Musical Bumpers : 40 Steps

This product was created keeping in mind children with visual impairment and Autism but can be enjoyed by any child under the age of 7. The product is a simple product which can be manufactured right at the comfort of your home. However, discretion and professional aid is advised in certain processes. We hope this product brings joy and empowerment to all the children and parents who use this product for their benefit!

Musical Bumpers-User Manual-Fixperts.pdf
Download

Supplies

Go on to get the instructions on the site or download it through the link given to print it and use it along the journey!

Step 1: Aim of Product

The product aims at solving problems regarding navigation with children who are visually impaired. With our fixpartner being visually impaired and on the autistic spectrum, it makes the product deal with the subject in an even more sensitive manner. It plays with the concept of sound and protection for children of this nature to enjoy themselves while being in a safe and protected environment by themselves.

The product has been designed keeping in mind the type of products designed for kids and their expensive nature. Thus our product has been kept open source and relatively easy to manufacture to increase it’s outreach to the people who need such a product. The manufacture and assembly are quick and the components used are easy to source and modify according to the user’s requirements

There are 2 Bumpers for the cycle or tricycle that the child maybe using

Step 2: Safety Instructions

- Processes like welding should be done under supervision of professionals.

- Gloves should be worn at all times while cutting metal bits to avoid burrs.

- Make sure all sharp edges are filleted to provide extra security for the child.

- Create the product as instructed in the manual for best results.

- Product should not be disconnected very often, to prevent wearing off of the paint.

- Metal edges or the tyres used should be rounded off.

- Paint used should be non toxic and children friendly.

- Toys should be good quality squeaking toys, for longevity.

- Sound checks with the toys should be done beforehand to avoid discomfort.

Step 3: Introduction

Before assembling the Musical Bumpers, separate sub assemblies have to be built and constructed.

The description of every sub assembly in this manual will contain:

• An overview of the needed tools;
• An estimation of the needed time to built the sub assembly; • The steps;

Every step in this manual will be described using the following structure:

• Cautions and warnings (if applicable); • The needed parts; • The actions to perform the step

To make this manual easy to understand, images are used as much as possible.

Step 4: Parts

In this manual, you will read about FRONT bumper and the BACK bumper,.

Step 5: Materials for Front Bumper

1. 1 Tyre - Cut 390 mm Chord from Tyre of Dia.- 420 mm, Thk.-70 mm

2. 3 Squeaky toys - 120 mm to 150 mm

3. 1 Iron Strip - 4 mm x 60 mm x 425 mm + extra mm (for bending)

4. 9 Iron Bits - 4 mm x 20 mm x 30 mm

5. 2 Steel Pipe - 12.5 mm OD x 220 mm

6. 2 Steel Rods - 6 mm OD x 65 mm

7. 4 Pipe Clamps - 23-25 mm

8. 2 Rubber Ends - 70 mm x 70 mm x 40 mm

9. 2 Screws ( Pan Phillips STS) - 25 mm Gauge size 4

Step 6: Time and Tools ( Sub Assembly 1 )

Time - 1 1/2 - 2 hours

Tools -

Circular Bending Machine / Jig

Abrasive Saw

Metal Sander

Gas Metal Arc Welding Machine

Sand Blasting Machine

Pliers

Sanding Paper

Measuring tape

Pen / Pencil

Protractor

Step 7: Step One - Cutting

All the metal parts should be cut and sanded before proceeding with other steps.

* The 45° angles for the metal pipe should be at right angles to each other

* The 25° angle for the metal rod should be only be on one side.

* The metal strip should have some extra length for gripping while bending.

Step 8: Step Two - Bending

Bend the metal strip that has been cut with some extra on a Circular Bending Machine.

* The metal strip should be cut to 425 mm length

Step 9: Step Three - Filleting and Drilling

Fillet the 9 Metal Bits and the Metal Strips. Drill holes in the Metal bits and a slot in the Pipes.

