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Transportrollator2012 montageplan7

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PlatteauThijs

The document is an assembly manual for building a transport rollator. It provides 32 detailed steps to construct the rollator, which includes milling, cutting, gluing, and assembling various wood, metal, and plastic parts. The overall cost to build the rollator is €180 and it takes approximately 2 days to complete. Precise tools like a CNC milling machine are used to shape some parts, while other pieces like the handle and pedal assembly involve additional fabrication steps like welding, painting, and finishing. Upon completing all 32 steps, the finished rollator is made up of conductors, a supporting board, and triangles to provide a rolling walker for transportation.

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http://designforeveryone.howest.be/
TRANSPORTROLLATOR 1.8 Overall cost: €180 (all tools included) Overall production time: 2 days http://transportrollator2012.blogspot.com/ Thijs Platteau/ Bram De Craecker http://designforeveryone.howest.be/
ASSEMBLY MANUAL http://designforeveryone.howest.be/
TRANSPORTROLLATOR 1.8 BILL OF MATERIALS - Multiplex (700 x 500 x 18mm) -Ayous (150 x 40 x 50 mm) - Volkern (750 x 400 x 8mm) (200 x 300 x 15mm) - Afzelia (70 x 70 x 50 mm) - Beech (300 x 50 x 50 mm) - Formica laminate black (1500 x 600mm) - Aluminium strip (35 x 100 x 2mm) - Aluminium profile (15 x 15 x 2 x 800) - Inox pipe (diam.42 x 3 x 30mm) - Bike pedal - Gardena connection piece (female) - Lock system - Closet door handle ( diam.14 x 22mm) - 8 Rivets (3.2 x 9mm) - 16 Screws (3.5 x 25mm) - 30 Screws (3 x 16 mm) - 1 Screw (6x100mm) - 2 Washers (M16) - 4 Hinges (62 x 25mm) - 1 Hinge (50 x 20mm) - Skai grey (1500 x 1500mm) - White rope (500 x 3mm) - Wood glue - Laminate contact glue - Textile glue - TEC7 - Black paint mat - Metal Plastic - Filler - Velcro (0.5m) 19 different tools needed 6 standard parts 14 parts tailored
1 TRANSPORTROLLATOR 1.8 DESCRIPTION Mill the platform with a CNC woodworking machine out of a Volkern board (700 x 450 x 6 mm). HINT: make sure your cutters are freshly sharpened, because the Volkern material is very hard. Also do not mill out in one step, but take something like 3 steps to complete the whole thickness. See Technical Addendum 1 37min. 15 sec. (only milling) CNC woodworking machine Volkern plate 8mm none € 40.35
TRANSPORTROLLATOR 1.8 RESULT If everything is done correctly, your result should look like this.
2 TRANSPORTROLLATOR 1.8 DESCRIPTION Find an old bike and take off one of the pedals. Start adjusting it with your grinding disc to achieve the right length as can be found on the technical drawing. Weld an inox cylinder at one end and two washers (M16) at the other end (where the pedal used to be). Refine the welds with a round file. The outer washer has two slots, made with a metalsaw. See Technical Addendum 2.1 1h Grinding disc, welder, round file Washers M16, inox pipe (diam. 42mm) Bike pedal €4
3 TRANSPORTROLLATOR 1.8 DESCRIPTION You can now refine the blends and the holes in the metal with Metal Plastic filler. Smoothen it afterwards with sanding paper. See Technical Addendum 2.1 . 0.5h Metal Plastic, sanding paper none none Metal Plastic (500gr.): €6.35
4 TRANSPORTROLLATOR 1.8 DESCRIPTION Check your work one last time with a filler spray and make adjustments if necessary. See Technical Addendum 2.1 0,5h Filler spray none none Filler spray (400ml): €11.55
5 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the adjusted bike pedal black, when you’re happy about the results you achieved with the filler. Don’t paint the center piece of the axis, this will be mounted into a support later on to turn the handle. Because the paint wouldn’t stand the friction, we tape this area while painting. No 5min. (without drying) Black paint (mat) none none Black spray paint : €6.60
6 TRANSPORTROLLATOR 1.8 DESCRIPTION Adjust a Gardena connection piece (female: connection between hose and tap) with a cutter. Cut of the part where the hose should come and remove the upstanding edge (see picture). This will make sure you can move the grey part from the orange part with maximum distance. No 5min. Cutter Gardena connection piece none Gardena connection: €5.30
7 TRANSPORTROLLATOR 1.8 DESCRIPTION Now remove the inner parts of the Gardena connection with a drill or any other tool you can find useful. No 0.5min. Drill Gardena connection piece none €0
8 TRANSPORTROLLATOR 1.8 DESCRIPTION Glue the adjusted Gardena piece into the cylinder of the adjusted bike pedal with a strong fix-all glue, like TEC7. No 1min. (without drying) TEC7 glue none none Fix all glue: € 8.75
9 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a handle on the lathe from a piece of beech wood. And finish it with sanding paper. Other types of wood are also fine, but beech is easy to manipulate. HINT: Use sharp chisels. See Technical Addendum 2.2 20min. Lathe, chisels none none €3
10 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a centered hole in the handle with a drill press. Use a wood drill of 5mm. See Technical Addendum 2.2 2min. Drill press none none €0
11 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the handle black. Then join the handle to the gardena piece with a long screw (6 x 100mm). The head of the screw gets stuck on the nozzle because of the tensile strain. Now complete the part with the white rope. Make a loop at the end and fix the rope in the two slots of the washer (see next slide). See Technical Addendum 2 2min. Drill Rope, screw 3 Rope: € 0.5
TRANSPORTROLLATOR 1.8 RESULT If you followed every step, the handle should look something like this.
