Issuu on Google+

Production and assembly manual coop-bike


Introduction This manual describes the production of the CooP bicycle. Step by step is explained what needs to be done to produce the different parts. Some steps are more important than others and have to be followed exactly. Every chapter takes care of a different part of the process and in every chapter explanaitions are guided with pictures and or illustrations.

Introduction 2 Parts List 4 Manufacturing of the frame and steering mechanism 6 Manufacturing of the front carier22 Manufacturing of the rear carier 32 Painting 40 Assembly 44 Testing 64 Endresult 65 Miterpaper 69

2


3


Parts list Part

Size

Needed per bicycle

Frame 1

Neelam Frame

1

2

front fork

fits a 20” wheel

1

3

steel tube headsets

“1 1/4”” external diameter 1/16”” Tube thickness 6 m Lenght”

585 mm (600 mm per bicycle)

4

steel tube steering

“1”” external diameter 1/16”” Tube thickness 6 m Lenght”

600 mm (10 per part)

5

steel tube main pipe

“42mm external diameter 1,5 mm Tube thickness 6m Lenght”

1000 mm (6 per part)

6

Carrier tube

“22 mm external diameter 2 mm Tube thickness 6 m Length”

400 mm (15 per part)

7

Steel sheet

“2”” wide 1 mm thickness 10 feet long”

50 mm

Steering mechanism 8

Bolt

35 mm M8 ( 10 mm threatless)

4

9

Nut

M8

8

10

Washer

M8

8

11

Steel sheet

“2”” wide 3 mm Sheet thickness 10 feet”

“2”” wide 450 mm Length”

12

Fork fitting set

13

Bearing balls

5/32” (25 balls per cup)

(100 balls per bicycle)

14

Steer

Curved steer

1

15

Steer pin

MTB steer pin

1

Tyre

26” x 2,125

1

26” x 2,125

1

2

Rear wheel 16 17

Tube

18

Spoke

19

Rimm

20

Coaster break hub

36 26” x 2,125

1 1

Front wheel 21

Hub

28 holes

1

22

Tyre

20” x 2,125

1

20” x 2,125

1

23

Tube

24

Spoke

25

Rimm

28 20” x 2,125

1

cable mechanism

1

Front Break system 26

4

Front break system


Parts list Propulsion system 27

Pedals

Hero

1 set

28

Chain

Neelam heavy duty

1

29

Crankset

Phoenix 44 teeth

1 set

30

BB Axel

Long Kidride

1

31

Bearing balls

22

32

Cotter peg

2

33

chain caster

2

Front carrier 34

Steel tube

“3/4”” external diameter 1,2 mm tube thickness 20 feet lenght”

4765 mm

35

Bolt & Nut

M8 x 1”

2

36

Bolt & Nut

M8 x 3”

2

37

Bolt & Nut

M8 x 2”

4

38

Washer

M8

8

39

steel sheet

“1”” wide 1 mm thickness 10 feet long”

200 mm

Back carrier 41

Tube metal

“3/4”” external diameter 1,2 mm tube thickness 20 feet lenght”

2340 mm

42

Steel sheet

“2”” wide 3 mm Sheet thickness 10 feet”

“1”” wide 110 mm length”

43

Bolt & Nut

M8 x 1”

1

44

Seat/sadle

Cyco medium sized

1

45

Seat pin

Neelam frame compatible

1

46

Mud guard set

Mtb plastic 26” (20” not in stock)

1

47

Chain guard

standard neelam/cyco

1

48

stand

Standard neelam

1

General 49

Grease

0,5 kg

2,5 gramme (200 products per box)

50

Rubber strip

20 mm x 3 m

500 mm

51

Paint job

“1 primer coating 2 color coatings”

5


Manufacturing of the frame and steering mechanism Steps 1) Manufacture the main tube 2) Manufacture the seal sheet for the main tube 3) Prepare the existing frame 4) Manufacture the small head tube 5) Manufacture the big head tube 6) Manufacture the front carrier support pipe 7) Manufacture the rear carrier support 8) Weld all the previous parts to the existing frame 9) Manufacture the steering levers and arms 10) Manufacture and weld the Steer tube 11) Prepare 22 inch front fork

Parts needed pipe 42mm x 1,5mm pipe 31,7mm x 1,6mm pipe 25,4mm x 1,6mm pipe 22mm x 2mm sheet 1mm sheet 3mm Neelam size 22 frame Frontfork 22 inch

result

Frame, front frok and steering arms

6


Manufacture the main tube 1a) Cut pipe into a piece of 1000 mm length (pipe 42mm x 1,5mm)

Manufacture the main tube 1b) Measure 562 mm and 817mm from one of the ends and make a mark

Manufacture the main tube 1c) At these marks create holes of 31,7 mm at an angle of 83 degrees

