A silver and black bike sits in front of a dark grey bridge. It is on a hard surface next to green grass. The bike has a large basket area in front of the steering tube that then connects to the front wheel which is at the other end of the basket from the handlebars. It is best described as a long john bike, but is a more modern take on it than the wooden box Dutch bike.

Building A Cargo Bike Dream

September 12, 2023 by Navarre Bartz 54 Comments

Cargo bikes can haul an impressive amount of stuff and serve as a car replacement for many folks around the world. While there are more models every year from bike manufacturers, the siren song of a custom build has led [Phil Vandelay] to build his own dream cargo bike.

The latest in a number of experiments in hand-built cargo bike frames, this electrified front-loader is an impressive machine. With a dual suspension and frame-integrated cargo area, this bike can haul in style and comfort. It uses a cable steering system to circumvent the boat-like handling of steering arm long john bikes and includes a number of nice touches like (mostly) internal cable routing.

The video below the break mostly covers welding the frame with [Vandelay]’s drool-worthy frame jig, so be sure to watch Part 2 of the video for how he outfits the bike including the internal cable routing and turning some parts for the cable steering system on the lathe. If you get an urge to build your own cargo bike after following along, he offers plans of this and some of his other cargo bike designs. [Vandelay] says this particular bike is not for the beginner, unlike his previous version built with square tubing.

Looking for more DIY cargo bikes? Checkout this Frankenbike, another front loader, or this Russian trike.

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Hoverboard Turned Into Bonkers Omniwheeled Bike

August 31, 2023 by Lewin Day 13 Comments

Segways stunned the world when they first hit the market in 2001. Hoverboards then terrified the world with nasty accidents and surprise fires. [James Bruton] loves hoverboards regardless, and set out on a mighty upgrade regime turning the ride-on toy into a giant omniwheeled bicycle.

The build relies on two giant omniwheels of [James’s] own creation, using lasercut and 3D-printed parts. The wheels are mounted perpendicularly on either end of a boxy plywood “bike frame” built in two sections, with a split in the middle. The two halves can rotate relative to each other, much like the two halves of a stock hoverboard.

Amazingly, the build relies on the stock hoverboard motors and electronics. The hoverboard wheel motors are responsible for driving the omniwheels at either end via a toothed belt drive. The gear ratio of the belt reduction is set up to cancel out the greater diameter of the omniwheels, such that the hoverboard’s tuning isn’t disrupted. Wisely, [James] also fitted a safety power cutout, too.

The result is a self-balancing “bike” the likes of which you’ve never seen before. At present, it can balance upright and rotate relatively well. However, control is difficult, requiring the use of the rider’s body weight and the twisting of the bike’s sections. [James] has instead contemplated using servos to tilt the hoverboard sensors instead for an easier control method than the current setup.

It’s a truly bonkers build which is a testament to [James’s] creativity and prowess. We’ve seen some other great hoverboard hacks before, but nothing quite like this. Video after the break.

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A man in a dark shirt stands at a podium in front of a projector screen with the text "50% OF US CAR TRIPS" in white above yellow text saying "1 HUMAN < 3 MILES". The screen is flanked by decor saying "Supercon" in white on a black background.

Supercon 2022: Bradley Gawthrop Wants You To Join The PEV Revolution

July 3, 2023 by Navarre Bartz 70 Comments

During the 20th Century, much of the western world decided that motor vehicles were the only desirable form of transportation. We built our cities to accommodate cars through parking, stop lights, and any number of other infrastructure investments so that you could go get milk and bread in style. In the US, 50% of automobile trips are less than three miles and have only one occupant. [Bradley Gawthrop] asked if there might be a more efficient way to do all this? Enter the Personal Electric Vehicle (PEV).

What Are PEVs?

PEVs are a nascent part of the transportation mix that fall under the wider umbrella of “micromobility,” including scooters, bikes, skateboards, and the like. The key differentiator here is that they are at least partially electrically-driven. [Gawthrop] walks us through several of the different types during his Supercon 2022 talk, but since they are all small, electric powered devices for transporting one or two people, they can trace their lineage back to the infamous Segway Human Transporter.

Using an electric motor or two connected to a controller and batteries, the overall system complexity for any of these devices is quite low and ripe for the hacking. Given the right tools and safety precautions, anyone should be able to crack a PEV open and repair or tinker with it. As with many things in life, the real story is more complicated.

As [Gawthrop] notes, many a hacker has said, “I wish I’d been able to be involved in X before…” where X equals some technology like home automation and it’s before it got creepy or dystopian in some manner. He exhorts us that the time to be in on the ground floor with PEVs is now. Continue reading “Supercon 2022: Bradley Gawthrop Wants You To Join The PEV Revolution” →

Rubber Tracked Bicycle Is Horribly Inefficient

June 29, 2023 by Lewin Day 31 Comments

Wheeled bikes are efficient machines, and most cycling speed and distance records are held by them. However, [The Q] has a taste for weirder creations that amuse perhaps more than they serve as viable transportation. His latest experiments revolve around tracked propulsion methods.

