Bits in Pieces | Deferred Procrastination

As the quest continues to find a manufacturer, and get the production prices for the parts, I’ve been building up a database of parts for public view. If you’d like to take a look, it’s currantly running at ~~beta.def-proc.co.uk/wiki/~~ (down at the moment because of suPHP). While it’s clearly not finished yet and (as of the time of writing) only has the standard tikiwiki skin, I am interested to know if there is enough of the right type of information on there for you. I’ve spent the best part of 9 months with these parts, so I have most information about them remembered, but it’s important that the parts database is relevant to even the casual user.

Please let me know if you have any suggestions, improvements or criticisms about the parts database, so I can take this on board in improve any areas now, during development. Email me at contact [at] def-proc.co.uk or add a comment to the bottom of this post.

It looks like I’ll have to use three manufacturers for the Atomic Duck parts so far. The mix of manufacturing processes means that I haven’t found one workshop that has the machinery to do all of them. So far it looks like I’ll use the following mix:

A Laser cutting shop for cutting and bending the sheet parts.
A general precision engineers for the turning, bar, tube and plate cutting.
And a tube bending specialist who can do the mandrel bending of the round, front axle tube.

More information as it comes, but as soon as the order goes in for the prototype build I will know the exact manufacturing prices, so I will then open the pre-order deposits in preparation for the development kits. Initially all purchases will be through paypal, so “pre-order deposits” will be purchased gift-vouchers, which can be redeemed against any purchase from Deferred Procrastination. Pre-order deposits will also give me an idea of the initial order volumes, and those with gift vouchers will get priority on the limited number of manufacturing slots.

Here’s a couple more images that I found from Maker Faire UK:

Saturday Morning Saturday Morning Chatting to OxHack Members

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Gonzalo Peréz Chomón wrote, “Dear Patrick, I am very impressed about your work on this project. I have read all of it. It is incredible how my thoughts and conclusions about a lot of issues are same as yours. I have started something very similar, may be we can cooperate with some ideas. I started a blog about my project, you can visit it here http://chomon-ev.blogspot.com/ BR”

Patrick Fenner wrote, “Looks like you are making a good start there. I hadn't even considered using a PVC pipe junction to connect metal tubing, even in really high stress joints, it could be possible to fill the whole of the joint with adhesive for even better load transfer. I suppose it's the opposite of using bamboo frames with metal junctions in bikes! I notice that you're look at using contact cement for the joints. It might also be worth looking at acrylic adhesives, there are some that are made to join plastic and metal in structural applications. A look at some manufacturer websites should give you some adhesive datasheets. Good luck, I'll keep an eye on how you get on. I'm more than happy to cooperate, what did you have in mind?”

Gonzalo Peréz Chomón wrote, “Hi Patrick, In order to reduce the stress on the PVC joint the idea is that the main chassis tubes and the cross members ara one piece of tube so fully cross the PVC "T" joints so the alum. pipes will take the main work not the joints, I do not know if I explained properly, will post pictures latter... I am not using contact cement fot the bi-material joints, I was testing PU cement that is supose to work quite well but I used for the tests a wood special one that I had around... I will test a better suitable one to see if it works well. Actually I think you can use a similar one for your project, it is not as strong as epoxi ones but it is easier to use (only one component) and it is a bit flexible when it cures so do not crack under high stress. Actually I am not planning like you to sell or distribute my project in any manner for the moment but never know, because every person I comment with about are interested on buying one ??? (can not belive...) so may be on the future. About cooperation I was meaning that please take a look to my blog now and then so you give your opinion and advises that will be very helpfull for sure I will try to do the same... Actually I have some sugestions hope they are wellcome, I have been invloved long time ago on racing car design and I have found out that about your drive wheel design, I find it a bit unsafe, It has open curves and corners, I think you have to redisign it to a a closed curve and avoid corners. And anoter point, this piece A003-P003-R001 I think it will be cheaper, same strength and lighter if it is a aluminum pipe, actually I think the lathe people will tell you that it is actually quite difficult to manufacture on 6xxx aluminum with out weakling the material at the end of the drilling. BR Gonzalo”

Patrick Fenner wrote, “I was assuming that you would be using straight cuts on the tube ends, so for a T-junction, most of the tube end is not in contact with the joining tube side. If you're cutting the tube ends to fit the profile then I agree that PVC will carry little load. I looked at the acrylic adhesives, they certainly have some very high strength ones, and would be fine for some of the joints, but for the critical joint at the back of the sill/bottom of the rear hanger, the greater shear strength of the high-strength structural epoxies is needed. Having the same glue throughout just makes it simpler. Same with the steering column; I've specified all the aluminium parts as 6061-T6/6082-T6, but for some of the parts it would be possible to make them from something softer with out too much difference, I'll be iterating and looking at each part in ever greater detail, but I'm starting as simple as possible to begin with — it needs more calculations yet. I did see the No More Nails adhesive the other day and thought of your project, might be worth a test.”

Brian wrote, “I'm glad to see someone else is trying this. I started a blog in 08 along similar lines, kept up for a few months and no one responded. Now that gas prices in the US are headed higher, peoples attitudes may change. Good luck!”

Patrick Fenner wrote, “I think I came across your velo as I was doing research in the last year, but I only saw the initial e-assist ride up and down the street, I looks really nice, and well finished. Now I've seen the build pictures, I'm really impressed by your construction method. I see that you're from a technical background and you mention technical drawings. Would you be interested in releasing the technical drawings, or more detailed images of manufacture?”

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