Manufacturing

    Well, with the design nearly completion there was nothing left to do but spend days at the machine shop.  I purchased all the sprockets from Recycled Cycles near UW campus, bearing form VXB.com and the belt/pulleys from EconoBelt.com  The rest was all manufactured at the Birdwell shop.


  All of the parts.


  The frame clamp, simple but very effective.

  Rear sprocket and ratchet assembly


  Crank floating sprocket.

  Motor mounted to the brackets and belt ready to be tensioned.


  Other side where the output comes out.

  Ratchet peice jigged up and ready to have the teeth cut.


  All set up, ready to cut teeth with 60 degree dovetail cutter.

  Aaaahhhh!  It's steel!  I don't like steel!  It's so hard!!!  - the dovetail screams...  (taken by Bill Bailey)


  A little messy.  Those burrs look really mean too...

  Ratchet reporting for duty!


  Assembly - with patience (photo taken by Julie)

  Starting the first assembly to test it all out.  This is gonna be a long night.


  The motor and crank sprocket are on in 1/2 hour.

  I think I'll need a wheel for this...


  Other side.

  Ratchet assembly on rear wheel.


  Rear wheel in, chain is on.

  Ready to test!


  Electronics are crudely strapped on with tape and zip-ties.  Hey, I can't wait anymore!


  The chain skipped with too much torque and not enough tension, so I improvised this tensioner with a deraileur from Recycled Cycles.


  Now it's a runner.

  Next day, figuring out the fairing.


  A Birdwell machine is born.  This place is f**king cool!

  I've been here too long though...  Starting to get the long stare.


  Ahhh...  Some radio helps a little... YAAAWWWNNN!
1