Tricycle manual Contents
- tools needed - materials needed - cutting the 1 inch square tubes - welding the 1 inch square tubes - cutting the tubes and flats - welding the tubes and flats - mounting the wheels and mudguards - mounting the bicyce frame - result
1
Tools Needed
- Handdrill - Hacksaw - Vice - Square - Grinder - Tape measure - Vile - Welding machine - Hydaulic jack tube bender - Bench drilling machine - Big drill bit for 1� hole - thread maker - Size 8 and size 6 drill bit - Compressor (for painting)
2
Materials Needed Bicycle parts
Metals
- Complete bicycle frame - Mens frame 22” - Complete with: pedals, cranks, BBset, chain chainguard and saddle - Including coasterbrake and freewheel - use 26” wheels - 1 rear wheel and 2 front wheels complete with: - hub, spokes, rim, tube and tire (assembled) - 3 rear mudguards - 1 Kidride headset - 50 bearing balls
Fasteners
- Steel bolts, nuts and washers M8 1” - Steel bolts, nuts and washers M6 1”
- Square tube 1x1x1.2mm 3,5 x 6m - Tube 1”x2mm 1/2x 6m - Tube 1,25”x2mm 1/2x 6m - Flat 2”x3mm 1/2x 6m
Additional
- Welding rods - Grinding disc 1x - hacksaw blade 1x
2x 4x
Paint
- Blue and Yellow - Primer - Filler - Thinner - Sandpaper
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1 package
Cutting the 1� square tubes
1
5
2
6
3
7
- Cut 8 pieces of square tube of 800mm - Both sides at 45 degrees with the square - Cut 4 pieces of 750mm - One side at 45 degrees and one side straight
Use a square for straight cuts Sizes are in millimeters
- Cut 9 pieces of 750mm - Both sides straight
- Cut 1 piece of 325mm - both sides straight - Cut 4 pieces of 220mm - Both sides at 45 degrees - Cut 6 pieces of 140mm - One side at 45 degrees and
4
- cut 2 pieces of 350mm - One side at 45 degrees and one side straight
4
Welding the 1� square tubes 1
Weld a square using the 800mm pieces Make sure the corners are 90 degrees using the quare.
2
Weld the square for the sides of the cage using two pieces of 750mm long with one side cut at 45degrees and one pieces of 800mm for each side of the cage. Make sure the welded piece is square and fits on the bottom square.
3
Weld the two squares made in step two on the bottom square from step 1 and make sure all the corners are square. And that the distance between the two sides is the same at all places.
5
4
Take four of the 750mm tubes with both sides straight and weld two of them on each side of the tricycle (made in the previous step) as shown on the drawing.
5
Take three of the 750mm tubes with both sides straight and the 325mm tube. And weld them on the frame as shown. Two 750mm on the back and one at the front, the 325mm will be placed at the back.
6
6
Take two 800 mm tube with both sides cut at 45 degrees and four pieces of 140mm one side cut a 45 degrees. First weld two frames of one 800 and two 140 pieces beforeWelding them on the sides of the frame as shown, make sure the corners are square.
7
Use the four 220mm pieces as support for the tubes welded on in step 6. One at the front of each side and one at the back of each side.
7
8
Take two 750mm tubes with both sides cut straight and weld them at the bottom of the frame. Make sure the corners are 90 degrees with use of the square.
9
Take the remaining tubes, two 140mm and two 350mm. First weld the 140mmm and 350mm piece together before welding it onto the frame
8
1
Cutting the tubes
- Cut a 440mm long piece from the 1 inch tube. - After cutting make the ends of the tube level using a flat vile and a square
2
- Cut two pieces of 700mm long from the 1inch tube for the handlebars
3
- Before cutting the 1,25 inch steeringtube first place the flats for the steering tube and the 1 inch tube, then measure the distance between the two flats minus the headset. - cut the tube slightly bigger than necessary to give you allowance while making this tube level, it is important the tube is level, use the square to comfirm. (because the bearingcups, and bearings, have to be level as they are a moving part) - To place the bearingcups make the inside of the tube bigger using a round vile.
4
Take the 440mm long 1 inch tube and make a thread for the headset on one side of the tube.
9
Cutting the flats 1
Cut 6 pieces of 3 inch long and 2 pieces 1 inch long
2
Give the pieces the holes as shown in the drawing. If the drillbitt for the one inch hole is nog big enough use the vile tot make the tube fit tthe hole
4x
1x
1x 10
2x
Welding the flats and tubes 1
- Take the four flats with the slot for the wheel axle and mount them on the frame. - Use an axle bar to put the flats in line and to hold them in place while welding.
2
- Weld the flat with only the 1 inch hole on to the 1 inch tube. - Very important to make sure that the tube is at 90 degrees with the flat all around!!
3
- Take the flat witch has the 1 inch tube welded on it, and weld it in the middle on the lower bar on the back of the frame
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4
- place the flat with the holes for the bolts in the middle of the top tube at the back of the frame, to hold the steeringtube and make marks on the frame where the holes should be drilled. then drill the holes for the M8 size bolts using a hand drill.
5
- After drilling the holes position the 1 inch flats over the holes so the bolts can pass through.
6
- Take the two 1inch tube pieces of 700mm long for the handle bars. - Bend the tube on both sides 90 degrees and make it 200mm high. - After bending cut the end at 45degrees before welding it on the frame.
12
7
- Take the 1,25 inch steeringtube and fit the bearingcups of the headset - Place the headset on the frame and insert bearing balls, put the flat in between the top bearingcup and the locknut, secure the flat with the two M8 bolts too the frame.
Mounting wheels and mudguards 1
Drill the holes for the M6 bolts for the mudguards in the frame
2
Place the wheels with the mudguards stays on the inside and tightend them.Then position the mudguards and mark the place where the hole for the bolt should come. Drill the hole with the handdrill and place the bolts on the mudguards.
13
1
Mounting the bicycle
- Cut the headtube from the bicycle off straight down using a square
2
- using the grinder cut out the shape of the steeringtube into the ends of the bicyce frame tubes.
3
- Place the frame behind the steeringtube and make sure both parts of thetricycle (cageframe and bicycle frame) are levelled. - Check if the pedals are high enough from the ground and if the angle between the steeringtube and bicycle is 90 degrees - After checking spotweld the bicycle on the steeringtube, then check again. - If everything is correct weld the frame on the steeringtube completly
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Result
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