The Impossible Build Challenge
 

I challenge myself sometimes, well, a lot. Not limited by my imagination, I think of things that I'd like to do, but sometimes my ideas are quickly thwarted by the starkness of reality. For instance, I've been courting the notion that I can build a complete bicycle without using a single bicycle component. Everything, and I mean EVERYTHING would be hand-made by me. As a second-generation machinist, aircraft mechanic, industrial machinery mechanic, welder/fabricator, and all-around tinkerer, I am confident with my skills. Still, there is one slight problem remaining: How do I make a tire?

Yes, I am challenging myself to not even use bicycle tires.

Now I realize that this may not be a C&V topic, and if deemed necessary, I'll harbor no bad feelings if it gets moved. I like everyone in here. I recognize and respect the talent. Plus, everyone in here seems a lot more civilized in their comments. Other subforums just aren't as nice. :love:

So fantasize with me a little. If you needed a tire, and there were no tires to be had, and you had materials at hand, how would you make one?

-or-

Are there any tall/narrow tires available that aren't built for bicycles? Have a sip of coffee, and let's indulge ourselves!

I admire your resolve! I’m not remembering the title at the moment, but I read a book last year on the history of cycling in The Netherlands. During Nazi occupation, tires were impossible to find but bicycles were essential to foraging for food, firewood, etc. one substitute was to wrap rims with rope. I don’t think it made for a very comfortable ride, but the overall idea of using cloth or twine would apply.

Use garden hose. Stuff it with whatever. Every few hundred miles, paint on some fresh Shoe Goo for grip.

This is pretty neat:

Two Nuns


https://cimg3.ibsrv.net/gimg/bikefor...eab43bd58a.jpg

Then there's the woodworker's wartime solution:


https://cimg7.ibsrv.net/gimg/bikefor...59b22a2570.jpg

Speaking of wartime, here's a German WWI Victoria:

https://cimg8.ibsrv.net/gimg/bikefor...f37d8dde55.jpg

Intriguing! I've never seen this pic before, and it definitely gives me some ideas.

I recommend you start with a unicycle first.
Less than 1/2 the effort.
Evaluate if you wish to more than double your time for a bicycle that's uncomfortable.to ride.

How long will it take to make a chain?
Will the frame be wood? Or are you going to roll&seam tubes?

Assuming this is a fixie?

Remember, the 2nd man to invent the wheel was stealing intellectual property. :innocent:

Final question: What, no bike co-ops nearby that could greatly use your time and skills? For a truly productive result.

Good luck with your project. A recumbent might be easier, if your chain making isn't too time consuming. Maybe front wheel drive?

edit: searching revealed a follow-on project.

Now I can see why the down-curved rifle bolt was invented. That thing would rub your leg on every revolution of the pedals.

Simple solution:

DUCT TAPE TIRES!!!! No flats, ever! :lol:

Concrete storm sewer O ring gaskets.
https://www.ameritexpipe.com/wp-cont...et-Website.pdf

If I was going to do your project, I'd build a Penny Farthing. There are several nice repros on the web. So much has to be custom anyway, from spokes to hubs.

https://stratingbrothers.files.wordp...8/sam_9557.jpg

https://stratingbrothers.wordpress.c...arthing-build/

I haven't done one myself yet, but I've done some research. I think at least one person made forms and poured solid rubber tires.

Where exactly would one draw the line on considering something "hand made" by you? Are you allowing yourself to purchase items and adapt them, or going back a few steps further to mine and refine the ore for the metal pieces, and then forge, or cast them, etc? (extreme, I know, but I could see a version of this where there would be no end to this). In the end, what truly matters is that you are challenging yourself in a way that you are enjoying.

This concept intrigues me as an onlooker. At some point I aspire to build my own canoe and do some woodworking, and I've engaged in some elementary leather crafting, so I get the attraction of testing and refining your skills and ending up with something pleasing that you can get extra satisfaction from doing it yourself. Beyond crafting some accessories, perhaps, and grinding down some generic bolts a bit to modify the profile, I'm quite content to be a mere, occasionally-informed consumer and connoisseur of innovative and inspired craftsmanship.

I will eagerly watch and celebrate your achievement. :thumb:

Could be done, the question is how fully functional do you wish it to be?

I would look at bicycle from the turn of the prior century, many had very proprietary fittings and components.
Know you skill set and tools.

As to tires, I forgot the name of the process, but consider heavy wire slipped into a hard rubber tube, wire is twisted a turn or two and pulled with large purchase force with the tube ends exposed and separated, brazed up, then the excess cut off, tubing worked back together with a splice.

Nipples?

One might ask whether it is the same to buy aircraft tubing vs bicycle tubing.

It should be easy enough to TIG weld lugs. Something like a fork crown might be more problematic, although I suppose one might go back the the vintage style with a round tube on top.

https://d1f7geppf3ca7.cloudfront.net...ltwentyfk2.jpg

And, of course, the Penny Farthing has different demands on the front and rear wheels.

As to what USAZorro wrote. Mining ore and vulcanizing rubber can be done at home. Just not very well.

https://www.ted.com/talks/thomas_thw...ce=tedcomshare
https://cimg5.ibsrv.net/gimg/bikefor...9e60e220f5.jpg

Hey, if Lego company can build a 1:1 scale driveable Bugatti Chiron 90 percent from Lego Technics parts, then you should be able to accomplish your mission.


I told my sons about it the first Saturday in December, and the elder one replied with this shot of his boys (third-generation Legomaniacs), "Yeah ... we've already been there ... done that."
https://cimg3.ibsrv.net/gimg/bikefor...70ab5445aa.jpg

CalfeeDesign.com has a bamboo build kit that might be useful for frame ideas. Craig has been doing it almost 2 decades - as a side project to his CF bikes.

There was a story about (or by) a guy who wanted to show that we don't have much choice but to build on the work of others. Then he decided to make a pencil. It took him a year.

See red text above! ;)

Actually I was thinking of some variation of this, perhaps using some sort of continuous belting.

How long would it have to last? I'm thinking that no challenge would be complete without a goal to achieve. What would be a reasonable goal? One goal would be to ride across the USA on it, but thats a bit of a stretch. Maybe I could ride into town and get a six-pack? That's be about 7 miles round trip. Does that seem reasonable and attainable?

Thanks for your vote of confidence! Why not challenge yourself? No sense to sit on your duff and wish your life away.

My goal will be to re-purpose and adapt as many non-bike parts as I can.

There is a very cool video about how Raleigh bicycles were made. It seems everything was made in house (don't know about tires), frame tubes, lugs, wheels, gears and cranks.

youtu.be/FaxRQh03BOw

It really does come down to, "How far are you going to take this"?

Are you going to buy aluminum billet or rod to make parts? Why not refine your own? Wait, you need a refinery for that. Why not make your own refinery, too? Then, you need ore. You'll have to have your own mine.

If it's steel, you need to mine iron and coal. Who makes the shovels?

You are hung up on the tires because you don't know how they are made. If you knew, they would not be so daunting to you. You need silk or cotton fibers (plantation, seeds, carding machines, spinning wheels), rubber trees, a few more chemicals for additives, tube and tire molds and some ovens.

Get my point?

Our success as a species is due, in part, to our collaboration with others.

Schwinn made a lot of their frame stuff in house too, although other components came in as "Schwinn Approved".

How many amps do I need for Schwinn Electroforging?