This is an instructables on how to make a wooden balance bike that is also my diary of making for my GCSE product design project.
Step 1: What You Will Need
To be able to make this balance bike you Will Need the following:
2cm thick plywood
2cm thick pine (floorboard without tounge and groove)
2.5cm thick dowling / brush handle
2x 28cm diameter hard foam wheels/balance bike wheels
1cm thick threaded metal rod
10x 8mm cap nuts
8x 6mm cap nuts
2x wing nuts to fit the threaded rod
6x washers to fit threaded rod
1x lock nut to fit threaded rod
8x 0.5cm thick screws
4x 8x2cm metal rectangles
6x multi purpose screws
pencil + measuring equiptment for marking
Step 2: Front Forks (X2)
To make the 2 front forks you will need the 2cm plywood and a saw. Firstly you will need to cut out 2 rectangles measuring 48x4cm each. Then measure 5cm from one end and mark then 19.5cm from the other end leaving 23.5cm inbetween the 2 points. Then at the 2 points cut in the wood 5mm on both sides of the wood on both pieces and then mark the ends of the cuts together and cut out this small rectangular section. This should now look like the picture
Step 3: Rear Swing Arms (X2)
You will then need the plywood again but this time it needs to be cut into 2 rectangles measuring 29x4cm each. Then from one 4cm end measure inwards half a cm from each edge. Then draw a line from the two points (either end of the 3cm marked previous) joining to the corners of the 4cm end opposite so it should look like an arrow and cut off the 2 triangles marked on the outside edge then using a sander round off the two corners of the larger end.
Step 4: Seat
Then using the 2cm thick pine cut out 2 triangles measuring 33x32x9.5cm each. For the main saddle part then cut out 10x35 cm rectangle. After that measure 2.5cm in from one end and mark so that you have 5cm left inbetween the 2 points and once again join the 2 opposite corners to form 2 outer triangles again and sand all the corners to a rounded edge so that it looks like the picture.
Step 5: Body
Main body With the 2cm plywood cut out a rectangle 32x37 cm roughly and using the picture as guidence cut out a body shape with the same measurements.
Step 6: Wheel Fixings
Take your metal plates and then drill a hole at one end so the fixing rod off the wheel fits through it and round off the edge around the hole and then drill 2x 6mm holes one 1cm in from the opposite end and the other 3cm in from the other end. All holes being in the center allignment.
Step 7: Drilling
you will need a 8mm drill bit then get the 2 seat triangles and measure from the 9.5cm side 1" inwards and mark a line down parrallel to the side and then from either side going up the line mark 1" and drill where the lines cross.
with the same drill bit get the swing arms and mark the centre line then 4cm in from the 4cm side and mark and 9cm in from the same side and mark and then drill where the lines cross.
Then get the body and measure 3.5 cm in from the 20cm edge and draw a line parallel then fron the 19cm edge measure down the line you have just marked 2" and drill a hole and then 3 more 2" apart going down the line as these will be to be able to adjust the seat height.
just then cut 2 small blocks 6.75x2.75cm in the 2cm thick pine wood then with the 2 blocks you have cut mark a hole in the middle using the same sized drill bit and drill both pieces the same.
Aswell cut a hole in the middle of the rectangle on the body going down the centre (lengthways).
Then find the centre of the squares at the top of the forks and drill a hole through both at the same time 24mm wide to fit the handle bars through.
Step 8: Finishing the Forks and Swing Arms
Get your front forks again and measure 5.5cm up from the larger rectangular end and cut down 5mm and cut out that section on both forks (only do to one side of either fork.
Then with the swing arms measure 6cm up from the 3cm end and cut down 5mm and remove that section on both arms (only do to one side of either arm.
You will now need the 6mm drill bit and drill 2cm up from the section you have cut out of the front forks and then 4.5cm up from the start point so you should have 1cm clearence of the top of the notch in the forks you have just cut (both holes in the centre allignment again)
Then with the rear swing arms measure 2.5cm up from the 3cm end and mark and then another 2.5cm fron the previous mark and mark once again leaving 1cm clearence from the top of the notch like on the front forks.
Step 9: Packers
Once again with the 2cm plywood cut out 4x 11x4cm rectangles as these will be the packers between the rear swing arms and the body. Then with 2 of the rectangle cut then down to 5mm thickness so you have 2x2cm thick pieces and 2x5mm thick pieces. Once you have done this place all the blocks in line with one of the swing arms and drill through the two 8mm holes previously drilled so that all packers and swing arms match. When you have done that sand around the packers to create a rounded edge fitting the swing arms.
Step 10: Attaching Swing Arms and Packers to the Body
Get the body and measure from the bottom of from where the 22cm and 20cm edges line up the packer should fit in line with the body's rounded edge and the swing arm line up so only leaving 3cm up from the body's 20cm edge to the end base of the swing arm so it should look like the picture. Then drill the hole through the swing arms and packers with the body sandwiched equally between and drill the body so it all lines up. After drilling insert 2 lengths of the threaded rod both cut to 14cm long and place through the swing arm a large and a small packer then the body and the same on the opposite side of the body making sure the notch that is cut out is on the outside and then glue all 7 pieces together making sure they are held firmly in place. Once the glue has dried put a washer on either end of the metal rods and attach 4x 8mm cap nut on all ends making sure to fit comfortably cutting off any excess rod for the cap to fit properly so no rod is exposed.
Step 11: Attaching the Seat
Take the 2 triangles you have cut and drilled and cut 2x 7cm of the threaded rod and place through the body and 2 triangles making sure the straight edge of the triangles are facing upwards. Then place the thinner enge of the seat 7cm away from the end of the straighter edge of the triangles making sure its straight and put 4 multi purpose screws through to attach the seat to the triangles. Also cut the rod to fit snugly on the 2x 8mm cap nuts the same as the swing arm and then put 2x wing nuts on the opposite side to allow you to adjust the height of the seat.
Step 12: Attaching the Handle Bars
With the dowle already cut to 36 cm put it through the 2 large holes drilled at the top of the forks and make sure it is even (about 12.5cm out of each hole) and then use 2 multipurpose screws to secure in place.
Step 13: Steering
Your bike should now be looking something like. Now take a bit of plywood and cut it so its the same size as the rectangular out crop of the body and then cut it so that its only 1cm thick. Now you should have 2x 1cm blocks the same size as the body piece. Once you have glue them to either side of the body and sand them to form a cylinder like shape.
Step 14: Then...
Using the 2 small rectagular blocks that were cut and drilled place 1 just under the top small rectangle of the forks so it sits with the longer length facing forward inbetween the 2 forks and secure in place so it all sits under the top rectangle and screw in place using 2x multi purpose screws. After that measure 10cm down from the base of the block and place the second block making sure the body sits in line at a small angle and the holes line up, once in line screw the second block in place using another 2 screws. Once done place a piece of threaded rod through all three holes (18mm in length) then put a washer on the top and a 8mm cap screw and underneath a lock nut and then a 8mm cap nut ontop of that (making sure that they all fit snugly on the rod without any rod showing, then your steering should be done.
Step 15: FINALLY...
Take the wheels with the metal already attached and line up the holes with the fork notched piece and drill holes putting in the 5mm screws and cutting down to fit the 6mm cap screws and then do the same for the rear swing arms. If the notches dont fit in with the wheels then take a small piece of wood further off the end of the notch until it fits properly.
Just to finish off paint the bike in your desired colour scheme and make sure all the screws and nuts etc. are tightened properly until finally then your DONE.
disclaimer: I will not be held responsable for any injuries that may occur when/after making this product or what the product is used for.
Step 16: My Finished Product