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
- 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