Instructables
Picture of DIY Bike Rollers
It is my personal belief that many people own bicycles, and that many of those people aren't interested in riding for pleasure / exercise when it is raining, snowing, dark, etc. outside, and that many of those people would ride their bicycle indoors if they had a fun and challenging device that allowed them to do so, and that many of those people would build such a device themselves if given the encouragement and advice to do so. Thus, if my calculations are correct, this Instructable my indeed be appropriate for, and benefit many people.

DIY Bike Rollers from Jason Sauers on Vimeo.


Some people prefer stands and other types of trainers over rollers, but to me there are a few appealing aspects of rollers vs others:

More enjoyable
Faster / more intense Workouts
More challenging / engaging
Better all-over body workout
No adapting or installation - just set the bike on and go

Some may argue that it isn't worth the cost (a new set can be bought ~ $200) and time to build your own, but that can be said about almost anything-
I enjoy building things, I had all the materials that I needed, and it only took a weekend to build.

The building isn't particularly challenging, so long as you are familiar with basic construction / projecting techniques, and have access to the necessary tools and materials.
I would not however suggest this as a first project, or for someone who does not have experience with similar projects.

P.S. I do not intended for this to be a set of step-by-step construction plans, as I feel that those who will likely have success in completing a project like this will be able to easily fill-in the b_a_ks that I may leave.

P.P.S. This is another homebuilt setup (much more sophisticated than mine) that I didn't find until writing this - however for me the free-motion feature isn't very important :
http://www.bikeforums.net/showthread.php/196027-Home-Made-Free-Motion-Roller-Assembly?highlight=home%20made%20free%20motion%20rollers
 
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bosko901 year ago
nice homemade roller. how long did you build?
I have also build roller, but it is metal.
http://www.youtube.com/watch?v=cuokBHPx2Mo
Sky-Monkey (author)  bosko901 year ago
Thanks. It was more than a couple years ago now, but I think that I built them in two evenings after work. I like yours also - At the time I had access to free lumber - If I were to make another set, It might be quicker to use Metal angle or tubing as you have. Cost might be higher for metal, depending on your source. Thanks for sharing
Please could you email me some pictures of you DIY bike roller without the bike on so I can have a go at making it? email: kirkpatrickaj2008@hotmail.com. Thanks,
Sky-Monkey (author)  kirkpatrickaj1 year ago
Are you looking for something different than this: ?
http://www.instructables.com/id/DIY-Bike-Rollers/step2/Dimensions/
Let me know -

jlocke81 year ago
Thank you for this instructable! Great plans, I built one and it works great! I modified two steps. Instead of using a steel rod which spans the entire pipe, I used 4 inch 5/16th bolts which are fixed to the frame. Also instead of sewing the strap which connects the front and back roller, I used a series of velcro patches.
Sky-Monkey (author)  jlocke81 year ago
Sweet! Glad to hear it. I like your idea of using velcro - makes it easier to assemble/disassemble and its adjustable. Good thinking.

lcit20031 year ago
The wooden inserts into the PVC roller.
lcit20031 year ago
What do you have between the roller and the frame so the roller doesn't wander and rub on the frame? Im thinking somehting like this:

|Frame| /\/\/\ |TW| |FW| |TW| |Roller| 

/\/\/\ = Spring TW=Teflon washer FW=Fender washer

...and kudos on the wheels, I had a guy turn mine with a lathe for $25. (yours are still better)
Sky-Monkey (author)  lcit20031 year ago
I actually didn't use any springs on mine, although there is no reason you couldn't. So long as the roller isn't too tight between the frame, or too sloppy, I think that you can pretty much get away with whatever configuration you want. On mine, I simply had a fender washer against the roller, and a regular flat washer against the frame so it was
|Frame|W| |FW|Roller|FW|W|Frame|.
Hope that helps.
What exactly do you mean by the wheels?
schumi231 year ago
Looks nice!
I got a resistance trainer for free recently, so the chances of my making it have been reduced to 0, but before I got it I was planning on making it...

