Cycling and bicycle discussion forums. 
   Click here to join our community Log in to access your Control Panel  


Go Back   > >

Tandem Cycling A bicycle built for two. Want to find out more about this wonderful world of tandems? Check out this forum to talk with other tandem enthusiasts. Captains and stokers welcome!

User Tag List

Reply
 
Thread Tools Search this Thread
Old 05-12-14, 04:02 PM   #51
PMK
Senior Member
 
PMK's Avatar
 
Join Date: May 2008
Location: Royal Palm Beach, Florida
Bikes: 2006 Co-Motion Roadster (Flat Bars, Discs, Carbon Fork), Some 1/2 bikes and a couple of KTM's
Posts: 1,154
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by chojn1 View Post
Monday Morning Progress Report:

I finished the exterior fiberglass on the base and started the carbon fiber layer of the lids:





Notice the base in the background. The foam core is 3/4in sheets of insulation glued together, not solid. The next step is to selectively grind out that foam for the reinforcement fiberglass layers around the wheel and the hardware mounts. Then I'll layer on the carbon fiber on the base.

What is a reasonably priced top coat I can get from Lowe's or Home Depot? I am running a little short on free time.

CJ
The photo did not upload.

Reasonbly priced top coat? I assume you mean a clear paint coat. If time is a concern, use Krylon clear, when you get home, remove it with thinner and finish the case how you like.

Not sure I answered your question correct. I tried.

PK
PMK is offline   Reply With Quote
Old 05-12-14, 04:54 PM   #52
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
PK,

Sorry about that.

Here you go:


I need a clear coat on the carbon. Just wondering what is easily available to use.

CJ
Attached Images
File Type: jpg carbon lid.jpg (98.5 KB, 44 views)

Last edited by chojn1; 05-12-14 at 04:58 PM.
chojn1 is offline   Reply With Quote
Old 05-21-14, 10:02 AM   #53
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
The carbon on the bases is done. I've also drilled out the holes for the wheels and pull handle. I tried partially clearing out the foam, but it got to be too much work. So, I removed all the foam from the base using a saw and sharp chisel. Here they are being washed.



I am out of free time for the next weeks - too many graduations, award ceremonies, and parties. Since it has to sit anyway, I went ahead and ordered some Duratec for the top coat.

CJ
Attached Images
File Type: jpg base carbon.jpg (92.0 KB, 43 views)
chojn1 is offline   Reply With Quote
Old 06-04-14, 05:30 AM   #54
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Things calmed down enough around here for me to finally finish the cases. Here they are getting ready to be packed for our trip next week:



The Duratec layers are great for UV and scratch resistance, but they made the cases too glossy for my wife's taste; we could see our own reflection in the case. So, I added another layer of matte clear to get finish she wanted.

Two more questions for you:

1) I printed some stickers for the sides of the cases:



Do you think they will help or am I wasting my time?

2) I use Boeshield T9 for lubricant, but I get it in an aerosol can form. Can I pack this in the case for non pressurized flights?

Thanks,
CJ
Attached Images
File Type: jpg cases.jpg (53.2 KB, 58 views)
File Type: jpg stickers.jpg (72.7 KB, 27 views)

Last edited by chojn1; 06-04-14 at 05:34 AM.
chojn1 is offline   Reply With Quote
Old 06-04-14, 10:24 AM   #55
colotandem 
Senior Member
 
colotandem's Avatar
 
Join Date: Oct 2007
Location: Golden, CO
Bikes: n+1
Posts: 315
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by chojn1 View Post

2) I use Boeshield T9 for lubricant, but I get it in an aerosol can form. Can I pack this in the case for non pressurized flights?

Thanks,
CJ
Nice looking cases!

I don't think you can take the aerosol can. I would use the bottle in liquid form to avoid any potential hassles.
colotandem is offline   Reply With Quote
Old 06-04-14, 12:27 PM   #56
vrooom3440
Senior Member
 
Join Date: Mar 2013
Location: Roseville/Folsom
Bikes: Co-Motion Primera Co-Pilot, Trek Madone 3.1, Trek 7300, Electra Townie 21D
Posts: 143
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Those came out great! Nice job.

