A brief overview of the steps involved in prototyping version 4.xx of an electric wooden bicycle.
This handmade bicycle project utilizes both traditional fabrication and digital fabrication techniques. The Sapele wooden frame was created by laminating plywood to get one inch thick sheets to work from. They were milled digitally with Autodesk Fusion 360 CAD/CAM software and our large format gantry style CNC (which we also made). The Bicycle frame chain stay and seat stays were also CNC Milled, along with the custom aluminum dropouts. The round overs on all edges were down with a laminate trimmer. Notching and exit holes for the internal aluminum tubing for the brake lines, along with wiring, channels were cut in by hand. Sanding and finishing were done by hand. Final assembly of all the components was done by hand. A small manufacturing run of 40 was planned in 2019 but the project did not move forward. It is possible it will return some day. We certainly enjoined building and riding this specialty bicycle.