12 TRANSPORTROLLATOR 1.8 DESCRIPTION Now make the first beam of the conductor on the CNC woodworking machine. Use ayous wood. This is very lightweight and not expensive. See Technical Addendum 3.1 17 sec. (only milling) CNC woodworking machine none First beam € 0.31 (milling) + €0.45 (all ayous)
13 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish the first beam by gluing small pieces at the end of the opstanding cubes. Because this is impossible to achieve with the CNC machine we do this now. When a CNC machine is not an easy accessible tool, you can make this whole part with this technique. Just glue all the upstanding part onto a regular beam. This will be less precise of course . See Technical Addendum 3.1 2min. White wood glue none none White wood glue €3.15
14 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the second beam for the conductor part with a topie milling machine. Make a slot in the ayous piece. See Technical Addendum 3.1 2min. Topie milling machine none Second beam €0.5
15 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the pieces you need to make a swallow’s tail in Volkern material. Put the circular saw under an angle to achieve the right parts (2outer parts which will be mounted on the conductor and 1 center part which will be mounted on the turning board later on). Sand the outer white layers off to get the black colour out. To do this in a controlled way, it is best to use a sanding machine. HINT: Again make sure the blade of the circular saw is sharp! See Technical Addendum 3.1 45min. Circular saw, sanding machine none Swallow’s tail pieces €5
16 TRANSPORTROLLATOR 1.8 DESCRIPTION Cover the second beam with formica on one side. Namely the side where you measure 23mm of material. It is also the side where the swallow’s tail will be mounted on. No 5min. Contact glue, Spray gun, tape none none €30 (for gluing all formica, also in next steps)
17 TRANSPORTROLLATOR 1.8 DESCRIPTION Make drilling holes into the second beam where later on the swallow’s tail will be mounted. Make a small hole (diam. 4mm) all the way through and a bigger hole (diam. 9mm) till about 15mm from the end (= the side you just covered with formica). This way we can draw the pieces of Volkern for the swallow’s tail from the other side. By doing this no screws will be visible. So drill a hole of 3mm into the pieces of volkern and screw them onto the beam. HINT: Use a Drill press for centered holes No 20min. Drill press, drill none none €0.2
18 TRANSPORTROLLATOR 1.8 DESCRIPTION Saw the standard aluminium profile at the right length with a metal saw. No 5min. Metal saw Aluminium profile none €0.1
19 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we can finish the second beam completely with formica. Afterwards glue the aluminium profile into the beam with all-round glue. HINT: Saw the formica pieces a bit too large, afterwards you can sand them. For more difficult parts you can use a cutter to complete the form. No 30min. Contact glue, spray gun, TEC7 none none See step 16
20 TRANSPORTROLLATOR 1.8 DESCRIPTION Spray paint the side with the upstanding parts of the first beam. We do this, because finishing it with formica would be very hard and now the dimensions of the part are just right. No 5min. (without drying) Black paint (mat) none none See step 5
21 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the aluminium hooks with a metal saw. Drill holes on the right places and make them tapered with a bigger drill. Make sure to chamfer all edges with a file. See Technical Addendum 3.2 30min. Metal saw, metal drill, file Aluminium strip none €3
22 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw the finished hooks onto the first beam. Use screws of 3 x 16mm, inox. See Technical Addendum 3 2min. Drill Screws 3 x 16, inox none €0.05
23 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish one side of the first beam with formica(the side that will touch the other beam). Again use a cutter for the more difficult parts of the formica. Also finish the back side (opposite to the side with the hooks). No 5min. Contact glue, spray gun none none See step 16
24 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw the two beams together. Make sure you use the right angle and position. Once this is done, you can finish the last side of the first beam. No screws are visible anymore. No 2min. Drill none none € 0.05 + See step 16
25 TRANSPORTROLLATOR 1.8 DESCRIPTION After you finish everything with sanding paper, you can colour the edges black. This wil give you an excellent finish. No 10min. Black marker none none €0
26 TRANSPORTROLLATOR 1.8 DESCRIPTION All steps from 12 till 23 have to be done twice, because we need two conductors. But keep in mind they have to be mirror images. So very carefully watch every step, so you can screw them together in the right way (step 24). HINT: When you apply formica onto the ayous wood, always garantee adhesion with pressure (see picture). See Technical Addendum 3 / / / / See step 16
TRANSPORTROLLATOR 1.8 RESULT At the end, the conductors should look like the picture below.
