Step 4: Metal work

Step 1:
Take the Aluminum sheet and print out the template 
Picture 1,2,3

Step 2:
Cut the bracket out of the aluminum sheet according to template using a metal saw and bend the bracket tab according to picture
Picture 4 and 5

Step 3:
Cut out the mount arm from the aluminum sheet
Picture 6

Step 4:
Cut holes into the mount arm (according to template) and attach the servo wheel to it using #3 bolts. Cut any excess bolt length after attaching a nut. 
Picture 7, 8

very good man great work welldone
<p>Has anyone actually been able to solve the battery life issue ?</p><p>If so then that would be great to hear how.</p>
<p>I've been tinkering around with an arduino and an old rear derailleur trying to implement something like this, but wasn't sure of the best type of motor to use. I'm thinking of a worm gear rather than a pushrodand servo, as it will hold its position without power. Does anyone have any recommendations about where I can find motors that are lightweight and powerful enough? It's a bit tricky trying to estimate how much torque you need to shift under load, so I'm just guessing as to how much grunt the motor needs.</p>
<p>I just want to ask if their are other factors that can change gears automatically besides to the bike speed, pedalling rate and pedalling torque?</p>
Such a great hack! Congratulations! I'll do this in my commuter bike! Thinking in house this inner seat tube and with 18650 cells in pararael custom mount. Congratulations!
thank you , <br>for the help,to make this very interesting project.
Thank you for this!!! <br>It's exactly what I was looking for.
Will say this is really incredible! Yes I know this is WAY too far in advanced but how about programming it around a smart phone app(s) that would take out alot of the problems with your GPS, Terrain inclination, heart rate, and other factors!?!?! Just a thought to help you out :) . By all means I know this right now is in it infancy.
Awesome idea and I look forward to reading your Blog!
great project!!!! <br>do you have in mind for the front derallier? <br>i would like to see a video with this working. <br>can you fine tune without pc just in case it happens somethin on your ride? <br>great!!!!if you add the front derallier i will built it the same time!!
Love the work you've done on this! <br> <br>Here's an idea for when you get the front der added to the mix: <br> <br>Since you are using an arduino, how hard would it be to program in a gear sequence so when you hit the upshift or downshift buttons it progresses to the next gear in a logical sequence, moving either or both the front and rear ders? <br> <br>Also, since my ride is a home built trike with a mid-drive, I have 1 front on a triple, a 6 cog mid, and a 7 cog final. Could this be programmed to account for all three? <br> <br>I would definitely be interested in building something like this! <br> <br>Thanks for the 'ible!
Very cool project!! <br> <br>Shifting in sequence is very doable but I question its usefulness on the road at least for the way most bikes are geared and the way I ride. <br> <br>First, although, mathematically, there may be 21 gears, there are usually duplicates. You would not want to waste time shifting to a gear that is marginally different. Ok, you need to (and can in fact) program the arduino to bypass one or the other. <br> <br>Secondly, when I shift I usually change only one derailleur. To clarify, say I have a triple chain ring. On the ride, I find a sweet spot using the middle ring. UpHill coming - I switch to the smaller front or a larger rear but not both on one shift. Don't need to - one or the other improves my situation and usually close enough. If not close enough, I tweak (probably with the derailleur I did not change initially). Chances are my changes are not sequential at all. <br> <br>So maybe a programmed set of &quot;my favs&quot; gears would be more useful whether accessed sequentially or directly. <br> <br>If we really were to put in the bells and whistles, Version 17.1 would chose the gear for you based on your cadence, heart rate, the incline, your power output and your fitness level and length of ride. It also stores your ride history and uses predictive logic to determine the gear and when it will shift. <br> <br>But I am happy with the promise you've shown so far! Good job. Very inventive.
