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== Technical Specifications and Assembly Instructions==
== Technical Specifications and Assembly Instructions==
# Provide directions for print/assembly - be detailed enough in your “how to” to ensure that someone could construct the device from your description. Consider the elegance of IKEA like instructions.
(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
 
Print time = 3 hours per caliper. 6 hours total
[[File:Bicycle_Brake_Caliper_Print.jpg |||||500px]]
[[File:Bicycle_Brake_Caliper_Print.jpg |||||500px]]
# Assembly time = approximately 15 minutes
Assembly time = approximately 15 minutes
[[File:Bicycle_Brake_Caliper_Assembled.jpg|||||250px]]
[[File:Bicycle_Brake_Caliper_Assembled.jpg|||||250px]]
# Including drawings or pictures of the device at stage of assembly at minimum. (http://www.appropedia.org/Special:Upload)
# Remove parts from the print bed
# Consider video if appropriate
# Attach the base of the calipers to the fork of the bicycle with bolts.  
{|style="border:1px solid #73BF73; background-color: #E6FFE6; margin-left:.1em; margin-top:2px; -moz-border-radius:15px;" align="right" width="150px"
# Use a washer on the far side before putting the nut on.
!<big>Example video summary of textbook</big>
# Install brake pads into inward facing cylinders.
|-
# Connect the cable guide receiver to the right caliper with a bolt.
|<center>{{#widget:YouTube|id=yiJDx9dCfEQ}} </center>
# Put the cable guide into the receiver.
|-
# Run a bolt backwards through the top of the left caliper.
|}
# Add a washer and screw the nut most of the way on.
# Adjust the brakes so there is only a small clearance (~3mm) between the brake pads and the wheel wall.
# Wrap the brake cable around the bolt underneath the washer.
# Tighten the nut down to secure the brake cable.
 
 


=== Common Problems and Solutions===
=== Common Problems and Solutions===

Revision as of 08:42, 8 December 2015

Bicycle Brake Caliper

Project developed by Albert Cowsky

Template:Statusboxtop Template:Status-design Template:Status-prototype You can help Appropedia by contributing to the next step in this OSAT's status. Template:Boxbottom

Abstract

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.

Bill of Materials

(Makes Two Calipers)

Files

Commercial Parts

Tools needed for fabrication of the OSAT

  1. MOST Delta RepRap or similar RepRap 3-D printer
  2. T30 Torx Screwdriver

Skills and Knowledge Necessary to Make the OSAT

N/A

Technical Specifications and Assembly Instructions

(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

Bicycle Brake Caliper Print.jpg

Assembly time = approximately 15 minutes

Bicycle Brake Caliper Assembled.jpg

  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.


Common Problems and Solutions

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

Cost savings

  • 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

References

N/A

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