Antique Bicycle

Picture yourself riding one of these, and you will be the talk of the town.
Here I'll show you how to build your own antique bike like the Ordinary Bicycle,
also called a Penny-Farthing -- common in the 1880s which became an
iconic symbol for transportation history. 
With an old bike, a few tools and materials, and some patience, you can
build this bike and bring history to your front door.
Although replicas and originals can cost thousands of dollars, yours does not have to!
I'll also teach you how to ride it!
So get your tools out, find an old bike, and let's get started!
 

Step 1 Materials and Tools

Materials:
old bike with 26" rims
16" front wheel w/ tire from a child's bike
1" OD steel tube x 6'
1" wide x 1/4" thick steel plate
1 1/2" wide x 23" long x 1/4" thick steel plate
5/8" OD steel tube
6 lbs 3/32" #308 stainless steel welding rods
tricycle hub
2 pillow block ball bearings (shaft size determined by hub)
1" OD solid rubber tire
1/8" solid galvanized steel wire x 16'

Tools:
Craftsman  MIG Welder with Cart (wish I had it)

Tubing Roller

Craftsman 10" Compound Miter Saw (w/ metal cutting blade)

Craftsman 6" Bench Grinder

Craftsman 5" Bench Vise

Craftsman Hammer

Craftsman Wrench Set


Kobalt 27/64" drill bit, 1/2"-13 NC Tap, and 1/2" - 13 NC Die

Threading die 2-56

spoke wrench

drill set for metal

Spray Rust Oleum metal primer and paint

misc: pipe clamps, vise grips

Comments

[freepenny]

Many thanks for your contributions.



How wide of a rim you used? I have a 26 X 1 3/8 .
Is that OK or should it be wider?

[27-ton Artillery Walker]

Where did you get the rubber for this? And do you know specifically what type of rubber? (Everything i find that has a 1" OD has a massive ID, so it would warp and all that jazz and the steel wire would swim in it...)

[carlitos]

Built another Penny. Used a steel C-channel for the rim and rolled it.
It's on sale at craigslist

[the_keiser]

Awesome instructions. I'm working on one right now. I was curious about the method you used for the c channel rolling. Did you use a machine like this http://www.youtube.com/watch?v=ke78PPtisF4&feature=related or like this http://www.youtube.com/watch?v=zjjIu9UdQmQ. My schools shop I think only has the first one. I assume that both machine can do the same thing. I also was thinking I could bend straight the old wheel rims and then turn it on the rig and get a bit better a shape than trying to do it by hand. Probably would be better to go with new straight channel but I figured I have the wheels all ready, so I could try that. Anyway. fantastic.

[carlitos]

Thanks. I used the one from harbor freight with dies for straight stock. Your school's should work well too. I rolled an extra 6" and let it hang out the sides as the ends crossed and then cut it at the marks I made for a precise radius.
I used 1"x1/2" C-channel. You'll get a truer wheel. Also discovered stranded steel wire works better (stronger) than solid.. once I figured out a trick to welding the ends even though I"ve read it can't be done.

[notingkool]

where you buy that die? because i can't find it anywhere. In several hardware stores the told that doesn't exist. (sorry for mi english, if i wrote something wrong, let me now)

¿donde compraste ese buje roscado? porque no lo pueod encontrar en ningun lado. En varias ferreterias me dijeron que no existia.

[carlitos]

I bought mine at a local RC Hobbies but you can buy online
http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXR765

[fredellarby]

Cold riveting the ends should give enough of a stop to keep the spokes in place and you don't have to find anything else to do the job. It's a technique often used, I learned it on a blacksmithing course. We used bolts, cut to length and hammered down. I often do it over a tightened nut .It will never come loose.

[Mcschphail]

How does one acquire a 1"OD 3/16"ID rubber tube? Unfortunately, I do not have one just laying around...

[kenbrbkr]

"My welded rim measured approximately 48" in diameter...
I guess 26" rims are really smaller than 26".

You're not doubling the diameter.

You're doubling the circumference.

[notingkool]

an 26" rim is 599mm bead dia. so is like 23.5 in.
and, yes, if you double the circumference, you double the diameter.

[iamcookie3000]

i belive a 26" wheel measures 26" with the tyre, i use old still 700c rims but my rim is 46" with 50 holes

[carlitos]

What I had meant to say is that a 26" rim is more like 24" without the tire.
C is directly proportional to D by a factor of pi
C = pi*D
So, if you double the diameter, you double the circumference.
If you double the circumference, you double the diameter.
So I'm doubling both the diameter and Circumference.

[iamcookie3000]

sweet build im making 1 at the moment, for the cranks i used a 16mm die steel rod and ground out a 10mm slot so i could use cottered cranks im guna upload them soon, were did you get the tubing from for the tire? im in the uk and cant seem to find it

[carlitos]

That's great. Love to see pictures. Mexico, Spain, and UK -- can't find the tire. I wonder where master builder Mr. Edwin Knight from Chelmsford gets his.
A company in Ohio sells the tubing for the tire and for 20 feet shipped, it will be in the $100 range which is why I'm sure you can do better in the UK. I like his 5 Penny's at a pub video. Riding must have been fun after a pint or two.

