DISCLAIMER: If you try this, it's your fault if it breaks and you get hurt. Frame failures are no fun, and if you build this and your frame fails, it is very possible you will get hurt. Don't blame me.
The basic process will be:
1. Get materials!
2. Design the frame
3. Heat treat the bamboo
4. miter the tubes; the head tube and the bb shell will be metal parts that fit inside bamboo sheaths.
5. Tack it all together
6. Reinforce the joints
7. Build up a bike
Step 1: Materials and Tools
- bamboo, of the appropriate sizes. I got mine from OSH. They had " 1" Bamboo ", which in reality ranged from .75" to 1.25" in diameter, and " 1.5" Bamboo ", which in reality ranged from 1.25" to 1.875". I used .875" for the rear triangle and 1.5"-1.75" for the front triangle. It's definitely strong enough.
- hemp fiber, or fiberglass, or carbon fiber. I used hemp fiber from hemptraders.com. Fiberglass is cheap and available at OSH. You can get carbon fiber ( and fiberglass, too) at fiberglast.com .
- epoxy resin and hardener. 10 minute pot life worked well. I got mine from West Marine, and it's available at fiberglast.com too.
- 5-minute epoxy. Or 30-minute, or 2-hour, it really depends on how patient you are. I got them from OSH.
- a head tube and a lugless bottom bracket shell. I got mine from novacycles.com .
- dropouts. I got mine from ebikestop .
- expanding foam. I'm not sure if it is needed, but Brano Meres seems to think foam does good things, so I put some in the rear triangle. It helped keep the dropouts in their place when it was all getting tacked together. It's light and cheap, and I got it at OSH.
Tools you'll need:
- a propane torch, or a heat gun. This isn't necessary if you can breathe fire. It's for heat treating the bamboo. Mine is from OSH.
- a hacksaw or a coping saw. This is for mitering the bamboo, and for cutting the tube to length. Mine is from Home Depot, I think. You probably have one already, though.
- if you have a drill press, I hear you can get an attachment that holds a tube at an angle so you can miter quickly and accurately. thavinator posted this link in the comments which points you toward where you can buy them.
- a half-round wood rasp. This is for mitering the bamboo. Got it from OSH.
- tubemiter.exe . Invaluable when mitering. Mitering tubes. Not so useful for mitering other things.
- a Dremel. Useful for everything. I bummed one off a friend, but I was almost done with the frame at that point. This would have made things go much faster.
- disposable gloves. Epoxy is bad for you, don't touch it. Costco sells these in bulk. Your local drug store will carry them too.
- a mask; epoxy and sawdust and the like is bad for you. Don't inhale it. OSH.
- a jig. I got aluminum from OSH and built the almost jig by dr welby . Well, you technically don't need one, but I found it to be very useful. You'll also need clamps if you use a jig.
- calipers are nice to have. I "borrowed" mine from my school's robotics lab. Harbor Freight carries them cheap, though. Measuring tape is also important.
- a protractor is important to have. Angles are important to get right.
- a Sharpie, or something else that marks up just about anything.
- trash bags; they are useful for making the joints.
- a camera, so you can document your work.
You'll also need bike components. I bummed around and got some free, and bought some for cheap. Total cost of the entire bike: about $300.