27 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we start making the support. Begin with covering one side of a multiplex board with formica (see technique in previous steps). Drill a hole with diameter 4mm on the right place. Make a second hole for the head of the screw ont the other side of the formica (not all the way through). Then insert the closet door handle and screw it tight (door handle on the side of the formica). See Technical Addendum 5 10min. Contact glue, spray gun, drill press Closet door handle Multiplex board € 0.1 + See step 16
28 TRANSPORTROLLATOR 1.8 DESCRIPTION Now make the conductor parts of the support with the topie milling machine. You can use a CLS slat for this, if you first sand it to the right dimensions. See Technical Addendum 5.1 5min. Topie milling machine CLS none € 0.25
29 TRANSPORTROLLATOR 1.8 DESCRIPTION Saw the conductors to the right length. Finish the sides with formica. But keep the two outer sides open (see picture). No 15min. Contact glue, spray gun none none See step 16
30 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw them onto the supporting board. And finish the last side with formica. Also finish the upper sides of the piece with formica. No 5min. Contact glue, spray gun, drill none none € 0.05 + See step 16
31 TRANSPORTROLLATOR 1.8 DESCRIPTION Mill the supporting triangles out of Volkern with the CNC woodworking machine. Then correct the rounded edges of the upper taps with a file. See Technical Addendum 5.2 53 sec. (milling only) CNC woodworking machine, file none none € 0.96
32 TRANSPORTROLLATOR 1.8 DESCRIPTION Fix the hinges onto the triangles with the rivets. Then fix them onto the supporting board with screws (3 x 16mm). See Technical Addendum 5 5min. Hamer, drill none none Rivets: € 1.75, Hinges: €8
33 TRANSPORTROLLATOR 1.8 DESCRIPTION To finish the part you can glue a piece of left over volkern between the hinges, so that when the triangles are opened they cannot exceed a 90° angle. No 5min. TEC7 none none €0
TRANSPORTROLLATOR 1.8 RESULT When all the work is done, the support should look like this image.
34 TRANSPORTROLLATOR 1.8 DESCRIPTION Now cover a multiplex with formica. Then mill out the turning board with a CNC woodworking machine. See Technical Addendum 6.1 3min. 24 sec. (only milling) CNC woodworking machine, contact glue, spray gun none none € 3.68
35 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish the other side with formica (cut out the form with a hand milling machine). Attach the parts of the swallow’s tail made earlier with srews. Embed the heads of the srews into the volkern and finish with metal plastic. See Technical Addendum 6.1 1h Contact glue, spray gun, metal plastic, drill none none € 0.1
36 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the locking part with Afzelia wood. Saw the two parts, drill the hole with the drill press and make it open with the circular saw. Then attach the two pieces together with the standard hinge. Use 3 x 16mm screws. See Technical Addendum 6 0.5h Drill press, circular saw, drill Hinge 50 x 20mm none €1
37 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the two Afzelia parts black. Attach the standard lock on the other side of the hinge. Use 3 x 16mm inox screws. Make sure the lock keeps the two parts tight together. See Technical Addendum 6 0.5h Drill press, circular saw, drill Hinge 50 x 20mm none € 0.5 + See step 5
38 TRANSPORTROLLATOR 1.8 DESCRIPTION Drill 2 holes trough the bottom piece of the lock system. Do this under an angle, so that you can attach this piece onto the turning board with screws. It’s advised to also glue the pieces together. When the glue is still wet, you screw the pieces tight. No 15min. Wood glue, Drill press, drill none none € 0.1
39 TRANSPORTROLLATOR 1.8 DESCRIPTION Now finalize the part by adding an extra support under the locking system. Afterwards you paint the whole thing black. Cover the screws with metal plastic. See Technical Addendum 6.1 10min. Drill, Metal Plastic, Black spray paint (mat) none none € 0.05 + See step 5
TRANSPORTROLLATOR 1.8 RESULT In the end the turning board should look like this.
