The Plastic Machine

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Not a frequent poster here by any means, but here's my latest scratch build. I have been working at a plastic fabrication plant for a few years now. That time is nearing an end, so I decided to get something done that I've been kicking around the entire time I've worked there: A plastic bike. I have made tons of parts for my bikes in the time I've worked here (seats, forks, tank plates, baskets, handlebars, etc) But a full bike would take a ton of engineering.

I did it anyway
render_zps4jzqvvbw.png


3/4" thick plates for rear triangle and fork
KIMG0146_zpspn9mqbo5.jpg


Machined Dropouts
KIMG0147_zpseetpzlrf.jpg


A brief mockup with the two 1/2" thick frame panels
KIMG0148_zpskr666xwc.jpg


Welded in a 1/4" opaque plastic "tank"
KIMG0156_zpsdpy5kmzg.jpg


Got some wheels: 3g 3speed with Kenda Kiniptions
KIMG0159_zpsb5uxreud.jpg


Another mockup with the pipe that holds it all together
KIMG0161_zps4szy3b1u.jpg


A rear view
KIMG0162_zpsgffbjfod.jpg


KIMG0163_zpstqdpuh3i.jpg


A rough idea of the finished product
KIMG0165_zps7awlgtso.jpg


1/4" aluminum reinforcing plates hot off the CNC plas
KIMG0167_zpsjnwjhtrd.jpg


Finished the fork:
KIMG0173_zps78pipfcs.jpg

KIMG0174_zps0o1dy9ip.jpg

KIMG0175_zpsh7wrxrae.jpg


Waiting on a few parts as of right now, but should be complete this week
 
Yeah it's heavy, but that's because the panels are 1/2" thick and 3/4" thick. The material is very flexible, so I had to use thicker material and box the frame to get rid of the flex.

I'm hoping for less than 50, but even if I don't, that's still only a couple pounds heavier than the Beast, and everyone seems to be obsessed with those

Sent from my E6782 using Tapatalk
 
Yeah it's heavy, but that's because the panels are 1/2" thick and 3/4" thick. The material is very flexible, so I had to use thicker material and box the frame to get rid of the flex.

I'm hoping for less than 50, but even if I don't, that's still only a couple pounds heavier than the Beast, and everyone seems to be obsessed with those

Sent from my E6782 using Tapatalk
50lbs is not excessive for a stretch, they are not meant to be a race bike, in fact the heavier they are, quite often the better they ride... :113:

Luke.
 
This is pretty slick!
Is that material similar to the Starboard material that is used for some boat accessory construction?
 
We use starboard, which is a High Density Polyethylene. This material, however, is a copolymer polypropylene. The same stuff used on high pressure water tanks for fire trucks

Sent from my E6782 using Tapatalk
 
I'm wondering how this is gonna ride/handle. Can't wait to see the final product.
 
awesome ideal and manufacturing! :rockout:
that fork is welded? can you trust that ?:39:

Not the first fork I've made.

NCM_0257_zpsc2180293.jpg


I trust it. This is tough stuff. Plastic welding is no different than any other form of welding. Two pieces are bonded using heat and a filler rod
 

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