Are they going to weigh enough to warrant the warning sticker for a heavy object?
vrooom3440 is offline   Reply With Quote
Old 06-04-14, 02:29 PM   #57
akexpress
Senior Member
 
Join Date: Nov 2007
Location: Anchorage, Ak
Bikes: Calfee Tetra tandem, Ventana ECDM 26, Ventana ECDM 29r, Orbea Orca, Santa Cruz Carbon 5010
Posts: 474
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
Wow first you build a carbon coupled tandem yourself then these cases you have great fab skills I am envious!!!!!
akexpress is offline   Reply With Quote
Old 06-05-14, 08:11 AM   #58
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Colotandem,
Thanks for the info. I'll order a bottle of the liquid form.

Vroom,
The cases are about 40lb each fully packed. I am not sure what weight warrants the warning, but I'm thinking the baggage handlers might be more cautious with those stickers on.

AK,
I do enjoy building things. Nice to have a lot help and support here.

I'll post a follow up on how the cases pack and travel once I get back from the trip.
CJ
chojn1 is offline   Reply With Quote
Old 06-05-14, 10:53 AM   #59
vrooom3440
Senior Member
 
Join Date: Mar 2013
Location: Roseville/Folsom
Bikes: Co-Motion Primera Co-Pilot, Trek Madone 3.1, Trek 7300, Electra Townie 21D
Posts: 143
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Wow 40 lbs each? Glad I am not pedalling your cases up a hill

I guess at 40 lbs those stickers might make sense. Hope those handles are up to the the task.

Do the latches lock? That flipped up end is great for fingers but might also catch on other baggage and self-open

Still some very nice looking cases.
vrooom3440 is offline   Reply With Quote
Old 06-05-14, 03:03 PM   #60
colotandem 
Senior Member
 
colotandem's Avatar
 
Join Date: Oct 2007
Location: Golden, CO
Bikes: n+1
Posts: 315
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by vrooom3440 View Post
Wow 40 lbs each? Glad I am not pedalling your cases up a hill

I guess at 40 lbs those stickers might make sense. Hope those handles are up to the the task.

Do the latches lock? That flipped up end is great for fingers but might also catch on other baggage and self-open

Still some very nice looking cases.
vroom3440, I'm surprised that you think that 40 lbs each is a lot. If you know of a lighter way to "fully pack" a tandem in two cases, I'm interested to hear the details.
colotandem is offline   Reply With Quote
Old 06-05-14, 05:12 PM   #61
vrooom3440
Senior Member
 
Join Date: Mar 2013
Location: Roseville/Folsom
Bikes: Co-Motion Primera Co-Pilot, Trek Madone 3.1, Trek 7300, Electra Townie 21D
Posts: 143
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Stipulated that I have not packed mine yet... but using cocktail napkin engineering:
I know my bike weighs about 40 lbs (yeah it's a steel frame...)
So basically 20 lbs of bike per case
That makes for 20 lbs of "case"

Of course I have included nothing else inside the box like shoes and helmets and and and... so it comes down to the definition of "fully pack" as you put it. With other stuff it gets a lot easier to meet or exceed 40 lbs each.

And if my wife packed the cases one of those stickers might not be enough
vrooom3440 is offline   Reply With Quote
Old 06-05-14, 06:23 PM   #62
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
My luggages are packed.
Just for you Vroom: the measured weight of the packed wheel case is 35 lb, and the frame case 39lb. The cases empty are ~15 lb each.
Packed in my case includes the bike, 2 helmets, 2 pairs of shoes, a mini wheel stand, a mini bike lock, half of my bike tools, spare belt, chains, tubes, tires, spokes, extra grease and lube.
Over all, I think I only saved about 25 lb from my wooden cases. And no, I am not planning on pedaling these cases anywhere. But now I have wheels, pull handles, and cool looking cases.
CJ

Last edited by chojn1; 06-05-14 at 06:35 PM.
chojn1 is offline   Reply With Quote
Old 06-05-14, 07:36 PM   #63
ebnelson
Member
 