40 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we make a bag to put all the parts in for transportation. Start by cutting out the pieces of skai you need. For the outer bag you need: a piece of 1100 x 580mm and two pieces of 500 x 200mm. For the inner bag you need a piece of 930 x 580mm and two pieces of 420 x 100mm. No 10min. Scissors Skai none € 20
41 TRANSPORTROLLATOR 1.8 DESCRIPTION Now stitch two bags. One with the side pieces of 500 x 200mm and one with the side pieces of 420 x 100mm. HINT: Start stitching the side at the bottom and work your way up. No 1h. Scissors, Sewing machine none none €5
42 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a clean edge on both bags by stitching the borders double. No 15min. Sewing machine none none €2
43 TRANSPORTROLLATOR 1.8 DESCRIPTION Now stitch the smaller bag onto the bigger bag (when they are inside out). Afterwards turn them back to normal. You now should have the smaller bag inside of the bigger bag. No 20 min. Sewing machine none none €0
44 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we make a flap to close the bag. Stitch 3 borders double of a piece of 500 x 600mm. Afterwards you can stitch the side you didn’t stitch double, onto the inner side of the big bag. No 15min. Sewing machine none none €0
45 TRANSPORTROLLATOR 1.8 DESCRIPTION We now glue some velcro onto the bag. The first side about 120mm from the top, the other side at the end of the flap. No 5min. Textile glue Velcro none € 2.75
TRANSPORTROLLATOR 1.8 RESULT The bag should look something like this.
TRANSPORTROLLATOR 1.8 DESCRIPTION You can gather all pieces in the bag for easy transport.
TECHNICAL ADDENDUM http://designforeveryone.howest.be/
MACHINERY DESCRIPTION -All CNC work was done with a Holzher ECO MASTER 2710 340 - The drawings for the CNC pieces were made in Twincam 32. If you want to use the files, please contact somebody of the team. (last slide)
TO BUY DESCRIPTION - All equipment you need can be bought in a regular do-it-yourself store.
0 Assembly PARTS 1. Platform 2. Handle 3. Conductor right 4. Conductor left 5. Support 6. Turning board
1 Platform
2 Handle PARTS 2.1 Adjusted bike pedal 2.2 Grip 2.3 Gardena connection piece
2.1 Adjusted bike pedal
2.2 Grip
3 Conductor right PARTS 3.1 Conductor 3.2 Hook (x2) 3.3 Screws ( 3 x 25 , inox) (x4)
3.1 Conductor
3.2 Hook
4 Conductor left DESCRIPTION This is the mirror image of the right conductor. The only thing that is different is the way the two main beams are attached to each other. The beam with the hooks mounted on is now placed on the left side of the beam with the conducting slot in.
