehow I think this idea would not end well


tryhard
tryhard
222 posts
222 posts
14 Nov 2014 8:49am
I cut the bits off using my other trusty tool


tryhard
tryhard
222 posts
222 posts
14 Nov 2014 8:50am
Another dry fit


tryhard
tryhard
222 posts
222 posts
14 Nov 2014 8:52am
Now I want to cut a hole in the apex to fit the spine,so I constructed this jig set up intending to cut the hole with a bimetal hole saw


tryhard
tryhard
222 posts
222 posts
14 Nov 2014 8:54am
But the hole cutter got totally munted.I will cut the hole with the pieces laying flat next time


tryhard
tryhard
222 posts
222 posts
14 Nov 2014 8:56am
The arrival of my rear wheels from the friendly and helpful Wheelco people cheered me up


Test pilot 1
Test pilot 1
WA
1430 posts
WA, 1430 posts
14 Nov 2014 10:21am
tryhard said..
The arrival of my rear wheels from the friendly and helpful Wheelco people cheered me up



That's a .....wheelie....positive note
tryhard
tryhard
222 posts
222 posts
17 Nov 2014 1:59pm
I laid the pieces flat and used the hole cutter


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:02pm
The result was not quite right so scribing and shaping was required.I sanded a pencil down flat along its length and used that flat against the spine sec



tion to get the correct shape
tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:02pm
and tried a dry fit


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:04pm
A dry fit is when you don't froth at the mouth in case you were wondering


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:05pm
A trip to the recycling centre and Bunnings secured this lot.The recycled stuff cost $13


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:06pm
The skis absent their metalware which I have stored away in case it might come in handy some day.My shed is somewhat full of that material I confess


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:08pm
another dry fit


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:08pm
my old handlebar


tryhard
tryhard
222 posts
222 posts
17 Nov 2014 2:09pm
and my foot pedal


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