[kevo63]

Excellent build! Thanks for this great Instructable. I'm in the process of building a Penny now, but I'm having trouble finding rubber to tire my wheel with. Where did you get yours? Or where should I look?

[voldemortkein]

Thanks man!, I'm watching it now

[carlitos]

The drawing shows the pulley 1/2 inch above the base, but instead should be
1 1/16" inches to prevent the tire from touching the pulleys.

[voldemortkein]

Is the function of the Bolts joint the metal plates and sandwich the wire??.

[carlitos]

Yes, the 2 bolts when tightened will hold the wire and maintain the tension in the wire so you can either start brazing or pick up more wire before loosening the bolts and tightening the wire further. I see you posted it to 3D Warehouse. I would rather post it there once it has no errors. The 2 pulleys need to be moved up at least 1/2 inch to provide clearance for the 1 inch tire.

[kptan69]

Supreme. Just change inches to centimeters and make it. Thanks a lot. It´s going to be very useful to me. I cannot believe that there are people who shares his time so generously. By the way I had to download the aplication.
I bought the rollers in a chinese store. Very cheap (about 0,2 $ each other). With them I´ll make my tire tensioner.

[carlitos]

Good. Another thing is the top hole in the tensioner must not be threaded since the bolt slides in and out of it. Only the hole in the middle piece is threaded. With the middle piece all the way down, the bolt will be in all the way. Then turning the bolt clockwise will raise the middle piece to pull the wire. You can make the top part longer if you have a longer bolt then you don't have to repeat picking up more wire as much.

[carlitos]

Here's a video addendum to Step 11 - Tiring the wheel

The homemade tensioner as you will see is the key to making the job easy.
I got the idea from this youtube video.
It has 2 bottom bolts which when tightened, will sandwich the wire and hold
it's tension.  The top big bolt, when turned clockwise will raise and pull the wire, thus applying tension.  Use clamps to hold the wire ends.
It measures 3 inches across and has a window opening for brazing.
You can get the rollers from Home Depot or Lowes and are the rollers found in sliding glass doors.  Tell them carlitos sent you.

Here's the outline of what re-tiring the Penny wheel entails:

1. Remove wheel
2. Inserting wire in tire.  Try to keep wire straight, roundover the end of the wire, and use lubricant.  May have to use pliers to help it along as the resistance becomes greater as you insert it. 15 ft. of wire is plenty as you need some extra to feed through tensioner.
3. Mount tire on tensioner and rim.
4. Apply tension on wire.
5. With 2 bottom bolts tightened, cut wire
6. Braze
7. Remove tensioner
8. Install wheel
Now go ride!

[T_T_]

could you make an instructable on that tensioner

[carlitos]

Added a Google SketchUp (tiretensioner.skp) drawing you can upload and play with on step 11.

[carlitos]

I suppose I could just that it's hard to justify the time unless there is good interest for it. How far are you on that wheel you've been wanting? I'm working on a youth Penny Farthing so the wheel is slightly smaller however this wheel will be truer as I have a new and easier approach spinning in my mind (no old bike rims).

[T_T_]

Haven't started yet, whats that new method?

[voldemortkein]

Yes, You may have to make a Wheel Tensioning Device's Instructable. :D

I have a skecth on my mind based on the idea that you mentioned and the youtube video, but... Did you have photos of this process?.

Thanks
Regards

[carlitos]

Added a Google SketchUp (tiretensioner.skp) drawing you can upload and play with on step 11.

[carlitos]

Did not take pictures of the process. If I make an instructable, I'll have to make another. I should at least be able to make a "google sketchup" drawing of it one day.

[voldemortkein]

Hi!, Well... And what about if I cant get Solid Rubber Hose??.

I mean, I live in Mexico City, and here the only that I can get is Round Extruded Solid Rubber 1" OC, but its solid!, It hasn't the 3/16" hole for put the wire inside it.


What can I do??, Buy this kind of rubber and anyone knows how to fit the wire on it.

Or What other product can I use, I mean, If that hose has another name or If I can get it by other name.


Cuz I've heard another guy that uses solid rubber and vulcanized the extremes.


Thanks.

[carlitos]

You can either move out of Mexico City or order from Holmes Wheel Shop (since they ship internationally), or order from me and I'll charge extra.

[voldemortkein]

More or less, How much It cost me the Penny Farthing's Tire?? with shipping to Mexico City.

I being moving around my country, and I found out a factory that makes Rubber extrudes, and they make rubber hose 1" external diameter/ 3/8" internal diameter, but they told me that they can only send me 1000 meters and up.

And I only want 10 meters.


Then I found a rubber shop, in this shop sells rubber extruded 1", I buy 1 meter for the rear wheel, Now I'm planning to find a powerful like Olli Erkilla used on his Penny Farthing wheel.