5 Support PARTS 5.1 Slide 5.2 Supporting triangle (x2) 5.3 Standard hinge (62mm) (x4) 5.4 Standard closet door handle 5.5 Screws (3 x 16, inox) (x12) 5.6 Rivets (3.2 x 9) (x12)
5.1 Slide
5.2 Supporting triangle
6 Turning board PARTS 6.1 Height setting board 6.2 Lock 6.3 Standard locking system 6.4 Standard hinge (50mm) 6.5 Screws ( 3 x 16, inox) (x 10)
6.1 Height setting board
6.2 Lock
TEAM CONTACTS http://designforeveryone.howest.be/
BRAM.DE.CRAECKER@HOWEST.BE THIJS.PLATTEAU@HOWEST.BE LISA.SURMONT@HOWEST.BE STEPHANIE.VERVAECKE@HOWEST.BE PETER.COSYN@TECHNUM-TRACTEBEL.BE http://designforeveryone.howest.be/

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Transportrollator2012 montageplan7

  • 2. TRANSPORTROLLATOR 1.8 Overall cost: €180 (all tools included) Overall production time: 2 days http://transportrollator2012.blogspot.com/ Thijs Platteau/ Bram De Craecker http://designforeveryone.howest.be/
  • 3. ASSEMBLY MANUAL http://designforeveryone.howest.be/
  • 4. TRANSPORTROLLATOR 1.8 BILL OF MATERIALS - Multiplex (700 x 500 x 18mm) -Ayous (150 x 40 x 50 mm) - Volkern (750 x 400 x 8mm) (200 x 300 x 15mm) - Afzelia (70 x 70 x 50 mm) - Beech (300 x 50 x 50 mm) - Formica laminate black (1500 x 600mm) - Aluminium strip (35 x 100 x 2mm) - Aluminium profile (15 x 15 x 2 x 800) - Inox pipe (diam.42 x 3 x 30mm) - Bike pedal - Gardena connection piece (female) - Lock system - Closet door handle ( diam.14 x 22mm) - 8 Rivets (3.2 x 9mm) - 16 Screws (3.5 x 25mm) - 30 Screws (3 x 16 mm) - 1 Screw (6x100mm) - 2 Washers (M16) - 4 Hinges (62 x 25mm) - 1 Hinge (50 x 20mm) - Skai grey (1500 x 1500mm) - White rope (500 x 3mm) - Wood glue - Laminate contact glue - Textile glue - TEC7 - Black paint mat - Metal Plastic - Filler - Velcro (0.5m) 19 different tools needed 6 standard parts 14 parts tailored
  • 5. 1 TRANSPORTROLLATOR 1.8 DESCRIPTION Mill the platform with a CNC woodworking machine out of a Volkern board (700 x 450 x 6 mm). HINT: make sure your cutters are freshly sharpened, because the Volkern material is very hard. Also do not mill out in one step, but take something like 3 steps to complete the whole thickness. See Technical Addendum 1 37min. 15 sec. (only milling) CNC woodworking machine Volkern plate 8mm none € 40.35
  • 6. TRANSPORTROLLATOR 1.8 RESULT If everything is done correctly, your result should look like this.
  • 7. 2 TRANSPORTROLLATOR 1.8 DESCRIPTION Find an old bike and take off one of the pedals. Start adjusting it with your grinding disc to achieve the right length as can be found on the technical drawing. Weld an inox cylinder at one end and two washers (M16) at the other end (where the pedal used to be). Refine the welds with a round file. The outer washer has two slots, made with a metalsaw. See Technical Addendum 2.1 1h Grinding disc, welder, round file Washers M16, inox pipe (diam. 42mm) Bike pedal €4
  • 8. 3 TRANSPORTROLLATOR 1.8 DESCRIPTION You can now refine the blends and the holes in the metal with Metal Plastic filler. Smoothen it afterwards with sanding paper. See Technical Addendum 2.1 . 0.5h Metal Plastic, sanding paper none none Metal Plastic (500gr.): €6.35
  • 9. 4 TRANSPORTROLLATOR 1.8 DESCRIPTION Check your work one last time with a filler spray and make adjustments if necessary. See Technical Addendum 2.1 0,5h Filler spray none none Filler spray (400ml): €11.55
  • 10. 5 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the adjusted bike pedal black, when you’re happy about the results you achieved with the filler. Don’t paint the center piece of the axis, this will be mounted into a support later on to turn the handle. Because the paint wouldn’t stand the friction, we tape this area while painting. No 5min. (without drying) Black paint (mat) none none Black spray paint : €6.60
  • 11. 6 TRANSPORTROLLATOR 1.8 DESCRIPTION Adjust a Gardena connection piece (female: connection between hose and tap) with a cutter. Cut of the part where the hose should come and remove the upstanding edge (see picture). This will make sure you can move the grey part from the orange part with maximum distance. No 5min. Cutter Gardena connection piece none Gardena connection: €5.30
  • 12. 7 TRANSPORTROLLATOR 1.8 DESCRIPTION Now remove the inner parts of the Gardena connection with a drill or any other tool you can find useful. No 0.5min. Drill Gardena connection piece none €0
  • 13. 8 TRANSPORTROLLATOR 1.8 DESCRIPTION Glue the adjusted Gardena piece into the cylinder of the adjusted bike pedal with a strong fix-all glue, like TEC7. No 1min. (without drying) TEC7 glue none none Fix all glue: € 8.75
  • 14. 9 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a handle on the lathe from a piece of beech wood. And finish it with sanding paper. Other types of wood are also fine, but beech is easy to manipulate. HINT: Use sharp chisels. See Technical Addendum 2.2 20min. Lathe, chisels none none €3
  • 15. 10 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a centered hole in the handle with a drill press. Use a wood drill of 5mm. See Technical Addendum 2.2 2min. Drill press none none €0
  • 16. 11 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the handle black. Then join the handle to the gardena piece with a long screw (6 x 100mm). The head of the screw gets stuck on the nozzle because of the tensile strain. Now complete the part with the white rope. Make a loop at the end and fix the rope in the two slots of the washer (see next slide). See Technical Addendum 2 2min. Drill Rope, screw 3 Rope: € 0.5
  • 17. TRANSPORTROLLATOR 1.8 RESULT If you followed every step, the handle should look something like this.