Join Date: Jan 2012
Location: Boulder, CO
Bikes:
Posts: 26
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
That is much better than my Co-Motion Supremo Co-pilot weighed packed. With gear in the S&S cases I had to measure and spread the gear to keep the boxes under the 50 lb each weight limit for free bags on Southwest.
ebnelson is offline   Reply With Quote
Old 06-05-14, 08:13 PM   #64
colotandem 
Senior Member
 
colotandem's Avatar
 
Join Date: Oct 2007
Location: Golden, CO
Bikes: n+1
Posts: 315
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by ebnelson View Post
That is much better than my Co-Motion Supremo Co-pilot weighed packed. With gear in the S&S cases I had to measure and spread the gear to keep the boxes under the 50 lb each weight limit for free bags on Southwest.
This is more like what I was thinking.

Granted, you can make your fully packed cases weigh less, but you'll likely have some packing materials and gear that will push the weight up. I'd be surprised if S&S cases weigh less than the custom cases noted in this thread. YRMV. I say that 35 and 39 are VERY reasonable weights.
colotandem is offline   Reply With Quote
Old 06-06-14, 12:56 AM   #65
akexpress
Senior Member
 
Join Date: Nov 2007
Location: Anchorage, Ak
Bikes: Calfee Tetra tandem, Ventana ECDM 26, Ventana ECDM 29r, Orbea Orca, Santa Cruz Carbon 5010
Posts: 474
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 5 Post(s)
Quote:
Originally Posted by colotandem View Post
This is more like what I was thinking.

Granted, you can make your fully packed cases weigh less, but you'll likely have some packing materials and gear that will push the weight up. I'd be surprised if S&S cases weigh less than the custom cases noted in this thread. YRMV. I say that 35 and 39 are VERY reasonable weights.
I wish I could keep it that low. Our Calfee in SS cases always weigh 48 lbs each with tools and spares shoes and some cloths. i can pack one half of the bike in each case with its corresponding wheel in each case. I take the tires off the wheels for easier packing and allows for TSA to repack easier if needed. Again nice job the best looking bike cases I have ever seen. I do wonder some times if the fragile stickers just invite more scrutiny by TSA and the baggage handlers , sometimes going simple is the best.
akexpress is offline   Reply With Quote
Old 06-06-14, 08:23 AM   #66
Team Fab
Senior Member
 
Team Fab's Avatar
 
Join Date: Jan 2012
Location: Vancouver BC
Bikes: Comotion Supremo, Trek T1000, Comotion Supremo Triple
Posts: 341
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
If you really want to test the strength of your cases fly through Amsterdam. Every time we go there or through there our luggage gets destroyed.
Team Fab is offline   Reply With Quote
Old 06-06-14, 10:58 AM   #67
vrooom3440
Senior Member
 
Join Date: Mar 2013
Location: Roseville/Folsom
Bikes: Co-Motion Primera Co-Pilot, Trek Madone 3.1, Trek 7300, Electra Townie 21D
Posts: 143
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Quote:
Originally Posted by chojn1 View Post
My luggages are packed.
Just for you Vroom: the measured weight of the packed wheel case is 35 lb, and the frame case 39lb. The cases empty are ~15 lb each.
Packed in my case includes the bike, 2 helmets, 2 pairs of shoes, a mini wheel stand, a mini bike lock, half of my bike tools, spare belt, chains, tubes, tires, spokes, extra grease and lube.
Over all, I think I only saved about 25 lb from my wooden cases. And no, I am not planning on pedaling these cases anywhere. But now I have wheels, pull handles, and cool looking cases.
CJ


Yes I like data
vrooom3440 is offline   Reply With Quote
Old 06-11-14, 06:14 PM   #68
PMK
Senior Member
 
PMK's Avatar
 
Join Date: May 2008
Location: Royal Palm Beach, Florida
Bikes: 2006 Co-Motion Roadster (Flat Bars, Discs, Carbon Fork), Some 1/2 bikes and a couple of KTM's
Posts: 1,154
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
They look very nice and obviously, as is typical for you, well designed and constructed.

All the best with them, and hoping they give many trips of pure happiness.

PK
PMK is offline   Reply With Quote
Old 06-19-14, 09:24 PM   #69
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Thanks PK, you're too kind. And thank you for all your help in the build.
We just got back from our first of hopefully many more trips of pure happiness.
The Adirondacks and Lake Champlain was amazing. We loved the isolated country and forest roads. It was also so much fun to hook up with the folks at the Saranac Lake tandem rally. Tandem people are always such nice people.