7


Manufacture the main tube 1d) Make a mark at 500 mm from the big head tube hole, this is where the miter will be

Manufacture the main tube 1e) Use the miter paper to draw the miter on the pipe (the miterpaper can be found on page 67)

8


Manufacture the main tube 1f) Cut and file the miter at the mark

Manufacture the main tube 1g) Create a sloth at 70 mm from the front of the pipe for the 22 mm support beam

Manufacture the seal sheet for the main tube 2a) Manufacture a 42 mm round circle from 1 mm thick sheet

9


Prepare the existing frame 3a) Remove the headset cups and throw them away

Prepare the existing frame 3b) Make a mark line right across the middle of the head tube

Prepare the existing frame 3c) Mount a metal strip as guide for the cutting

10


Prepare the existing frame 3d) Cut the head tube from both sides and file the edges smooth

Prepare the existing frame 3e) Remove the paint from the two areas that will be welded

11


Prepare the existing frame 3f) Remove the bottom bracket cups from the frame and store them

Manufacture the small head tube 4a) Cut the pipe into a piece of 85 mm (pipe 31,7mm x 1,6mm)

Manufacture the small head tube 4b) File out both ends until the head set cups will fit

12


Manufacture the big head tube 5a) Cut the pipe into a piece of 490 mm (pipe 31,7mm x 1,6mm)

Manufacture the big head tube 5b) File out both ends until the head set cups will fit

Manufacture the front carrier support pipe 6a) Cut the pipe into a piece of 400 mm (pipe 22mm x 2mm)

13


Manufacture the front carrier support pipe 6b) Drill two holes at the ends of the pipe

Manufacture the rear carrier support 7a) Cut and drill this part from the 3mm thick sheet as shown in the drawing

14


Weld all the previous parts to the existing frame (parts 1 until 7) 8a) Weld the construction together according to the drawing (Welding should be done in short intervals to prevent the frame from melting)

15


16


Manufacture the steering levers and arms 9a) Cut file and drill the sheets as shown in the drawings from 3mm thick sheet

17


Manufacture and weld the Steer tube 10a) Cut the pipe into a piece of 540 mm (pipe 25,4mm x 1,6mm)

Manufacture and weld the Steer tube 10b) Tap external wire at the First 30 mm of the tube

18


Manufacture and weld the Steer tube 10c) Weld lever sheet at the other side, 5 mm from the bottom of the tube. Caution, only weld from the bottom

Manufacture and weld the Steer tube 10d) Fixate the bottom race on the lever with some spot welds

Prepare 22 inch front fork 11a) Sand of the paint at the desired spots

19


Prepare 22 inch front fork 11b) Weld steering lever on the front fork

Prepare 22 inch front fork 11c) Cut of the wired pipe of the front fork at 120 mm

20


21


Manufacturing of the front carrier Steps 12 Manufacture the bottom section of the carrier 13 Manufacture the top section of the carrier 14 Manufacture the support pipe of the top section 15 Manufacture the bars of the top and bottom sections 16 Manufacture the rear support beam of the carrier 17 Manufacture the mounting strips 18 Weld the front carrier

Parts needed pipe 20mm x 1,2mm pipe 22mm x 2mm sheet 1mm

result

Front carier and mounting brackets

22


Manufacture the bottom section of the carrier 12a) Cut the pipe at a length of 1340 mm (pipe 20mm x 1,2mm)

Manufacture the bottom section of the carrier 12b) Make marks at the indicated spots

Manufacture the bottom section of the carrier 12c) Bent the two corners as shown in the drawing, make sure they are in the same surface

23


Manufacture the bottom section of the carrier 12d) Squeeze 30 mm of both ends flat in the bench vice

Manufacture the bottom section of the carrier 12e) Drill 8 mm holes in the middle of both flat ends

Manufacture the bottom section of the carrier 12f) Drill two 8 mm holes at the indicated spots on the pipe

24


Manufacture the top section of the carrier 13a) Cut the pipe at a length of 1100 mm (pipe 20mm x 1,2mm)

Manufacture the top section of the carrier 13b) Make marks at the indicated spots

Manufacture the top section of the carrier 13c) Ben the two corners as shown in the drawing, make sure they are in the same surface

25


Manufacture the top section of the carrier 13d) Squeeze 30 mm of both ends flat in the bench vice

Manufacture the top section of the carrier 13e) Drill 8 mm holes in the middle of both flat ends

Manufacture the support pipe of the top section 14a) Cut the pipe at a length of 600 mm (pipe 20mm x 1,2mm)

26


Manufacture the support pipe of the top section 14b) Make marks at the indicated spots

Manufacture the support pipe of the top section 14c) Ben the two corners as shown in the drawing, make sure they are in the same surface