Step 10: Step Four - Welding

1. Insert the 6 mm rods into the slots and weld to the pipe.

2. Weld the Pipe and Rods to the Pipe Clamps.

Step 11:

3. Weld the Connected Pipe structures with connectors to the metal Strip

Step 12:

4. Weld the Metal Bits to the Metal Frame, 4 on top 5 on the bottom.

Step 13: Step Five - Powder Coating

Post finishing the frame send your frame for powder coating to protect it from rusting and also to give it a colour finish. Your frame should look something like this!

The powder coating should be done after you finish the frame for the back bumper as well.

Step 14: Sub-Assembly Two (Front Bumper)

Time - 1/2 hour to 1 hour

Tools -

Miter Saw

Wire Cutter

Drill

Riveter

Brushes

Screwdriver

Step 15: Step One - Cutting

Cut a Tyre with a Miter Saw to a 39 cm Chord from Tyre of Dia.- 42 cm, Thk.-7 cm

Step 16: Step Two - Filleting and Drilling

1. Fillet the ends of the cut tyre to make it safe for the child.
2. Drill 4 mm holes where ever the metal bit’s holes coincide with the tyre. ( 9 holes )

* Most tyres will have a metal wire sticking out which should be removed from the ends .

Step 17: Step Three -

Place toys in the tyre. ( 3 according to measure )

Step 18: Step Four -

Rivet the Tyre to the Frame using Blind Rivets. 9 required.

Step 19: Step Six -

Put in the endings

* Squeeze the Endings to go in only till the end of the tyre and not more.

Step 20: Step Seven -

Screw the Endings to the tyre.

* Prefer screws so that toys can be replaced if required.

Step 21: Step Eight - Painting

Post Assembly Paint the grooves of the tyre or the entire tyre in any colour you want and enjoy! The Paint used should preferably Optilon synthetic rubber or Chlorinated Synthetic Rubber Paint to keep it long lasting!

Step 22: Materials for Back Bumper

1. 1 Tyre Cut 420 mm Chord from Tyre of Dia.- 420 mm, Thk.-70 mm

2. 5 Squeaky toys 120 mm to 150 mm

3. 1 Iron Strip 4 mm x 60 mm x 660 mm + extra mm (for bending)

4. 13 Iron Bits 4 mm x 20 mm x 30 mm

5. 2 Steel Pipe 12.5 mm OD x 240 mm

6. 1 Steel Pipe 12.5 mm OD x 410 mm

7. 3 Pipe Clamps 40-43 mm

8. 2 Rubber Ends 70 mm x 70 mm x 40 mm

9. 2 Screws ( Pan Phillips STS) 25 mm Gauge size 4

10. 13 Blind Rivets 1/4 dia 3.76 - 5.00 mm

Step 23:

Time - 1 1/2 - 2 hours

Tools -

Circular Bending Machine / Jig

Abrasive Saw

Metal Sander

Gas Metal Arc Welding Machine

Sand Blasting Machine

Pliers

Sanding Paper

Measuring tape

Pen / Pencil

Protractor

Step 24: Step One - Cutting

All the metal parts should be cut and sanded before proceeding with other steps.

* The 45° and 25° cut angles should be at right angles to each other for both set of Pipes

* The metal strip should have some extra length for gripping while bending.

Step 25: Step Two - Bending

Bend the metal strip that has been cut with some extra on a Circular Bending Machine.

* The metal strip should be cut to 660 mm length

Step 26: Step Three - Filleting and Drilling

Fillet the 9 Metal Bits and the Metal Strips. Drill holes in the Metal bits and a slot in the Pipes.

Step 27:

1. Weld the Pipes to the Pipe Clamps.

Step 28:

2. Welding the Connected Pipes to Bended Metal Strip.

* Make sure the angles align to the Connectors and Metal Strip

* Left to Right 45°, 25°,45° towards the Metal Strip.

Step 29:

3. Weld Metal Bits to Metal Strip at alternate points on both sides. 6 on top 7 on the bottom.

Step 30: Step Five - Powder Coating

Post finishing the frame send your frame for powder coating to protect it from rusting and also to give it a color finish. Your frame should look something like this!