Bicycle Brake Caliper

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Project developed by Albert Cowsky Template:Status Template:Status

Brake Calipers are an important component required to build a bicycle. In order to build a cheaper, open source, bicycle, the calipers can be printed and fitted with brake pads. Open source bicycles could reduce the cost of transportation for people that cannot afford to buy a commercial bicycle. This project can be combined with others to make a largely cheaper and printable bicycle.

(Makes Two Calipers)

Files

• Brake Caliper SCAD Model
• File:Caliper.stl

Commercial Parts

• 2x Commercial Brake Pads Cost = $4.98
• 8x M6x1 Torx Bolts Cost = $0.63
• 8x M6 Nuts Cost = $0.04
• 8x M6 Washers Cost = $0.05
• 1x Brake Line Guide Cost = $1.59 (For two)

• MOST Delta RepRap or similar RepRap 3-D printer
• T30 Torx Screwdriver
• 10mm wrench

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(I do not currently have all the necessary materials so they will not all be shown here. I will update this in the future if I get a chance to actually implement it.)

Print time = 3 hours per caliper. 6 hours total

Assembly time = approximately 15 minutes

1. Remove parts from the print bed
2. Attach the base of the calipers to the fork of the bicycle with bolts.
3. Use a washer on the far side before putting the nut on.
4. Install brake pads into inward facing cylinders.
5. Connect the cable guide receiver to the right caliper with a bolt.
6. Put the cable guide into the receiver.
7. Run a bolt backwards through the top of the left caliper.
8. Add a washer and screw the nut most of the way on.
9. Adjust the brakes so there is only a small clearance (~3mm) between the brake pads and the wheel wall.
10. Wrap the brake cable around the bolt underneath the washer.
11. Tighten the nut down to secure the brake cable.

• Brake line comes loose
  • Ensure that the bolts are still properly tightened every few weeks

• Total Cost (two calipers) = $19.60
  • Commercial Component Cost = $17.31
  • Plastic Cost - 99.4g (49.7 each) at $23/kg = $2.29
• |Commercial Calipers
  • $16-$40 each
  • $32-$40 for two
• $12.4 - $20.4 savings for two calipers
• 38.75% - 51% savings

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