Step 6: Wrapping the fan in Aluminum

The fan provides resistance for your pedaling by moving air the faster it spins the more air it moves and the more resistance is created. The fan is designed to be completely enclosed except for the side where it draws air in. So far the fan is about half enclosed and we need to make a cover for the top of the fan. This is accomplished with some left over aluminum flashing.

1. Cut a piece of flashing to a rough size larger than you need my fan required a piece 7" wide by 15" long
2. You will need to bend the edges at both ends to a 90 degree angle bending sheet metal is easy as long as you support the edge you want to bend with a metal brake or two pieces of wood and a couple of clamps. Just line up the strips of wood with the mark where you want to make the bend and clamp the wood like a sandwich around the metal. You can use your hands to bend soft or thin metal like aluminum.
3. Start with one end and work your way to the other. Ben one end and hold or clamp it in place while bending the metal around to the other mark it a little over length and cut it off. Then bend it over again and mark your second 90 degree bend at the other end. Using the wood blocks make the bend.
4. Line the aluminum up and mark the cutout to go around the upright support. Cut this out and make sure it fits snug. Once satisfied with the fit nail the flashing down with some short ring nails beginning with one end and moving to the other. Finally go around the edges with a hammer to flatten the edges over making it safe to handle without cutting yourself.

With the flashing in place the fan will now intake air from the side and expel the air at the front under the top of the base.


<p>This inspired me to make my own. However I did modify few points. I bought a set of BMX pegs. Recycled some wood I had lying around in the garage and constructed a mount of sort. It works! Thanks!</p>
<p>Southern Kentucky...long winters...yuk yuk. You're crackin' me up. (Come see us in MN anytime between Oct and May, aka winter.) Great 'ible. Thanks :)</p>
Haha, cool idea!
Why not run some ducting off of that fan and use the airflow produced while pedaling to help keep you cool?
Not a bad idea. The air is tunneled thru the base and out the front already, so really all that i'd have to do is add a piece to the front to deflect the stream of air upwards.
Would constricting the airflow increase the resistance felt when pedalling?
I believe in theory reducing the ammount of air flow would increase the resistance but the resistence is very high as it is because the fan is quite large. The resistence increases proportionally with the speed of the fan so shifting into a higher gear increases the resistance. I would recommend increasing the axle diameter to decrease the fan speed because I have never been able to ride above the lowest gear.
It would, but you will want to restrict the inlet so air is thrown out creating your own little vacuum which makes it mad so it tries to stop you.
This is exactly what i need to set up in front of the tv and just pedal. Its way to expensive to buy one even with my store discount.
Very nice instructable. Gonna have to try this out. I love the extra block of wood you used to level out the bike. I don't think I would enjoy going &quot;down hill&quot; inside the house... It took me a little while to figure out what the fan is for but you pointed it out. <br> <br>Thanks agin and good job.
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I did one of these, too. But it holds the rear wheel an inch over the soil by the axis, and keep it in its central position by means of two little wood wheels. I made the mistake of underestimating the effect of friction on the axis of these wheels, which causes that after a few minutes of pedaling they overheat and I must stop. I have to replace the shafts with ball bearings, I will do it next winter.
You did a nice job. I did something similar quite a number of years ago, but used only the resistance of the tires on my roller and no fan. (I have two photos.) I used 1/2&quot; steel shaft in bearings with 1/2&quot; ID, but ganged up 5&quot; squares of 3/4&quot; pine. Each had a 1/2&quot; hole at the center. I slid them onto the shaft and glued them together. I turned the ganged squares to make a round cylinder using a spinning circular saw blade set sideways. That part was easy because I have a radial arm saw and could push the whole assembly into the saw blade while manually advancing the rotation of the ganged squares until they were a nice round cylinder with a dip in the center. I had to pin the cylinder to the shaft so it did not turn on the shaft. <br><br>The rear axle is an inch or two over center to the rear of the cylinder's axle so the bike's rear wheel wants to go off of the cylinder to the rear. But, it cannot because there is a wheel chock behind the front wheel. To &quot;ride&quot; this trainer I position it in a doorway and use my shoulder to balance. (It was actually made for a different bike, so the rear wheel does not appear in the photo as &quot;over center&quot; as I described.)
Nice, I bet yours is a lot quieter than mine. When that fan gets to spinning it really humms.
Mine is rather noisy. The pieces of wood I sandwiched together creak on the shaft somehow. I have not used this roller support for a bike in recent years. All of the parts were free. Some renter left a home quickly and I drove by when the owners were setting out all sorts of stuff on the curb for the next garbage day.

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