Presentation of our DIY, tailor made, low cost hometrainer. Entry for Handicap International Award.

1. http://designforeveryone.howest.be/

2. PEDALOKRUKKEN 3.4 http://designforeveryone.howest.be Jan Leyssens / Jan Van Loo / Thomas Vandendriessche 260 minutes € 170 http://pedalokrukken2010.blogspot.com

3. ASSEMBLY MANUAL http://designforeveryone.howest.be

5. 01 Technical addendum 4 Eyes Bill Of Materials No definitive part have been added This action costs €0 PEDALOKRUKKEN 3.4 60 minutes action DESCRIPTION It can be useful to start with arranging all the components to get a clear view of the total assembly. Most of the parts are made from wooden multiplex plates. There might be some difference in colour or damaged parts. Carefully check the parts and select which sides are the best to show. In order to avoid unwanted situations check the bill of materials mentioned before and inspect all the needed materials. NOTE: it is easier to assemble this home trainer with two people.

6. 02 Technical addendum 1 & 2 Wood glue 0 standard components are used 2 part have been added This action costs €30 PEDALOKRUKKEN 3.4 5 minutes action DESCRIPTION It takes a while for the glue to dry, so it is important to start with the glue actions. First of all glue one of the two “body” parts of 9mm and the 18mm “body” together.

7. 03 PEDALOKRUKKEN 3.4 DESCRIPTION Fix the construction with cramps. Some wood remains are helpful to protect the parts and distribute the pressure more equally. No technical plan needed Some cramps 0 standard components are used 0 part have been added This action costs €0 5 minutes action

8. 04 Technical addendum 2 Silicon pistol (+ grinding machine) 2 pedal supports 1 part has been added This action costs €15 PEDALOKRUKKEN 3.4 15 minutes action DESCRIPTION While the glue of the first subassembly is drying there is some time to start preparing the pedal construction. Use the TEC7 silicon superglue to fix the two pedal supports in the foreseen milled holes. If the pedal supports are to long, a grinding machine can be used to shorten them. OPTIONALLY: paint the part in a preferred colour. This colour will later on accent the pedals.

9. 05 Technical addendum 2 Electric drill 2 rings + 8 screws 2 part have been added This action costs €3 PEDALOKRUKKEN 3.4 15 minutes action DESCRIPTION Make a draft assembly to see how the circles would look like on the final model (with pedals and the necessary rings). Bore 4 holes in the ring and fix it with 4 screws. Repeat this action at the other side. These rings will fix the pedal supports. OPTIONALLY: to make the construction even stronger the screws can be replaced by bolts.

10. 06 DESCRIPTION One of the two circles of 9mm and the 18mm circle have to be glued together. Pay attention to the construction at the bottom. This will be used to centre the two circles together. The metal pieces are 10mm thick because there is a difference of 10mm between the radii. Technical addendum 1 & 2 Piece of wood Wood glue 1 part has been added This action costs €5 PEDALOKRUKKEN 3.4 5 minutes action

11. 07 DESCRIPTION The previous described construction makes it easy to position the two circles. The inner circle has to be concentric with the screw thread, therefore a sliding calliper can be used. Fix the composition with two 25mm screws. No technical plan of this part. PEDALOKRUKKEN 3.4 Electic drill 2 x 25mm screws 0 part have been added This action costs €1 5 minutes action

12. 08 DESCRIPTION Disassemble the draft assembly and squeeze the circles together with cramps. PEDALOKRUKKEN 3.4 No technical plan of this part. Cramps 0 standard components are used 0 part have been added This action costs €0 2 minutes action

13. 09 DESCRIPTION While the two sub-assemblies are hardening, there is time to get on with the other parts. Take the handlebars and the handlebars-support and indicate where it has to hinge. PEDALOKRUKKEN 3.4 Technical addendum 2 Pencil 2 part have been added This action costs €15 2 minutes action 0 standard components are used

14. 10 DESCRIPTION Position the hinge on the previously made indication. Attach it with some screws. Pay attention to the angle of the hinge. Try to connect the hinge in a way that you avoid screwing parallel with the multiplex plate. PEDALOKRUKKEN 3.4 Technical addendum 2 Electic drill 1 part has been added This action costs €4 10 minutes action 500mm ribbon hinge + 16 x 15mm screw

15. 11 DESCRIPTION Screw down the trestle hinges. In this case it is not possible to avoid screwing parallel with the multiplex plate. It is necessary to drill small holes before adding the screws. 5 minutes action Electric drill (bit and twist bit) 2 trestle hinges + 4 x 15mm screw 2 parts have been added PEDALOKRUKKEN 3.4 This action costs €5 No technical plan of this part.