  • 18. 12 TRANSPORTROLLATOR 1.8 DESCRIPTION Now make the first beam of the conductor on the CNC woodworking machine. Use ayous wood. This is very lightweight and not expensive. See Technical Addendum 3.1 17 sec. (only milling) CNC woodworking machine none First beam € 0.31 (milling) + €0.45 (all ayous)
  • 19. 13 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish the first beam by gluing small pieces at the end of the opstanding cubes. Because this is impossible to achieve with the CNC machine we do this now. When a CNC machine is not an easy accessible tool, you can make this whole part with this technique. Just glue all the upstanding part onto a regular beam. This will be less precise of course . See Technical Addendum 3.1 2min. White wood glue none none White wood glue €3.15
  • 20. 14 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the second beam for the conductor part with a topie milling machine. Make a slot in the ayous piece. See Technical Addendum 3.1 2min. Topie milling machine none Second beam €0.5
  • 21. 15 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the pieces you need to make a swallow’s tail in Volkern material. Put the circular saw under an angle to achieve the right parts (2outer parts which will be mounted on the conductor and 1 center part which will be mounted on the turning board later on). Sand the outer white layers off to get the black colour out. To do this in a controlled way, it is best to use a sanding machine. HINT: Again make sure the blade of the circular saw is sharp! See Technical Addendum 3.1 45min. Circular saw, sanding machine none Swallow’s tail pieces €5
  • 22. 16 TRANSPORTROLLATOR 1.8 DESCRIPTION Cover the second beam with formica on one side. Namely the side where you measure 23mm of material. It is also the side where the swallow’s tail will be mounted on. No 5min. Contact glue, Spray gun, tape none none €30 (for gluing all formica, also in next steps)
  • 23. 17 TRANSPORTROLLATOR 1.8 DESCRIPTION Make drilling holes into the second beam where later on the swallow’s tail will be mounted. Make a small hole (diam. 4mm) all the way through and a bigger hole (diam. 9mm) till about 15mm from the end (= the side you just covered with formica). This way we can draw the pieces of Volkern for the swallow’s tail from the other side. By doing this no screws will be visible. So drill a hole of 3mm into the pieces of volkern and screw them onto the beam. HINT: Use a Drill press for centered holes No 20min. Drill press, drill none none €0.2
  • 24. 18 TRANSPORTROLLATOR 1.8 DESCRIPTION Saw the standard aluminium profile at the right length with a metal saw. No 5min. Metal saw Aluminium profile none €0.1
  • 25. 19 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we can finish the second beam completely with formica. Afterwards glue the aluminium profile into the beam with all-round glue. HINT: Saw the formica pieces a bit too large, afterwards you can sand them. For more difficult parts you can use a cutter to complete the form. No 30min. Contact glue, spray gun, TEC7 none none See step 16
  • 26. 20 TRANSPORTROLLATOR 1.8 DESCRIPTION Spray paint the side with the upstanding parts of the first beam. We do this, because finishing it with formica would be very hard and now the dimensions of the part are just right. No 5min. (without drying) Black paint (mat) none none See step 5
  • 27. 21 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the aluminium hooks with a metal saw. Drill holes on the right places and make them tapered with a bigger drill. Make sure to chamfer all edges with a file. See Technical Addendum 3.2 30min. Metal saw, metal drill, file Aluminium strip none €3
  • 28. 22 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw the finished hooks onto the first beam. Use screws of 3 x 16mm, inox. See Technical Addendum 3 2min. Drill Screws 3 x 16, inox none €0.05
  • 29. 23 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish one side of the first beam with formica(the side that will touch the other beam). Again use a cutter for the more difficult parts of the formica. Also finish the back side (opposite to the side with the hooks). No 5min. Contact glue, spray gun none none See step 16
  • 30. 24 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw the two beams together. Make sure you use the right angle and position. Once this is done, you can finish the last side of the first beam. No screws are visible anymore. No 2min. Drill none none € 0.05 + See step 16
  • 31. 25 TRANSPORTROLLATOR 1.8 DESCRIPTION After you finish everything with sanding paper, you can colour the edges black. This wil give you an excellent finish. No 10min. Black marker none none €0
  • 32. 26 TRANSPORTROLLATOR 1.8 DESCRIPTION All steps from 12 till 23 have to be done twice, because we need two conductors. But keep in mind they have to be mirror images. So very carefully watch every step, so you can screw them together in the right way (step 24). HINT: When you apply formica onto the ayous wood, always garantee adhesion with pressure (see picture). See Technical Addendum 3 / / / / See step 16
  • 33. TRANSPORTROLLATOR 1.8 RESULT At the end, the conductors should look like the picture below.