I'm thinking in Cement for cold Vulcanizing purposes.


And Today I've found the K&S Threading Die 2-56, find this out was a true oddisey!! LOL. I bought it on a Modeling/Radio Control Scales shop.

Also I have the Stainles ssteel TIG Welding rods.
and I made the hub from stratch, cutting in half a bike axis. In the middle I welded a 6" length pipe, and a 4" or 5" diameter discs with 30 holes each disc.


For the rims I went to a pipe bending shop, now I have the front and rear rims.

[carlitos]

You are about as determined as I was! Yes, finding the K&S Die was not easy. I will also be making my next hub from scratch. I would build the bike and leave the tire for the very last thing. 10m of tire? Are you making 2 bikes
or just want to have extra for replacing? This tire material is great. and I don't think you'll need to worry of it wasting and needing to replace. I don't know what shipping would cost but if you want me to pursue this for you, we can figure something out. Did you get the 308 TIG rods? Don't get 316 because I was told by my friend 316 are not easily machineable so threading may not be possible.

[voldemortkein]

Well, I wanna say 10 meters tire, for the front and rear wheels, and of course to have an extra for maybe reaplacing or another stuff.

I think I bought 308 TIG Rods, now I machined 10 spokes, the thread is pretty cute!!!!, and finally the nipples fit on spokes!. This rods I bought it on a Welding Instruments, Equipment and Gases Shop called "INFRA".

Mr Graeme Simpson bring me that Idea of welding rods.

For now I think I gonna sleep This threading job is exhausting.
In this current week I worked on Wooden Pedals, Moustache shaped Handbar, and Wooden Handles.

I'm seeing that I'll need to cut the crank arm's length. Cuz that cranks are too large, and maybe my feet dont touch the pedals! LOL.

Another goal that I need to achive it is saving money for buy a basic MIG or TIG Welder.
Cuz also as you I dont have it, and go to the blacksmith is too expensive! 10 bucks for each weld.

In home I have 4 Classic Electrical Arc Welders AC. But I was reading and I heard some experts opinions that this kind of welder is not appropiate for this kind of job.


Also I have another doubt, my front wheel has 60 spokes, my weight is 180.59lbs
But maybe a friend of mine wanna ride it, his weight is 220.46lbs.

Which lacing setting recomends me?, Radial? 1 cross or 2 crosses?
I had a little Idea about calculating spokes length, but I dont remember clearly, so, What method uses you for this part of the Job??.

Thanks

[carlitos]

Trust me, you will not need to replace the tire material. Have patience my friend. Just think, one day you will ride and the world will admire. I've heard the same about arc welding not being appropriate but if I had one, I would at least try. I have since bought a MIG and learning to use it. I have been reluctant to let anyone else ride mine but I trust it can handle the extra weight. Just wear protection at first! As far as lacing, I think radial is best because it is straightforward and I believe it's just as strong. Have you tried calling Holmes at 330-279-2891 for the tire? They ship internationally.

[voldemortkein]

Hi Carlitos!!!.

I only have another question in the Materials and Tools needed you are mentioning a Craftsman MIG Welder.

But In Step 5's Pic "Welding the Rim" the photo says "TIG Welded".

Now, Did you used MIG o TIG weld??.

I mean, now I save some money, bit I have the possibllity to buy a cheap 90Amp MIG Welder, with Core Flux Wire.
Will It work for this bike purposses???.
Or Should I wait and buy a TIG?, Thanks
Regards.

[carlitos]

HI voldemortkein,

I've been using now a Core Flux Wire welder and yes it will work fine. You just have to be careful when welding the rim not to burn a hole through. Mine is 140 amp and setting it at the lowest heat level and tack welding (little at a time) works. I recommend you get a spare rim, cut it up into pieces, clamp 2 pieces, and practice. It's a matter of knowing what settings work best for the thickness of the material and how to avoid burning through it. I mentioned TIG welding because that's what my friend used as it offers the most control. However, TIG welders are very expensive and do require more practice than MIG. I've now built a hitch and bike carrier with my MIG (Core Flux Wire) and works great.

[voldemortkein]

Ohhhh. my friend!!!!, you save my day!, now tomorrow I Will buy it :D Yeeeeeehaaaa. sorry, LOL, but I'm really happy with this notice.

P.D. your bike carrier looks really good, at first I was frightened of make a bad purchase. Then, I think I will finish up my bike the next week.

Also I wanna make a tutorial on instructables too.
Thanks for all
Regards

Voldemortkein

[voldemortkein]

Thanks my friend, I'm lacing the wheel, If doesnt like me, well, i 'll choose radial. :D

Thanks so much for the cheers!,You really know how I`m feeling respecting the bike!!

Then I remembered an ancient phrase: "Patience is a virtue".

The other day when I'm seing your Bike photos, I'm asking myself, Why did He use at last time a pneumatic tire on the rear instead of the solid tire of the first??.

Thanks for the Holmes phone!, I Call he later :D