Manufacturing

*In Progress*

Operation Mechanism Manufacturing

Tie Rod Wheel Connections

1. Find and purchase parts to connect the wheel rim to the tie rod system.  We used the following components from McFadden Dale Industrial Hardware:
• 2--Coupling Nut Z (3/8-24)

• 2--Rod End Female R.H. w/STD (3/8-24)

• 1--All Thread PLN (threaded rod) (3/8-24)

*Picture*

2.  Find the appropriately sized axle to fit the coupling nut purchased in step 1.  This will require having the right diameter and the right threading measurements.  There are special tools to measure threading, and an example is shown below.  Note that these may be in both english and metric units.  Then, find appropriately sized cones and locknuts for the axle previously selected. We did this at "Bike Saviours."

This website has some good information on what these parts are:  http://sheldonbrown.com/cone-adjustment.html.  We didn't use the other parts mentioned for simplicity.

3.  Find a used wheel rim.  Make sure it is in good shape by examining the metal and checking for balance.  To check for balance, add it to an apparatus (shown below) and rotate freely.  If the tire moves horizontally when rotating, the frame is bent.


4.  Using the wheel rim, take out the old components.  Remove the ball bearings.  Clean out the inside where the ball bearings were.  Add grease to the ball bearings themselves AND inside of the rim where the ball bearings were.  Replace ball bearings.

Cleaning the inside of the rim.                                          Picture of the grease we used.  

Applying grease to the inside of the rim.  

Applying grease to the ball bearings.  

5.  Carefully put in axle and add components to one side of the axle

6.  Use the components on the other side of the axle to properly secure the axle.  See a bicycle mechanic for more information (it should be tight enough not to wiggle but loose enough that the axle can freely rotate).

  7.  Add components purchased during step 1 to the axle.

Another good website related to these manufacturing procedures is: http://www.pinkbike.com/news/Tech-Tuesday-Cup-and-Cone-Hub-Rebuild-2011.html

Hand Crank and Attachment Parts

Gear System and Back Wheel

Frame Manufacturing

 *in progress ...