16. 12 DESCRIPTION Wind the handlebars tape around the handlebars. There are notches provided. It is important to wind it very strong and with a small pitch. If the handlebars tape doesn’t stick enough, use PVC tape. PEDALOKRUKKEN 3.4 15 minutes action Some extra pvc tape can be useful Handlebars tape (and PVC tape) 2 parts have been added This action costs €8 No technical plan of this part.

17. 13 DESCRIPTION Use the superglue to fill the thread of the handle. Thereupon screw the spindle in the handle. OPTIONALLY: paint this part in the preferred colour. In this project all functional parts are coloured black. No tools are used in this action PEDALOKRUKKEN 3.4 2 parts have been added M4 spindle + Cupboard handle + Superglue 3 minutes action No technical plan of this part. This action costs €6

18. 14 DESCRIPTION Drill holes in the remaining wood for the spindle. Use a 3,5mm drill. The M4 spindle can be screwed in the wood. This is necessary to create a pressure on the piece of Teflon afterwards. PEDALOKRUKKEN 3.4 Electric drill + 3,5mm drill 0 parts have been added 3 minutes action No technical plan of this part. This action costs €0 0 standard components are used

19. 15 DESCRIPTION Screw the two lowest wheels on the 18mm body. Hold the remaining wheel against the upper notch. Indicate the corresponding spots from the wheel housing on the wood. Drill two 8mm holes on these marks. PEDALOKRUKKEN 3.4 Electric drill 2 parts have been added 5 minutes action No technical plan of this part. This action costs €5 4 x 15mm screw

20. 16 DESCRIPTION Again make a draft – not definitive – assembly to check all dimensions and functions. At this stage the assembly should look like this picture. PEDALOKRUKKEN 3.4 10 minutes action No technical plan of this part. This action costs €0 No tools are used in this action 0 parts have been added 0 standard components are used

21. 17 DESCRIPTION Spread the glue on the 2 connected bodies. Be sure to use enough glue. This step is very important and irreversible. PEDALOKRUKKEN 3.4 10 minutes action No technical plan of this part. This action costs €1 Piece of wood to spread the glue 0 parts have been added Wood glue

22. 18 DESCRIPTION Position the remaining 9mm body carefully on the glue. Wood glue allows small moves the first minutes after connection. Next, squeeze the assembly together with cramps. PEDALOKRUKKEN 3.4 10 minutes action Technical addendum 1 This action costs €14 Piece of wood to spread the glue 1 part has been added Wood glue

23. 19 DESCRIPTION With all bodies assembled, the main part is ready. Add the piece of Teflon. Probably the dimensions of the standard piece will not fit in the foreseen hole. A metal saw is the ideal tool to form the Teflon. PEDALOKRUKKEN 3.4 3 minutes action This action costs €2 1 part has been added Piece of Teflon No technical plan of this part. Metal saw

24. 20 DESCRIPTION Make a subassembly for the last wheel. Screw two bolts through the holes in the wheel housing. Fix them with nuts using spanners. Add the two springs as shown on the picture. Assemble the subassembly to the body. PEDALOKRUKKEN 3.4 6 minutes action No technical plan of this part. This action costs €4 Some spanners 7 parts have been added 1 wheel + 2 springs + 2 bolts + 2 nuts

25. 21 DESCRIPTION Assemble the body with the wheels and the two connected circles. Place the last 9mm circle on the assembly and make sure the margin is equally divided using folded snippings of papers. PEDALOKRUKKEN 3.4 5 minutes action Technical addendum 1 This action costs €5 Snippings of papers 1 part has been added 0 standard components are used

26. 22 DESCRIPTION Attach the circle with 6 screws. Don’t use glue for this step. The screws allow to easily optimise the inner wheels or Teflon when something seems to be wrong. PEDALOKRUKKEN 3.4 5 minutes action This action costs €1 Electric drill 6 x 35mm screws 0 parts have been added No technical plan of this part.