Though I have never understood how those work! (Other than keeping your balance, like with a track stand (I do track cycling.)

O, and final note: Get in the drops! :)
Suzukisv2 years ago
Hello Sky-Monkey

I like your design. I've used steel rods but they are to heavy, arround 4kg. Will now use pvc rods to see if this goes better. Will let you know the results.

Greetings from Holland

Suzukisv
Sky-Monkey (author)  Suzukisv2 years ago
Did you use steel pipe? What diameter and wall thickness? Did you make a complete setup or just make the rollers so far?

Sounds Interesting. Look forward to hearing more about it.

Best Regards from the US
spincycle472 years ago
Hi everyone,
i am using the white pvc pipe for my rollers. i am planning on using clean out caps to hold my bearings. the problem is the clean out caps are made of ABS not pvc. apparently the hardware stores (Lowes, home depot, ace) around my area does not carry pvc clean out caps. Does anyone know if the ABS material can hold up to the load? i am at 196 lbs and my bike is about 22lbs. thanks in advance.
RadEd2 years ago
I finished my build - but am having issues getting everything to roll under load, everything rolls easily without the bike (and me) but as soon as I added the webbing and add the bike the front and centre roller freeze up,
There's no movement in the webbing - so that's tight enough (could this be too tight to accomodate any flex under load?)
Sky-Monkey (author)  RadEd2 years ago
Do the rollers spin easily with the webbing on and no bike? sounds like something is binding somewhere -
What size bearings are you using? what size axles?
if you can take some pictures of what you have together, It might help with identifying the trouble area.
jamesblond2 years ago
Hey there.....this is an amazing site -- i really like all the enthusiasm people have for actually doing and making things instead of sitting around and watching TV!

I recently picked up a vintage set of rollers that I would guess date to the 60s, made of steel tubing with three bright blue steel rollers, and I have two questions that maybe you can answer.

The frame is adjustable, so you can slide the front half backwards or forwards as you like. And so I did it guess-timating that the front roller should be just a little ahead of the front axle -- which is pretty much just what you said. But then, you also said to estimate 53 inches distance between the front roller and the ":averaged" distance of the two back rollers, for a bike with axles that are 51 inches apart -- and I don't think my front axle is a full two inches behind the front roller, it's more like a 1/2 inch distance.

Sooooo....I guess I am wondering if that discrepancy matters? The thing is, the further I expand the frame, the less sturdy it gets, so if this is fine, I would rather leave it as is, but if it;'s not, I will expand it. Not even sure if you can answer, but any insight is welcome.

Other question is about the rollers -- they were once a bright, bright blue enamel over the steel, but the enamel in the middle of the rollers has worn away leaving nothing but a swath of rust-covered steel, which makes the whole thing look bad and makes me a little nervous that the rust needs to be stopped somehow or it will compromise the rollers somehow -- get in the bearings, or even -- as a fine powder coming off the rollers -- get into the gears and workings of the bike.

Sorry to go on -- the question is, do you have any idea if I could repaint them myself, and if so, what kind of paint I could use?

Thanks again!
Sky-Monkey (author)  jamesblond2 years ago
The distance between the rollers is mainly just important to keep the bike in place. If the front tire is too far forward on the front roller, the bike tends to want to roll forward and off of the rollers. If the bike stays put with where you have it set, I would leave it there.

If you want the rollers to look shiny and new, I would recommend cleaning, sanding, and re-cleaning them before priming and re-painting them. If the rollers see heavy use, the paint will likely wear off eventually, but it should be fine for a while. If you spray a couple coats of clear over the color coat, it will hold up better than color alone (not too heavy with each coat - a few lighter coats is better). Be sure to let the paint dry well before using them - if you can leave them out in the hot summer sun for a couple days you should be good.

Let me know how it goes, and post a picture if you can once you finish, I'd love to see them
Hey thank you for this -- I would have guessed some of this but not known exactly, so this is very helpful.