&gt; how hard would it be to program in a gear sequence so when you hit the upshift or downshift buttons it progresses to the next gear in a logical sequence, moving either or both the front and rear ders? <br>Not difficult at all. A few people have requested this so I'll add it to the feature list. The only difficulty is making installation easy with all of these new configurations. <br> <br>&gt; Could this be programmed to account for all three? <br>Definitely. The next version has an LCD so each user could choose their configuration on the screen.
Fantastic! <br> <br>Thanks!
Nice Instructable!<br> <br> I can tell you the front derailleur is much easier to control with a servo than the rear. I have been working on a similar project for some time <a href="http://www.diyshift.com" rel="nofollow">http://www.diyshift.com</a> . Have you had any problems with derailleur ghost- shifting over large bumps? That&nbsp; was one nut that I was having difficulty cracking without leaving the servo powered up and eating batteries.<br> <br> I look forward to seeing your updates and test results.
maybe the inclusion of a wormgear would hold the derailleur in position when the electronics are sent to sleep between shifts? Perhaps something along the lines of this would optimise battery power conservation http://interface.khm.de/index.php/lab/experiments/sleep_watchdog_battery/ <br> <br>I think this is great and should provide endless funin the dark winter nights when riding is impossible... <br> <br>well done to all!
Thanks for the kind comment. Good to hear the front derailleur will be easier to modify. I've seen your project a while ago and looks like you've made a lot of progress lately. I'm really impressed how professional it looks especially for someone who started tinkering with electronics in 2011!<br><br>&gt; Have you had any problems with derailleur ghost- shifting over large bumps? <br>I have. I'm thinking of adding some tension or a normally closed brake to hold the derailleur in place to fix this.<br><br>Maybe we should chat and see if we can help each other out. Email me at nabil dot tewolde gmail.com. <br><br>
The Shimmano system makes sure it moves the derailleur when the chain lines up with the shift ramps on the cogs. This means you can stand up and pedal as hard as you want while shifting and the shift is still smooth. I have no idea on how they manage this. It doesn't look like they have an optical sensor on their. Anyway, just an idea if you're looking for upgrades. Great work! I've been wanting to try something like this myself.
Thanks :)
Great work!!! <br>Referring to the schematic, could you please explain futher the use of the transistor to switch the servo power? I've only seen this done with the base being used to control the load. Thanks.
This is a mistake in the diagram. The transistor I'm using has a different pinout than the one in the Fritzing. I wired it so the breadboard view was correct, but this meant the schematic was incorrect. Thanks for the heads up. I'll get on that.
How can I hold position on the servo, <br>for example I want to shift into Gear 5 and hold that ?
In the current implementation the servo is always on so that should hold whatever gear you're on. In the future I plan on designing a mechanical fix.
Put a force sensor on the pedal and program it to change gears automatically ;-)
VERY cool, enough that I may spend some of my limited free time to try this. Went a little crazy with the text boxes... :-)
Hahahah, yeah I totally did.
Instead of fixed step sizes, I would think an array of ideal positions would be better, since the best rear derailleur position changes depending upon the front derailleur. When in manual mode, it could tweak the current position for the gear combination.
You could also install a temporary set of +/- buttons on a removable tether near the gear shift buttons so that the derailleur positions for each gear could be adjusted on the fly, while riding. Once the positions are ideal for each gear the tether could be removed.
This is a great idea. Once I get the front derailleur working I'll add this feature.
That's a cool idea!<br> <br> For an anti-theft system: <ul> <li> install a teeth-less gear, <li> at shutdown, servo will select that one, <li> implement a secret sequence of presses to unlock, or a keypad. </ul>
Great idea! I was also thinking to have the computer removable so nobody steal. This could also act as another form of anti-theft.
So my thoughts are, first, this is already really fancy, but if you wanted to get EXTREMELY fancy, you could input your specific sprocket sizes into the program, then add a gyroscope, and some way to measure speed onto the system. Then, (idk if the arduino can get this fancy) you could program the computer to automatically shift depending on the incline of the road and your current speed, using its knowledge of the sprocket sizes to find the ideal gear ratio. With some trial and error, the system could ensure you are at an optimal gear ratio and there for optimal (maximum) speed at all times.
