(14 intermediate revisions by one other user not shown)
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*8x [http://www.albanycountyfasteners.com/M6-x-1-0-Torx-Pan-Head-Machine-Screw-Metric-A2-SS-p/1099-010.htm?1=1&CartID=0 M6x1 Torx Bolts] Cost = $0.63
*8x [http://www.albanycountyfasteners.com/M6-x-1-0-Torx-Pan-Head-Machine-Screw-Metric-A2-SS-p/1099-010.htm?1=1&CartID=0 M6x1 Torx Bolts] Cost = $0.63
*8x [http://www.fmwfasteners.com/products/Class-10-Finished-Hex-Nuts-DIN-934?custcol_dia_metric_tpi=3&custcol_plat_bolt=1&gclid=COrZjc2ey8kCFQyPaQodAiAA9g#.VmZDZLgrKJA M6 Nuts] Cost = $0.04
*8x [http://www.fmwfasteners.com/products/Class-10-Finished-Hex-Nuts-DIN-934?custcol_dia_metric_tpi=3&custcol_plat_bolt=1&gclid=COrZjc2ey8kCFQyPaQodAiAA9g#.VmZDZLgrKJA M6 Nuts] Cost = $0.04
*8x [http://www.fmwfasteners.com/products/Flat-Washers-Metric-DIN-125?custcol_dia_metric=3&custcol_plat_bolt=1&gclid=CL2wk6Gqy8kCFQ8vaQodM6wPGg| M6 Washers] Cost = $0.05
*1x [http://www.ebay.com/itm/like/131340363118?ul_noapp=true&chn=ps&lpid=82 Brake Line Guide] Cost = $1.59 (For two)
*1x [http://www.ebay.com/itm/like/131340363118?ul_noapp=true&chn=ps&lpid=82 Brake Line Guide] Cost = $1.59 (For two)


== Tools needed for fabrication of the OSAT==
== Tools needed for fabrication of the OSAT==
# [[Athena Build Overview| MOST Delta RepRap]] or similar RepRap 3-D printer
* [[Athena Build Overview| MOST Delta RepRap]] or similar RepRap 3-D printer
#
* [http://www.homedepot.com/p/Husky-T30-Torx-3-8-in-Drive-Bit-Socket-H3DHBST30/202913546| T30 Torx Screwdriver]
* [http://www.amazon.com/TEKTON-21271-10mm-Combination-Wrench/dp/B000NPUL0G| 10mm wrench]


== Skills and Knowledge Necessary to Make the OSAT ==
== Skills and Knowledge Necessary to Make the OSAT ==
* If you used special skill – link to relevant wikipedia or wikiversity articles/courses
N/A


== 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.)
# Include print time estimate
 
# Include assembly time estimate
Print time = 3 hours per caliper. 6 hours total
# Including drawings or pictures of the device at stage of assembly at minimum. (http://www.appropedia.org/Special:Upload)
[[File:Bicycle_Brake_Caliper_Print.jpg |||||500px]]
# Consider video if appropriate
Assembly time = approximately 15 minutes
{|style="border:1px solid #73BF73; background-color: #E6FFE6; margin-left:.1em; margin-top:2px; -moz-border-radius:15px;" align="right" width="150px"
[[File:Bicycle_Brake_Caliper_Assembled.jpg|||||250px]]
!<big>Example video summary of textbook</big>
# Remove parts from the print bed
|-
# Attach the base of the calipers to the fork of the bicycle with bolts.  
|<center>{{#widget:YouTube|id=yiJDx9dCfEQ}} </center>
# Use a washer on the far side before putting the nut on.
|-
# Install brake pads into inward facing cylinders.
|}
# Connect the cable guide receiver to the right caliper with a bolt.
# 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===
* Include common mistakes/problems to avoid in building your OSAT and how to overcome them
* Brake line comes loose
** Ensure that the bolts are still properly tightened every few weeks


== Cost savings==
== Cost savings==
* If your solution is not a low cost one then it is not really appropriate.
* Total Cost (two calipers) = $19.60
# Estimate your costs
** Commercial Component Cost = $17.31
# Find a commercial equivalent
** Plastic Cost - 99.4g (49.7 each) at $23/kg = $2.29
# Calculate $ savings and % savings
*[http://www.chainreactioncycles.com/us/en/avid-single-digit-5-brake/rp-prod22386?gs=1&gclid=CILJ_7-jy8kCFQcOaQodhVYMVg&gclsrc=aw.ds |Commercial Calipers]
**$16-$40 each
**$32-$40 for two
*$12.4 - $20.4 savings for two calipers
*38.75% - 51% savings


==References==
==References==
N/A


* The sources of information (e.g. engineering handbooks, journal articles, government documents, webpages, books, magazine articles etc.). References should use the <nowiki> <ref> </ref> and <references/>  </nowiki>tags and can be in any format but should include all the information necessary for someone else to find the same information you did. For example: <ref> web page: Department of Energy (DOE) Landscaping and Energy Efficiency, DOE/GO-10095 (1995) Available: http://www.eren.doe.gov/erec/factsheets/landscape.html</ref>
[[Category:Cycling]]
 
<references/>
<nowiki>
Based on the developmental needs addressed (e.g. food, heat, electricity, clean water, health  care, etc.) be sure to label your device in the proper categories e.g. use [[Category:Water]]. Be sure to categorize your device so that it will be easy to find – for example “Low voltage connection basics” is categorized in
 
 
 
[[Category:How tos]]
[[Category:Electricity]]
[[Category:Electric lighting]].
 
</nowiki>
 
[[category:OSAT 3D-Printable Designs]]

Revision as of 22:38, 17 December 2016

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

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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