  • 34. 27 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we start making the support. Begin with covering one side of a multiplex board with formica (see technique in previous steps). Drill a hole with diameter 4mm on the right place. Make a second hole for the head of the screw ont the other side of the formica (not all the way through). Then insert the closet door handle and screw it tight (door handle on the side of the formica). See Technical Addendum 5 10min. Contact glue, spray gun, drill press Closet door handle Multiplex board € 0.1 + See step 16
  • 35. 28 TRANSPORTROLLATOR 1.8 DESCRIPTION Now make the conductor parts of the support with the topie milling machine. You can use a CLS slat for this, if you first sand it to the right dimensions. See Technical Addendum 5.1 5min. Topie milling machine CLS none € 0.25
  • 36. 29 TRANSPORTROLLATOR 1.8 DESCRIPTION Saw the conductors to the right length. Finish the sides with formica. But keep the two outer sides open (see picture). No 15min. Contact glue, spray gun none none See step 16
  • 37. 30 TRANSPORTROLLATOR 1.8 DESCRIPTION Screw them onto the supporting board. And finish the last side with formica. Also finish the upper sides of the piece with formica. No 5min. Contact glue, spray gun, drill none none € 0.05 + See step 16
  • 38. 31 TRANSPORTROLLATOR 1.8 DESCRIPTION Mill the supporting triangles out of Volkern with the CNC woodworking machine. Then correct the rounded edges of the upper taps with a file. See Technical Addendum 5.2 53 sec. (milling only) CNC woodworking machine, file none none € 0.96
  • 39. 32 TRANSPORTROLLATOR 1.8 DESCRIPTION Fix the hinges onto the triangles with the rivets. Then fix them onto the supporting board with screws (3 x 16mm). See Technical Addendum 5 5min. Hamer, drill none none Rivets: € 1.75, Hinges: €8
  • 40. 33 TRANSPORTROLLATOR 1.8 DESCRIPTION To finish the part you can glue a piece of left over volkern between the hinges, so that when the triangles are opened they cannot exceed a 90° angle. No 5min. TEC7 none none €0
  • 41. TRANSPORTROLLATOR 1.8 RESULT When all the work is done, the support should look like this image.
  • 42. 34 TRANSPORTROLLATOR 1.8 DESCRIPTION Now cover a multiplex with formica. Then mill out the turning board with a CNC woodworking machine. See Technical Addendum 6.1 3min. 24 sec. (only milling) CNC woodworking machine, contact glue, spray gun none none € 3.68
  • 43. 35 TRANSPORTROLLATOR 1.8 DESCRIPTION Finish the other side with formica (cut out the form with a hand milling machine). Attach the parts of the swallow’s tail made earlier with srews. Embed the heads of the srews into the volkern and finish with metal plastic. See Technical Addendum 6.1 1h Contact glue, spray gun, metal plastic, drill none none € 0.1
  • 44. 36 TRANSPORTROLLATOR 1.8 DESCRIPTION Make the locking part with Afzelia wood. Saw the two parts, drill the hole with the drill press and make it open with the circular saw. Then attach the two pieces together with the standard hinge. Use 3 x 16mm screws. See Technical Addendum 6 0.5h Drill press, circular saw, drill Hinge 50 x 20mm none €1
  • 45. 37 TRANSPORTROLLATOR 1.8 DESCRIPTION Paint the two Afzelia parts black. Attach the standard lock on the other side of the hinge. Use 3 x 16mm inox screws. Make sure the lock keeps the two parts tight together. See Technical Addendum 6 0.5h Drill press, circular saw, drill Hinge 50 x 20mm none € 0.5 + See step 5
  • 46. 38 TRANSPORTROLLATOR 1.8 DESCRIPTION Drill 2 holes trough the bottom piece of the lock system. Do this under an angle, so that you can attach this piece onto the turning board with screws. It’s advised to also glue the pieces together. When the glue is still wet, you screw the pieces tight. No 15min. Wood glue, Drill press, drill none none € 0.1
  • 47. 39 TRANSPORTROLLATOR 1.8 DESCRIPTION Now finalize the part by adding an extra support under the locking system. Afterwards you paint the whole thing black. Cover the screws with metal plastic. See Technical Addendum 6.1 10min. Drill, Metal Plastic, Black spray paint (mat) none none € 0.05 + See step 5
  • 48. TRANSPORTROLLATOR 1.8 RESULT In the end the turning board should look like this.