The build is a wheelless bike that relies on long thin tracks mounted to a mountain bike frame. The tracks carriers are fabricated using steel box section fitted with cogged rollers. The tracks themselves are made using a pair of bicycle chains joined with welded steel bars. They’re fitted with slices of rubber cut out of traditional bike tires for grip. The rear track is driven from the bike’s pedals, while the front is merely left to run freely.

By virtue of its wide, flat tracks, the bike actually stands up on its own. It’s capable of riding in a straight line at slow speed, albeit relatively noisily. Steering is limited by virtue of the flat tracks, which don’t operate well at an angle to the ground. Since the tracks only contact the ground at a point, too, the bike has very high ground pressure, which would make it likely to sink into anything less solid than asphalt.

The build is relatively similar to [The Q]’s previous efforts to build a supposedly square-wheeled bike. What we’d really love to see at this point is a tracked bicycle that actually made the best of the technology – by being both swift and capable of crossing soft, marshy terrain. Video after the break.

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Tennis Balls Serve As Decent Bicycle Tires That Don’t Easily Puncture

April 3, 2023 by Lewin Day 41 Comments

Pneumatic tires provide a great ride, great grip, and yet have one fatal flaw — they’re always getting punctured and leaving you stranded. [The Q] decided to solve this problem with a unique design: tires that use tennis balls as the cushioning medium instead.

The build begins with small cut sections of plastic water pipe. These are used as housings to hold tennis balls, which are pressed in with a unique tool of [The Q]’s own construction. The individual ball assemblies are then bolted into a standard bicycle wheel, and a tread from a regular bike tire is stretched around the outside for grip.

It goes without saying that these tires won’t offer the same quality of ride as regular pneumatic bike tires. Nor will the performance be as good, due to the significant extra unsprung weight. They are eye-catching and fun, however. Plus, if you live in an area with tons of nails or prickles, you might find these are just the ticket. Maybe.

We’ve seen some other great bike hacks before, too.

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Tiny Yet Functional Bike Built From Scratch

March 31, 2023 by Lewin Day 10 Comments

Sometimes, you just want to go ride your bike in the great outdoors, but you can’t be bothered throwing it in the back of the car. That wouldn’t be a problem if you rode this latest build from [The Q]: a bike small enough to fit in a handbag.

The build starts by customizing a rollerblade wheel to act as the driven rear wheel of the bike. It’s fitted with a tiny sprocket allowing it to be chain driven. Welding some steel tubes then nets a small diamond-layout bike frame. It’s fitted with a chain ring, pedals, and steering assembly just like a full-sized bike, just in absolute miniature.

Riding the bike is “uncomfortable,” in [The Q]’s own terms, but entirely possible. It basically requires the same level of contortion and technique as displayed by the clowns of your local circus. Don’t expect to use it as viable transportation, though. Walking would be much faster.

We’ve seen [The Q] build some wild bikes before, too, like this great hubless design. Video after the break.

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A line art schematic of a bicycle CVT drive. Two large green circles at the bottom have the text "1. Increases speed" where the crank arm would enter the system. A series of cam arms highlighted in red say "2. Converts from rotary to reciprocating motion." Finally, a blue highlighted bearing says "3. Converts from reciprocating back to rotary motion."

A Look Inside Bicycle Gearboxes

March 2, 2023 by Navarre Bartz 23 Comments

While bicycle gearboxes date back to at least the 1920s, they’re relatively unseen in bike racing. One exception is Honda’s race-winning mid-drive gearboxes, and [Alee Denham] gives us a look at what makes these unique drives tick.

Honda has developed three generations of bicycle gearbox as part of their company’s R&D efforts, but none have ever been released as a commercial product. Designed as a way for their engineers to stretch their mental muscles, the gearboxes were only used in bike races and seen at a few trade shows. In 2004, the third gen “derailleur in a box” led to the first gearbox victory in the Downhill World Cup Circuit.

The third gen gearbox differs significantly from the CVT drivetrains in the first and second generation gearboxes, but it is unclear why Honda abandoned the CVT. [Denham] has a nice animation detailing the inner workings of these CVTs based on information from the original patents for these rarely seen gearboxes.

Derailleurs remain the primary drivetrain in racing due to their lighter weight and higher overall efficiency. While still expensive, the decreased maintenance of gearbox drivetrains make a lot of sense for more mundane cycling tasks like commuting or hauling cargo, but only time will tell if the derailleur can be supplanted on the track and trail.

For more on bicycle drivetrains, check out this chainless digital drivetrain or the pros and cons of e-bike conversions.

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