Wednesday, February 23, 2011

Central Steering

The picture shows the new steering mast and handlebar installed on a Sprint NT.  There is about 5 cm of height adjustment so you can fine tune the fit once it is inside the Borealis.  The mast makes getting in and out a bit different from before.  You can still step onto the ground through the footholes but it is easier to just stand on the frame and sit down.  I avoided trying this before as I didn't want to mess up the paint on the frame.  I found when I tried this that I actually stepped on the composite bracket that wraps around the curciform to attach the shell to the frame.  There is a little area in the middle where you could still step on the paint but a bit of protective film over this area would solve that issue. 

Monday, February 21, 2011

Borealis V3 rear Fender

I have had a delay in getting the Borealis V3 on the road.  My original idea for the rear fender didn't work out as well as hoped. So I ended up making a new set of moulds for a new fender. First we build a flange onto the bottom of the fender so that it matches the shape of the floor in the back section of the shell.  From this I built a pattern (plug) to use for making the moulds that the fender will be built it.  As it is a bit awkard to bag the part in a one piece mould I split the moulds into two parts.  After making each part we will bond them together to make the whole fender. We now have these moulds built and have made the first set of parts.  Still need to refine the laminate used but it looks like the parts will be lighter than how we were doing it before.  The previous fender was a hand layup while the new one is made using vaccum.   I would guess  the weigh saving at between 250-500 grams just for the composite parts.   When you include the fabic storage bag that is in the back of the V2 the weight saving is more like a kilo. 

Friday, February 18, 2011

Wiring Connections

As we normally ship the Borealis shell in parts the wires for the lights need to be able to be connected together at some point.  We do this inside the control panel so it is all neat and tidy.  Here is a picture of the ends of some of the wires.
To make the connections you push the connections together and then cover them with a piece of heatshrink tubing.  They are all labeled so it easy to figure out. 

Monday, February 7, 2011

Steering Mast and Handlebar

The jig for glueing up the steering mast and handlebar.  I enjoyed making this jig.  It wasn't too much of a challenge to make it with bits we already had in the shop. doing a little woodworking is a lot different from sanding and polishing moulds which can be more than a bit tedious.   

Tuesday, February 1, 2011

Handle for moving your velomobile

I have a handle of the back of all the velomobiles we make.  I consider it an essential piece of equipment.  It came about after the first time I had to wheel the velomobile down a ramp onto the ferry behind the shop that used to cross the Fraser river to Fort Langley.  It almost got away from me as the ramp is pretty steep.  About half the time when I crossed the attendent allowed me to ride down the ramp with the motorbikes but you couldn't rely on this.  Bicycles were required to walk on and off the ferry.

This is the handle on the back of the Borealis.  A webbing strap with some rubber moulded around it.  It is held on with two bolts.  If you would like one for your velo we have some in stock. 

On the Borealis V3 the handle is a much more aero.  After making a very clean back edge is would be shame to mess it up with the webbing handle.  It is a cord that retracts inside the shell so it lies flush on the outside.  A piece of shock cord  inside the shell  pulls it flush. 
Here is a picture of with partially pulled out.