Build a Bamboo Bicycle (And Light it up!)

If you have ever wanted to build your own bicycle frame, but can't afford a framebuilding class or the materials to braze a frame, building one out of bamboo and carbon fiber is a great and relatively inexpensive way to get started.  In this Instructable, I will explain in detail how to build a great looking bamboo frame.  After that, you will learn how to make some LED spoke lights to go along with your DIY bike, or any other bike you want to put them on.

WARNING:  If you are not comfortable with being stopped by strangers and answering their questions about your bicycle, this is not the project for you.  And DEFINITELY do not build the spoke lights.

Step 1 Gather Your Tools and Materials

For the bicycle frame:

• Bamboo:  I used 1 7/8" diameter for the down tube, 1 3/8" for the top and seat tubes, 15/16" for the seat stays, and 1 1/16 for the chain stays.  All values are approximate, and anything close to those should work.
• Carbon Fiber Tow:  I got 5000 meters of it off ebay for 50$.  I have enough left over to build at least 4 more bikes.
• Epoxy:  I used West Systems 105 resin and 205 Hardener.
• Old Bicycle Frame:  I chose to cut apart an old frame for the lugs, rather than buy new ones.  Using an old frame also lets you get away with not building a proper jig.
• Propane Torch:  For heat-treating the bamboo.
• Basic hand tools:  Saws, a decent knife, a drill, a rotary tool.
• Electrical Tape:  For compressing the carbon fiber while the resin hardens.
• Aluminum angle bar:  For making a simple stand to hold the frame in place.
• Threaded rod and nuts:  For holding the dropouts in place in the stand.
• Spar Varnish:  For finishing the bamboo.
• Paint remover:  For stripping the old frame.
• Sand Paper:  For sanding, of course!
• Rubber Gloves:  For working with epoxy.  Apparently, you can develop a nasty allergy from too much skin exposure to the hardener.  You will need at least 50 pairs of these.

For the lights:

• 4 square wooden dowels
• Drill and 1/16 drill bit
• 80 LED's:  I used 3mm orange ones
• 2x 9V battery clips
• Resistors:  To run the orange LED's off 9V, I needed 20x 30 Ohm resistors
• Electrical tape
• Soldering Iron

Comments

[#OccupyInstruct]

would it be possible to make some fenders and attach some reflectors to is and some accent LED's under them? i think that would be really cool :D

[metrometro]

LEDs can be embedded into epoxy and are fairly waterproof when they are. So, probably. But you're going to fling all kinds of road crude at them, so think about sealants, like a clearcoat over the top of all of it.

[jacko622]

For carbon, where should i get it, and how much do i get? I'm having a bit of trouble on this but this looks like a fun project. Also, when riding the frame what cautions do i need to be aware of?

[Technochicken]

I found mine on ebay, but if you just search for "carbon tow" you should be able to find other sources. I do not know an exact amount, but 1000 m should be more than enough. As far as cautions, I ride it just as I would any other road bike.

[jacko622]

Thanks! I had heard that you can't get the bike wet, is that true?

[metrometro]

The Epoxy should seal the outside surfaces, but really high humidity for long periods might do bad things for the 'boo. You really don't want it changing shape.

[kingandygonz]

when you say "nodes" is that the little membrane the compartmentalizes the bamboo?

[Technochicken]

Yes, exactly.

[cletero]

Hi, I'm stuck with the wrapping of the tubes with carbonfiber: what pattern should be used to wrap around the joints? especially the bottom bracket area! I would appreciate any comments about this? Using carbon cloth is nice but at the long run, it takes longer, since you have to do one layer at a time, wrap it, let it dry, sand, etc, etc.

[Technochicken]

I doubt using cloth would take longer. For the joints to be strong, the direction of the carbon fiber needs to vary (as it does in woven cloth), so that the joint is strong in all directions instead of just one. To get fibers perpendicular to the natural wrapping direction, I cut short strips of tow, lay them along the joint lengthwise, in the direction of the tubes, and then wrapped around the tubes with more fiber. The bottom bracket area is especially difficult to fill by just wrapping around the tubes in an easy wrapping pattern, so you will need to cut shorter strips of carbon tow to lay across these gaps and fill them.

[cletero]

Thanks for your reply, I think I've got it. Great! Seriously, cloth takes longer, you have to carefully cut the patterns, lay each layer, wrapp it, let cure, then same layer on the other side of joint, etc, etc. Check out Brano Meres website and see. But anyway, it's just my opinion. Thanks again and have a great day!!