One question, though -- what kind of paint would be the best to use to paint them? And what kind of clear coat would you recommend? And also....if I can't all the rust off, should I not bother trying to repaint them?

Again, thanks again for your helpful feedback.

Blond.......James Blond
pbagus2 years ago
I like how the blog is loaded with new ideas and thoughts. I love the way everyone who visits it leaves their comment.
fuj1b1ke2 years ago
Rollers are finished. See http://photos.toast.net/trost/Bike . I used a replacement belt from Performance which was relatively inexpensive and beveled narrow slices of the PVC pipe to form a pulley. Works well.

One big surprise is how much peddle effort it takes even though the rollers run very free. I had assumed it would take hardly any. The bike is a road bike with 700 x 23 tires. Is this typical? So far I'm riding keeping one elbow against the wall for support. I can see it will take some time.

Fun project! Thanks! RCT
Sky-Monkey (author)  fuj1b1ke2 years ago
Excellent job! - looks very well thought through and executed.

It is surprising the amount of effort it takes to turn them - if you haven't already, try shifting while you are riding and see how the different gear ratios effect the difficulty.

For a while I rode mine one handed with one hand against a wall - it does take some time to get the hang of it, but your balance will improve quickly

Nice work
fuj1b1ke2 years ago
Bought bearings from ebay, $1.50 each, pvc pipe from the local hrdwr. store and cut discs from oak ply I had on hand. The rollers are assembled with bearings, looking good, so off the the hardware store for 3/8" steel rod. OH CR*P!! Turns out hardware store rod is "roughly" 3/8". Not only is it oversized but not perfectly round either and won't fit the bearings. A 3/8" drill bit fits the bearings perfectly. Did you use 3/8" drill rod or luck into hardware store rod with proper dimensions.
Sky-Monkey (author)  fuj1b1ke2 years ago
The 3/8" rod I used was from the hardware store - I would take one of the bearings you have to a couple different stores and try checking for fit. Some hardware stores also offer galvanized steel rod - which may also be worth checking. Worst case I guess you could order a length online - the rod that mcmaster sells says that it is .003" undersized which should work fine. Good Luck
fuj1b1ke2 years ago
The picture appears to show the center of the front roller well ahead of the front wheel's axle. My sense, maybe wrong, is that the further ahead the roller is in relation to the wheel's axle the twitcher the steering would become. The problem being that if the axle were directly above the roller the front of the bike would be higher than the rear unless you accomodate that by either lowering the front roller or raising the rear rollers or frame. Is this truly an issue or am I over thinking things?

I do like the idea, especially the foot pads! I'm off to price parts.
Thanks, Rich
Sky-Monkey (author)  fuj1b1ke2 years ago
I think that the alignment concern is less of an issue than you might think. I have used the setup with the rollers in the same position with three different bikes - each with a different wheel-base. The shorter wheel-bases (the front tire further behind center of the roller) didn't seem to effect the "twitchiness" much if at all. The height change from having the front tire slightly higher (or even lower) than the rear is almost imperceptible. If you can notice it, I would either just shim the lower end up, or put screw-adjustable feet on the frame for leveling purposes. The one thing I would recommend is that you make sure that the front tire doesn't go in front of the front roller. Having the front tire slightly behind the front roller helps keep the bike from wanting to jump forward off the rollers. Let me know if any of that is confusing, or you want further clarification.
Thanks! I can see the wisdom of your advice. And after giving my post more thought I may have been wrong about making the steering more sensitive. Checked the local hardware store for 3" PVC schedule 40. They only carry that in grey pipe intended for electrical conduit. Guess there's no problem with that.