  • 49. 40 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we make a bag to put all the parts in for transportation. Start by cutting out the pieces of skai you need. For the outer bag you need: a piece of 1100 x 580mm and two pieces of 500 x 200mm. For the inner bag you need a piece of 930 x 580mm and two pieces of 420 x 100mm. No 10min. Scissors Skai none € 20
  • 50. 41 TRANSPORTROLLATOR 1.8 DESCRIPTION Now stitch two bags. One with the side pieces of 500 x 200mm and one with the side pieces of 420 x 100mm. HINT: Start stitching the side at the bottom and work your way up. No 1h. Scissors, Sewing machine none none €5
  • 51. 42 TRANSPORTROLLATOR 1.8 DESCRIPTION Make a clean edge on both bags by stitching the borders double. No 15min. Sewing machine none none €2
  • 52. 43 TRANSPORTROLLATOR 1.8 DESCRIPTION Now stitch the smaller bag onto the bigger bag (when they are inside out). Afterwards turn them back to normal. You now should have the smaller bag inside of the bigger bag. No 20 min. Sewing machine none none €0
  • 53. 44 TRANSPORTROLLATOR 1.8 DESCRIPTION Now we make a flap to close the bag. Stitch 3 borders double of a piece of 500 x 600mm. Afterwards you can stitch the side you didn’t stitch double, onto the inner side of the big bag. No 15min. Sewing machine none none €0
  • 54. 45 TRANSPORTROLLATOR 1.8 DESCRIPTION We now glue some velcro onto the bag. The first side about 120mm from the top, the other side at the end of the flap. No 5min. Textile glue Velcro none € 2.75
  • 55. TRANSPORTROLLATOR 1.8 RESULT The bag should look something like this.
  • 56. TRANSPORTROLLATOR 1.8 DESCRIPTION You can gather all pieces in the bag for easy transport.
  • 57. TECHNICAL ADDENDUM http://designforeveryone.howest.be/
  • 58. MACHINERY DESCRIPTION -All CNC work was done with a Holzher ECO MASTER 2710 340 - The drawings for the CNC pieces were made in Twincam 32. If you want to use the files, please contact somebody of the team. (last slide)
  • 59. TO BUY DESCRIPTION - All equipment you need can be bought in a regular do-it-yourself store.
  • 60. 0 Assembly PARTS 1. Platform 2. Handle 3. Conductor right 4. Conductor left 5. Support 6. Turning board
  • 62. 2 Handle PARTS 2.1 Adjusted bike pedal 2.2 Grip 2.3 Gardena connection piece
  • 65. 3 Conductor right PARTS 3.1 Conductor 3.2 Hook (x2) 3.3 Screws ( 3 x 25 , inox) (x4)
  • 68. 4 Conductor left DESCRIPTION This is the mirror image of the right conductor. The only thing that is different is the way the two main beams are attached to each other. The beam with the hooks mounted on is now placed on the left side of the beam with the conducting slot in.
  • 69. 5 Support PARTS 5.1 Slide 5.2 Supporting triangle (x2) 5.3 Standard hinge (62mm) (x4) 5.4 Standard closet door handle 5.5 Screws (3 x 16, inox) (x12) 5.6 Rivets (3.2 x 9) (x12)
  • 72. 6 Turning board PARTS 6.1 Height setting board 6.2 Lock 6.3 Standard locking system 6.4 Standard hinge (50mm) 6.5 Screws ( 3 x 16, inox) (x 10)
  • 75. TEAM CONTACTS http://designforeveryone.howest.be/
  • 76. BRAM.DE.CRAECKER@HOWEST.BE THIJS.PLATTEAU@HOWEST.BE LISA.SURMONT@HOWEST.BE STEPHANIE.VERVAECKE@HOWEST.BE PETER.COSYN@TECHNUM-TRACTEBEL.BE http://designforeveryone.howest.be/