Project Run Down

For those of you that only want the Engineering Fact Sheet

Objective: Build Kaydee a small road bike such that she can reach the brakes while riding.

Requirements:
· Kaydee must be able to reach handle bars and breaks comfortably while riding
· Road bike must look cool and be safe to ride.

Schedule:
The original idea for this project came about early September. September was spent brainstorming ideas and Ian practicing welding thin walled aluminum tubes into sculptures.

October 1- 15 – Modeled bike in Catia *

Citia is a high dollar software 3-D modeling tool. This software was used to determine the correct geomery for the bike.

October 15-31 – Disassemble Trek 1000

November 1-15 Build jig

November 15-20 Weld frame

Thanksgiving Break For Kaydee, Ian plans to keep working on building the bike frame

December – Paint new frame hot pink

December – Re-assemble new bike

December 25 Kaydee get’s new bike as Christmas present

January – Adjust and test ride bike.

February 15 – First test ride – Seattle Cascades Chilly Hill Bike Ride

February – July – Kaydee (and hopefully Ian) train for Seattle to Portland Bike Ride –
Make adjustments to bike

July – Seattle to Portland Bike Ride

Budget:
Parts:
Most of the parts for the bike will come from my old Trek 1000, 2004 road bike. Total cost – Free – However, I do not have a bike to ride until this bike is successfully finished.

· Aluminum Bike tube for new frame - - $120
· Pieces that hold back tire (Drop outs) – 20.00
· Threaded bottom bracket – Included in tube set
· Break caliper – $5.00
· Parts for Jig – $25.00 – This includes nuts bolts scrap steal, 2X3 ft piece of plywood and

some other gadgets laying around Ian’s garage. Things in garage include mid-steal angle

Tools:
· Tig welder – Ian bought off craigslist for $1000.00
· Plasma Cutter – Ian borrowed from Ben
· Argon gas – $40.00 per tank
· Chain break – $15.00
· Metric Hex Wrench Set – $7.00
· Crank arm removal tool – $15.00

Labor: Free – There may be a professional bike fitting after the bike is constructed .

Total Cost: Does it really matter? It is the journey that counts

Key Players:

Kaydee – The bike rider and blogger

Ian – The welder and design engineer

Approach:
My 2004, well used, Trek 1000 road bike will serve as the inspiration, jig, and all parts except for the frame. Ian will weld me a new frame using 7005 aluminum butted tubes. All dimensions of the frame will remain the same except the angle of the top tube will be reduced and the head tube will be shortened. This will shorten my reach from the seat to the hand bars.

Key Assumptions:
Ian can weld 7005 Aluminum – He has never triedI am sure I will think of others as the project progresses.