Manufacture the support pipe of the top section 14d) Cut of the two ends as shown in the drawing

27


Manufacture the support pipe of the top section 14e) File miters at the two ends of the pipe

Manufacture the bars of the top and bottom sections 15a) Cut the pipe in 5 pieces of 365 mm (pipe 20mm x 1,2mm)

Manufacture the bars of the top and bottom sections 15b) File miters at the ends of all the pipes

28


Manufacture the rear support beam of the carrier 16a) Cut the pipe at a length of 355 mm (pipe 22mm x 2mm)

Manufacture the rear support beam of the carrier 16b) Weld two M8 weld nuts into the pipe at both ends. (see instructions for manufacturing of weld nuts)

29


Manufacture the rear support beam of the carrier 16c) Drill two 8 mm holes in the pipe at the desired spots

Manufacture the mounting strips 17a) Manufacture 2 strips as illustrated in the drawing from 1 mm thick sheet

30


Weld the front carrier 18a) Weld the bars in the bottom section as shown in the illustration

31


Weld the front carrier 18b) Weld the bars and the support pipe on the top section of the carrier

32


33


Manufacturing of the REAR carrier Steps 19) Manufacture the top part of the carrier 20) Manufacture the bars of the carrier 21) Manufacture the mounting plate 22) Manufacture the legs of the carrier 23) Weld the rear carrier

Parts needed pipe 20mm x 1,2mm sheet 3mm

result

Rear carier

34


Manufacture the top part of the carrier 19a) Cut the pipe at a length of 1200 mm (pipe 20mm x 1,2mm)

Manufacture the top part of the carrier 19b) Make marks at the indicated spots

Manufacture the top part of the carrier 19 c) Bend the pipe at the marks like illustrated

35


Manufacture the top part of the carrier 19 d) Cut the ends at an angle of 35 degrees

Manufacture the bars of the carrier 20 a) Cut two pipes at a length of 140 mm (pipe 20mm x 1,2mm)

Manufacture the bars of the carrier 20 b) File miters at both ends of all the pipes

36


Manufacture the mounting plate 21 a) Cut file and drill the sheet according to the illustration from 3mm thick sheet

Manufacture the legs of the carrier 22 a) Cut two pipes at a length of 430 mm (pipe 20mm x 1,2mm)

Manufacture the legs of the carrier 22 b) File miters at one side of both pipes

37


Manufacture the legs of the carrier 22 c) Squeeze 50 mm of one end of both pipes flat in the bench vice

Manufacture the legs of the carrier 22 d) Forge the flat ends into the shape illustrated

Manufacture the legs of the carrier 22 e) Cut and file sloths in both flat ends as illustrated

38


Weld the rear carrier 23 a) Weld the whole rear carrier together as illustrated in the image

39


Painting Steps 24) All the blank metal parts need to be painted to protect them from corrosion, sever al layers are needed. If stickers are being placed they need to be stuck between the paint and the clear coat. The parts that need to be painted are:

Parts needed Frame Front fork Steering arms Steering pipe Top section front carrier Bottom section front carrier Support bar front carrier Mounting strips front carrier Rear carrier Mud guards Chain guard

Tools needed Sandpaper Primer Color paint Stickers Clear coat

result

All parts are painted

40


24 a) Sand all the surfaces, filler is an option

24 b) Spray the parts with primer and let it dry

24 c) Spray the parts with paint in the desired color and let it dry

41


42

24 d)

Place all the wanted stickers on the frame

24 e)

Finish the bicycle with a layer of clearcoat, also let this layer dry


43


Assembly of the bicycle Steps 25) Insert the headset cups 26) Assembly of the front fork 27) Assembly of the steering tube 28) Assemble the steering arms (2x) 29) Assemble the bottom bracket 30) Assemble the front wheel 31) Assemble the rear wheel 32) Mount the stand 33) Assemble the rear carrier 34) Mount the cranks 35) Assemble the chain 36) Mount the chain guard 37) Mount the saddle 38) Mount the handlebar 39) Mount the front brake 40) Assemble the front carrier 41) Mount reflectors 42) Mount the rubbers traps

Tools needed

result

The bicycle is fully assembled

44


Insert the headset cups 25 a) Grease the cups and the holes

Insert the headset cups 25 b) Force the cups into the frame

Assembly of the front fork 26 a) Put the bottom race around the front fork

45


Assembly of the front fork 26 b) Put grease on the race and put 25 bearing balls in the grease

Assembly of the front fork 26 c) Put grease in the top cup and put another 25 bearing balls in the grease

Assembly of the front fork 26 d) Insert the front fork into the head tube, watch out for the bearing balls

46


Assembly of the front fork 26 e) Mount the top race on the front fork and tighten this