If you did this with a IOIO board and an android phone, you could use the android's accelerometers or GPS + topo map to get decent results, I think. That would be a fun project. Maybe I'll try this next summer.
Maybe add an accelerometer so it does not shift while the chain is on heavy load?
These are great ideas, which I'm in the process of <a href="http://www.nabiltewolde.com/2011/11/bike-computer-v01-build.html" rel="nofollow">testing</a>. I'm not sure I would like my gears to change for me, but this seems to be a feature lots of people want. Thanks for your input.
I was previously thinking of doing that but have an lcd dashboard and stepper motors all controlled by an arduino uno and an atmega 32 or pic16f877a. There was no gps idea but I won't include it as it is expensive in our country. can it be made with steppers? and if so can you upload another code for the stepper one? <br>I try to get a new derailleur and use the old one for this project. and what servo size are you using?
PS: I only have a rear derailleur ok.
&gt; can it be made with steppers? <br>Maybe, but I wouldn't recommend it. They tend to have less torque compared to an equivalent size servo. They are generally used when you need high accuracy. <br> <br>&gt; and what servo size are you using? <br>I am using the medium size HiTEC HS-225MG Servo.
Great instructable. I am thinking of something similar myself. I think the front derailleur will be a harder nut to crack because of the forces on the chain esp when going up hill or when out of saddle. <br> <br>I also thought of using a worm gear from a guitar machine head and then send the arduino to sleep to save battery consumption. <br> <br>Anyway keep up the good work. <br>
When you do the front derailer, if you make it workable with a 3-ring derailer then you will be ahead of Shimano and Campagnolo, since thier electronic shifters work ONLY with 2-ring front derailers. <br> <br>Super cool project!
Awesome! You could add a dynamo and charge controller so you can ride an unlimited time. <br>http://www.google.com/products/catalog?hl=en&amp;q=bike+dynamo&amp;um=1&amp;ie=UTF-8&amp;tbm=shop&amp;cid=3052823855019776153&amp;sa=X&amp;ei=btHQT6LqA4f69QTKj6G_AQ&amp;ved=0CKkBEPMCMAc <br> <br>Good work.
Di2 envy?
Finally a way to fix my bike! My derailleur has been messed up for quite some time now because it has not been shifting properly. Thanks for posting!
Do you think that this will work w/ a velomobile? <br> <br>I am just getting into the Arduino myself (still haven't gotten it in the mail, I ordered it last week lol) &amp; I can't wait to get into the work w/ it &amp; start programing &amp; posting projects for people to use. <br> <br>All things considered this is a wonderful project &amp; I can't wait to try it out myself.
&gt; Do you think that this will work w/ a velomobile? <br>Not sure. Did a quick google search and it looks like the gearbox is in a case. Maybe you could connect a servo to the cable lines.
I was thinking of something along those lines, thanks for the incite, that's quite helpful. Keep up the good work.
This is wicked awesome! Did you consider mounting the battery pack and Arduino on or near the seat tube at all? That would reduce a bit of the aerodynamic drag and might keep the aesthetics super sleek. How fast does the servo move into its new position once a button is pressed? Is there a way to increase/modify that speed? How well does the servo handle switching the gears while the chain is under load from pedalling? Great work. I look forward to seeing more!
Thanks! <br> <br>&gt;Did you consider mounting the battery pack and Arduino on or near the seat tube at all? <br>I have and plan to for the next version. <br> <br>&gt;How fast does the servo move into its new position once a button is pressed? <br>Pretty fast. The time it takes a regular servo to move a few degrees. <br> <br>&gt; Is there a way to increase/modify that speed? <br>Not with servos. Only way I can think is buying a faster servo. <br> <br>&gt; How well does the servo handle switching the gears while the chain is under load from pedalling? <br>With the servo on it moves without problem. I wouldn't put all of your weight on it tho. Not good for the gears anyway. <br> <br>&gt; I look forward to seeing more! <br>Thanks a bunch!

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