Build Procedures

Designed by Nghia (Wilson) Ly, Caleb Mayer, Daria Frame

Assembly and Parts List

• • Custom Frame Assembly

    • Custom. Steel. Welded together.

    • Metal piece foot grip, rubber

  • Front Handlebar/Wheel Assembly

    • Stem, handset, rubber handle bar, brake and shift lever, front brake, cable stop (front wheel)

    • Rim, rim sidewall, spokes, axle, hub, spoke nipple, freehub body, hub flange.

  • Seat assembly

    • Seatpost, seatpost binder, seat clamp, padding, shell, rail,( seatpost clamp: nut, D shape retaining plate, center rod), adjustable nut, quick release.

  • Brake system assembly

    • Adjusting barrel, side pull, anchor bolt/mounting bolt, brake block, brake arms, cable, balance screw, spring, ,cable bridge

  • Custom Mounting Bracket for Caster Assembly

    • Spacer, torsion spring, mounting bolts, bearing,

Procedure

• 1. Use 20”Kent KS Chaos Boys’ Bike, Matte Gray/Orange as the ‘standard’.

     1. Brake system, wheels, handlebar assembly and seat assembly.

  2. Dennis Frame is building custom frame assembly. All pieces are attached to this.

  3. Front Handlebar/Wheel Assembly.

• • 1. Handlebar system: do not take apart all of it. Remove as one piece.

       1. Wrenches

    2. Add to custom same way it was taken from Chaos bike.

    3. Front Wheel System: keep the bars framing the wheel so that it is easily attached to the custom frame.

    4. We may need to change the angle of this assembly, just for ease of movement, but that may be a change later in the process. Depends on testing.

• 4. Seat Assembly: Take the seat from the Chaos bike, install same as it was on Chaos.

• • 1. We may change seat angle later for ease of movement.

• 5. Footrest: already attached to custom frame. Cut out size for the TALON rubber grips sheet and wrap it around the foot rest.

• • 1. Make sure the cut is right and lined up, reviews of the TALON say that once it is laid, it is really hard to take back up. It sticks.

• 6. Back Twisting Function: reference the drawing for help visually. This needs to be assembled before attaching to bike.

• • 1. Fit the metal shaft into the smaller hole for the right cap. Inside the right cap, attach the ball bearing to the shaft on the cap with an appropriate bolt.

    2. Fit the metal shaft into the left cap. On the outside of the left cap, place a spacer. Attach a ball bearing to the shaft on the inside of the left cap. Above the ball bearing, slip the torsion spring onto the shaft: the cap/cover should still be around this part.

    3. This piece looks separated in the picture, but they should be closer together in reality.

• 7. Back Twist Attachment 1: Use the bolt mounting points on the left cap to attach the Back Twist to the rear tube extending from the custom bike frame.

  8. Back Wheel Assembly: Remove only the back wheel from the Chaos bike. Attach the custom wheel frame pieces to the back wheel.

• • 1. Angle of framing pieces may need to be changed for ease of movement.

• 9. Back Twist Attachment 2: Use the bolt mounting points on the right cap and attach them to the Back Wheel Assembly.

  10. TEST!!! Anywhere discussing the ease of movement will most probably be changed here.

• • 1. Will we need to change the attachment of the twisting function?