Videos I've watched show the rear wheel slewing side to side rather rapidly. That must feel wierd at first.
Sky-Monkey (author)  fuj1b1ke2 years ago
It is a very different sensation than riding a bike on a flat stationary surface, and it takes a bit of practice to get the hang of it. Don't get discouraged if you don't pick it up immediately. It takes a bit of persistence. Good luck with it
sb372 years ago
Can you (or anyone else) explain why the front wheel needs to spin ?
Sky-Monkey (author)  sb372 years ago
If the front wheel isn't spinning, it is extremely difficult to stay upright
(this essentially happens if the belt jumps off the roller or becomes overly slack)

There are two main reasons that I can identify:

1- If the front tire is not turning, it will not want to track side to side, and you wont be able to steer or balance well (you could set something up to hold the front fork fixed and steady, but then you would essentially have a stationary trainer)

2- The added gyroscopic effect of the spinning front wheel helps you to balance. Rollers are reasonably difficult to ride on even with both wheels spinning... trust me. It takes a bit of practice

Let me know if you need further clarification
Hi Sky,
nice stuff here--I'm prepping to do a version of this. But where did you find 3/8" bore bearings to be able to fit 3/8" rod? All the skateboard bearings I've found are 8 mm or 0.31"...
Thanks,
Sam
Sky-Monkey (author)  oldbaldfatSam2 years ago
The bearings I used were not actual skateboard bearings, but 3/8" ID bearings I had left over in my shop from something else.

If you want 3/8" ID bearings, it looks like you can get them off ebay for ~$2 each
http://www.ebay.com/itm/10-R6-ZZ-Ball-Bearings-3-8-x-7-8-ID-Bore-375-inch-875-/130253727695?pt=LH_DefaultDomain_0&hash=item1e53ba27cf

dhouggy used actual skateboard bearings in his build - you might want to check it out if you haven't already: http://www.instructables.com/id/Bicycle-roller-trainer/

I guess my suggestion is to use whatever is easily accessible and fits within your budget - Im sure you can come up with a more clever solution than mine.

Post some pics and send me a link when you finish it. I'd like to see it.
tnx!
gb23832 years ago
I'm going to have a crack at building this. Rollers are a bit pricey for me, but this looks spot on. Thanks Sky-Monkey.
There's one issue, I can't source material for the rollers that would suit. I live in the UK and the hardware stores have plenty of PVC pipes for plumbing (guttering and waste), but they are too thin/flimsy. Where would you find plastic pipes with walls like yours in the photo? Are they used for anything specific? I'm clueless about this.
Thanks!
Sky-Monkey (author)  gb23832 years ago
The PVC pipe is pronounced as "schedule 40" (Sch40) and is used for plumbing - I'm not familiar with what material is available in the UK, but here in the US it is very common. It may be worth checking at a dedicated plumbing material distribution place, or some other hardware stores. A thinner walled version that is available around here is "class 200" which is used in irrigation and drainage.
I have also seen wooden rollers used - if you can find some decent 3" or so diameter logs, and have a way of drilling them - that may work.

If you can find 2" diameter sch40 PVC - you could also follow dhouggy's instructable http://www.instructables.com/id/Bicycle-roller-trainer/

Best of luck, and let me know how it turns out
susanrm3 years ago
Nice, nice, nice. Wish I had a wood shop, or the ex-boyfriend who had a wood shop. :-) I also like the idea of connecting it to power something.
snotty susanrm2 years ago
I used my living room as a workshop. I ran a small bike repair business and even fabricated a camera crane and dolly there. The trick was having understanding roomies and cleaning up promptly when I was done. Nobody in the house minded much since I would repair their bikes for free... Also hand saws are quiet and don't kick up much dust so they're more house friendly.
susanrm snotty2 years ago
That's really cool. I just don't have the space, plus with pets around, it makes things more complicated.
snotty susanrm2 years ago
I get ya.

I guess my point is that it's important to remember how very much we can do with a few simple tools. Our best tool and our biggest impediment is often our own imagination.

But that's enough ranting out of me for today.
GeArGuY2 years ago
I'm not seeing too much flex in the pvc, but If I ever built this, I would use steel, just to play it safe.
tigerbomb82 years ago
a more stable way is to lift the back tyre and put it on a stand and put a roller against the tyre to add friction
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