Assembly of the front fork 26 f) Mount the locknut on the front fork and fixate the whole assembly

Assembly of the steering tube 27 a) Put the bottom race around the steering tube

47


Assembly of the steering tube 27 b) Put grease on the race and put 25 bearing balls in the grease

Assembly of the steering tube 27 c) Put grease in the top cup and put another 25 bearing balls in the grease

Assembly of the steering tube 27 d) Insert the steering tube into the head tube, watch out for the bearing balls

48


Assembly of the steering tube 27 e) Mount the top race on the steeringtube and tighten this

Assembly of steering tube 27 f) Mount the locknut on the steering tube and fixate the whole assembly

Assemble the steering arms 28 a) Mount the bolts, nuts, washers and rubbers according to the illustration

49


Assemble the steering arms 28 b) Grease the rubbers

Assemble the steering arms 28 c) Tighten the two nuts by turning them in opposite directions. Do this for all four the bolts

Assemble the bottom bracket 29 a) Put grease in the fixed bottom bracket cup and place 11 bearing balls in it

50


Assemble the bottom bracket 29 b) Place the cup in the frame

Assemble the bottom bracket 29 c) Put grease on the axel and insert the short side into the already placed cup

Assemble the bottom bracket 29 d) Put grease into the adjustable cup and place 11 bearing balls

51


Assemble the bottom bracket 29 e) Place the adjustable cup in the frame

Assemble the bottom bracket 29 f) Tighten the adjustable cup with the lock ring

Assemble the front wheel 30 a) Spoke the hub into the 22 inch rim

52


Assemble the front wheel 30 b) Mount the inner tire and the outer tire and inflate the wheel

Assemble the front wheel 30 c) Mount the wheel into the frame

Assemble the rear wheel 31 a) Spoke the coaster brake hub into a 26 inch rim

53


Assemble the rear wheel 31 b) Mount the inner tire and the outer tire and inflate the wheel

Assemble the rear wheel 31 c) Mount the wheel into the frame with the chain casters, do not tighten it jet

Assemble the rear wheel 31 d) Fix the coaster hub arm to the frame, don’t forget the rubber

54


Mount the stand 32 a) Mount the stand on the rear axel, do not tighten it jet

Assemble the rear carrier 33 a) Place the carrier on the bicycle

Assemble the rear carrier 33 b) Mount the carrier underneath the saddle with an M8 bolt and nut

55


Assemble the rear carrier 33 c) Push the carrier down and tighten the axel nuts.

Mount the cranks 34 a) Tighten the peddles into the crank arms

Mount the cranks 34 b) Place both crank arms on the axel

56


Mount the cranks 34 c) Insert the cotter pegs and hammer them in place

Mount the cranks 34 d) Tighten the pegs with the nuts

Assemble the chain 35 a) Place the chain around the gears and measure the desired length

57


Assemble the chain 35 b) Remove the number of links needed

Assemble the chain 35 c) Mount the chain around the gears and mount the lock link

Assemble the chain 35 d) Tension the chain with the chain casters

58


Assemble the chain 35 e) Put grease on the chain

Mount the chain guard 36 a) Place the chain guard over the chain

Mount the chain guard 36 b) Mount the guard with the brackets

59


Mount the saddle 37 a) Insert the saddle stem into the frame

Mount the saddle 37 b) Tighten the frame with an M8 bolt and nut at the desired height

Mount the saddle 37 c) Mount the saddle on the stem

60


Mount the handlebar 38 a) Insert the steering stem into the frame, align it and tighten the bolt

Mount the handlebar 38 b) Insert the handle bar into the stem and tighten the bolt

Mount the handlebar 38c) Slide the grips over the handlebar, use soap if needed

61


Mount the front brake 39 a) Mount the caliper on the front fork

Mount the front brake 39 b) Mount the brake handle on the handlebar

Mount the front brake 39 c) Pull the cable through the system and tighten it as desired

62


Mount the front brake 39 d) Fix the cable to the frame with tie wraps

Assemble the front carrier 40 a) The bottom and the top section are both mounted to the support pipe with two M8 bolts

Assemble the front carrier 40 b) Place the carrier on the frame

63


Assemble the front carrier 40 c) Mount the bottom section to the frame with long M8 bolts and nuts, use rubbers as spacers

Assemble the front carrier 40 d) Mount the top section to the frame with the mounting strips and 4 M8 bolts and nuts. Also rubbers are needed here

Mount reflectors 41 a) Mount the reflectors at the indicated spots

64


Mount the rubbers traps 42a) Wrap two rubber straps around the front carrier and one around the rear carrier.

65


TESTING Take the bicycle out for a testride and check all the bolts and nuts afterwards. If needed tighten the bolts or nuts.

! 66


Endresult

67


68


Miterpaper

69


Production manual CooP Bike