[Hiphoppapotamus]

That frame looks incredible. I was wondering could it be built using carbon fibre cloth instead of tow? What would be the advantages/disadvantages?

[Technochicken]

You could definitely build it with cloth. With cloth, you will be able to use less material to get a strong joint. Also, cloth may be easier to work with, since it covers much more area at a time. The reason I chose tow is because cloth is much more expensive.

[pcook-2]

I am desperate to do this. I live in the UK and cannot find bamboo poles for love nor money though. If anyone could point me in the right direction I'd be forever indebted....

[Hiphoppapotamus]

I'm in the same boat, though I've found a couple of options. eBay has a limited selection, but look at the right time and you may get what you need. also, try this website -> http://www.japangarden.co.uk/Buy-Bamboo-Poles-Twine-c-346.html
It's pricey but has a decent selection

[Toastalicious]

i'm sure you'll find some. Either go to the garden shop and buy a plant and wait for a few months, or maybe you'll find some at a fancy asian hotel and maybe they'll let you take a pole or two

[Aik68]

The chain seems too short, you may need to add some links.
As a rule of thumb the two idle gears of the rear derallieaur should have their axle on a vertical line when you put the bigger crank and the smaller pinion.
Compliments for the nice frame!

[frisbeechamp1983]

Total cost?

[Technochicken]

For the frame:

Bamboo: Free
Donor bike for droputs, bottom bracket, headtube: Free
Carbon Fiber: 50$ on Ebay
Epoxy: ~50$ + 20$ for dispensers

[curious youth]

this is a great looking bike. would the frame be strong enough to make into a bmx ? id love to show it off at the local skate parks lol

[Technochicken]

I think you could build one strong enough for BMX, as long as you used thick walled tubes and heavily built up the joints. However, I do not think it would do well if the tubes were impacted frequently. In situations were metal tubes would dent, bamboo would more likely crack.

[curious youth]

ok then cheers mate. but yeah i wouldnt be doing anything to special. when i get to it and get it done (finding suitable bamboo is hard around my parts) ill definately post pictures

[#OccupyInstruct]

how much does it weigh? it looks relatively light

[Technochicken]

The frame or the bike? The frame weighs in at about 5 pounds, which is not especially light. If I built another, I could definitely cut at least a pound off the frame.

[yellohello]

How much would you charge to make me a bamboo frame?

[Technochicken]

I've decided that I would not sell frames for a few reasons. First, the amount of time they make means that I would have to charge a lot to make it worth while. Also, if somehow the frame did fail, I would not want to be responsible. If you are interested in buying frames, I would take a look at Boo Bikes and Calfee Design, or Bamboosero for less expensive options.

[khall-1]

Very Cool design, fascinating, thank you for sharing.
What is the ability for the power to source the LED lights to be generated from the movement of the bike?

[Technochicken]

You could easily harness enough energy from the movement of the bike to power the LEDs. You could use systems like these:

http://www.instructables.com/id/Bike-Generator/

http://www.instructables.com/id/Contactless-dynamo-bike-wheel-lights/

If you built the coils of a contactless dynamo into the wheel rather than the frame, you would not even need any brushes to conduct the electricity to the spinning wheel.

[Tyler5]

For the first tacking did you just use epoxy, and did that hold the tubes in place well?

[Technochicken]

Yes, I used epoxy. It works well, as long as you are not putting much stress on the frame.

[frisbeechamp1983]

where can you get bamboo? I would like to get it free, any ideas?

[Technochicken]

I cut mine down behind a local park. Chances are there is someone in your neighborhood with a bamboo growth who would happy to let you cut some down.

[Tyler5]

What kind of bamboo did you use and did you buy it locally or off a website?

[Technochicken]

I cut down the bamboo locally, so I did not have to pay for it.

[Tyler5]

Ok. But what bamboo did you use?

[Technochicken]

I don't know what variety it is, but as long as the bamboo you use has sufficient diameter and wall thickness, the variety should not matter too much.

[jboucher2]

How much did the sum of the materials end up running you? Don't want to get started if I can't afford to finish it.

[Technochicken]

I paid about 120$ in total for the epoxy, dispensers, and carbon fiber.

[apray12]

How much of the Epoxy resin/hardener did you end up using? Did you mix 1 to 1?

[Technochicken]

I used west 105a resin and 205a hardener, which is the smallest size set West sells. I used about 3/4 of the epoxy. I bought dispenser for the containers, which dispense them in the appropriate ratio, which is 5:1.