27. 23 DESCRIPTION This action demands some improvisation. Depending on the preferred kind of saddle their might be another manner of attaching the saddle to the saddle pin. Generally the original saddle pin has to be removed and some extra wood pieces and screws can make a strong and secure connection. Technical addendum 2 PEDALOKRUKKEN 3.4 30 minutes action This action costs €24 Electric drill + spanners Saddle + 2 x M12 bolts and nuts + Screws 1 part has been added

28. 24 DESCRIPTION Assemble the two braces. Normally, no tools are required for this job. If the fitting seems to tight, the “body”-plates might have shifted while hardening. Use abrasive paper to smoothen the gaps or use a hammer to force it. Please note that using a hammer can make this action irreversible. PEDALOKRUKKEN 3.4 Technical addendum 2 10 minutes action This action costs €12 Abrasive paper/hammer optional 2 parts have been added 0 standard components are used

29. 25 DESCRIPTION Attach the pedals. Make sure to attach the left pedal on the left side of the home trainer. Fix the pedals as tight as possible, this will reduce chance of the pedals to wiggle loose. PEDALOKRUKKEN 3.4 6 minutes action This action costs €6 Spanner 2 parts have been added 2 pedals No technical plan of this part.

30. 26 DESCRIPTION Insert the previously made assembly with the handlebars. As described in step 24, this step should be pretty straightforward. If the handlebars do not fit immediately, use abrasive paper or a hammer. PEDALOKRUKKEN 3.4 Technical addendum 4 5 minutes action This action costs €0 Abrasive paper/hammer optional 1 sub-assembly has been added 0 standard components are used

32. ACCESSORIES http://designforeveryone.howest.be

33. 1 DESCRIPTION If standard pedals are not big enough for your comfort, you can easily make add-ons to tackle this problem. By screwing 2 pieces of wood together, you can make an extra support as shown in the picture. To attach the add-on to the pedal(s), use straps or glue. PEDAL EXTENSIONS 1.3

34. 2 DESCRIPTION For those that experience difficulties getting on or off the home trainer, a footboard was designed. This footboard will give you a higher degree of freedom when getting on or off, and it collapses once seated. One way of creating this is by using a door-spring that helps during the collapsing and restoring of the footboard. This movement can be connected to the hinging of the handlebars. FOOTBOARD 1.0

35. 3 DESCRIPTION When adding extras to the home-trainer, the possibility arises that the pedals are to close to the floor or hit other objects. To avoid this, a bike holder is created. Other useful advantages of this holder are more stability, floor protection and a finishing touch. BIKE HOLDER 1.0

36. TECHNICAL ADDENDUM http://designforeveryone.howest.be

37. ADDENDUM 1 Wooden plate 9mm – parts composition

38. ADDENDUM 1.1 Wooden plate 9mm – Body (2x)

39. ADDENDUM 1.2 Wooden plate 9mm – Circle (2x)

40. ADDENDUM 2 Wooden plate 18mm – parts composition

41. ADDENDUM 2.1 Wooden plate 18mm – Body

42. ADDENDUM 2.1 Wooden plate 18mm – Handlebars

43. ADDENDUM 2.1 Wooden plate 18mm – Brace (2x)

44. ADDENDUM 2.1 Wooden plate 18mm – Handlebars support

45. ADDENDUM 2.1 Wooden plate 18mm – Circle

46. ADDENDUM 2.1 Wooden plate 18mm – Saddle pin

47. ADDENDUM 3 Dimensions related to the users physique DESCRIPTION By connecting the dimensions of the home trainer with an Excel sheet, the entire model can be turned into a fully personalised home trainer in just a few seconds.

48. ADDENDUM 4 Exploded view

49. ADDENDUM 5 Computer render

50. ADDENDUM 5 Final result

51. TEAM CONTACTS http://designforeveryone.howest.be/

52. [email_address] TEL +32 479 06 88 04 [email_address] TEL +32 493 11 61 07 [email_address] TEL +32 496 44 61 99 http://designforeveryone.howest.be