Velomobile: Pixels to plastic

900MM STATION

900MM STATION FRAME

Once we had agreed the drawing Layout One.1 was a good starting point for a build, I started the process of converting the outline drawings to working ones. This means placing the 28 lengthways 15 mm pipe (longerons) inside the outer skin. I started with the 900 mm Station and made it the Master. This has a registration box that is used in each seperate Station, and remains identical throughout. My initial idea was to print the Station on to paper and use that as a template to cut flat boards. The registration box stops the programme deciding what size each one is best for you.

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Two things happened about the same time, I bought a laptop projector and Davy Jamieson introduced me to underfloor heating pipe. At 16 mm it has 2 layers like the PVC plumbing pipe, but it has an added layer of aluminium. When you bend it it retains the shape. I redid the drawings with 15 mm and 16 mm pipe and projected the drawing directly on to a board, taped in the registration box on the board and the feet of the Workmate and tripod on the floor

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I built a frame called a Strong Back to support and keep all the Stations properly spaced and in line. I should have stayed with my first plan of using aluminium extrusions. It is more expensive but it would not have twisted and warped like the timber in the centrally heated atmos. However this failure has lead to a solution which could give great benefits to structural frame strength and building simplicity, more later.

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Charles and I then lashed the structure together loosely with zip-ties. At this stage nothing is really finalised, the drawing is one thing, what we have here is another and it can be useful go with what evolves rather than rigidly pursue an ideal.

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