The cases themselves did not fare very well.
On both the outbound and inbound trip, there were significant surface scratches.

One of the latch on the frame case was sheared off. Luckily the carbon layer and the shell structure remain intact. After replacing the latch, I will have to sand down and reapply another clear coat before the next trip. Amazingly, the contents was unscathed which is probably due to the poured foam packing.

Both cases were easily handled by my wife at luggage claim while I picked up the car. They traveled for free on the outbound flight, but cost us an unexpected $50 on the return due to a cancelled United flight and rerouting through another airline.
Packing and unpacking took less than 30 minutes.

CJ
Attached Images
File Type: jpg Luggage after trip.jpg (95.1 KB, 39 views)
File Type: jpg Frame case 1.jpg (102.8 KB, 42 views)
File Type: jpg Frame case 2.jpg (98.3 KB, 39 views)
File Type: jpg Wheel case 1.jpg (99.6 KB, 36 views)
File Type: jpg Wheel case 2.jpg (96.7 KB, 33 views)

Last edited by chojn1; 06-20-14 at 04:32 PM.
chojn1 is offline   Reply With Quote
Old 06-20-14, 03:11 PM   #70
vrooom3440
Senior Member
 
Join Date: Mar 2013
Location: Roseville/Folsom
Bikes: Co-Motion Primera Co-Pilot, Trek Madone 3.1, Trek 7300, Electra Townie 21D
Posts: 143
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
Very cool, I really like how the poured foam worked out. No questions how the bike packs in there and no movement of parts. Definitely a post for future reference.
vrooom3440 is offline   Reply With Quote
Old 06-21-14, 04:39 AM   #71
PMK
Senior Member
 
PMK's Avatar
 
Join Date: May 2008
Location: Royal Palm Beach, Florida
Bikes: 2006 Co-Motion Roadster (Flat Bars, Discs, Carbon Fork), Some 1/2 bikes and a couple of KTM's
Posts: 1,154
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 0 Post(s)
Quote:
Originally Posted by chojn1 View Post
Thanks PK, you're too kind. And thank you for all your help in the build.
We just got back from our first of hopefully many more trips of pure happiness.
The Adirondacks and Lake Champlain was amazing. We loved the isolated country and forest roads. It was also so much fun to hook up with the folks at the Saranac Lake tandem rally. Tandem people are always such nice people.

The cases themselves did not fare very well.
On both the outbound and inbound trip, there were significant surface scratches.

One of the latch on the frame case was sheared off. Luckily the carbon layer and the shell structure remain intact. After replacing the latch, I will have to sand down and reapply another clear coat before the next trip. Amazingly, the contents was unscathed which is probably due to the poured foam packing.

Both cases were easily handled by my wife at luggage claim while I picked up the car. They traveled for free on the outbound flight, but cost us an unexpected $50 on the return due to a cancelled United flight and rerouting through another airline.
Packing and unpacking took less than 30 minutes.

CJ
Without going back to read the posts, are the latches sitting proud and caused the problem or did something else remove the latch? Being composite, you could make a simple mod to go with a flush latch. Might not hurt to go with stealth handles also, so the monkeys cant swing the case when loading.

As for scratches on the clear, that is to be expected, though your method should provide easy touch up.

Curious if both ways had TSA leave tags inside, showing they opened and inspected the cases / bicycle.

PK
PMK is offline   Reply With Quote
Old 06-21-14, 06:13 PM   #72
chojn1
Senior Member
Thread Starter
 
chojn1's Avatar
 
Join Date: Jun 2009
Location: Sugar Land, TX
Bikes: Eriksen Tandem, DIY CF Tandem, Aluminum Tandem, Lightspeed, Cervelo, Specialized, Trek
Posts: 262
Mentioned: 0 Post(s)
Tagged: 0 Thread(s)
Quoted: 6 Post(s)
PK,
The latches were raised. I am thinking of making bumpers to recess the latches and the handles. Part of the problem is that the clear coat was too smooth which allows the cases to move too easily around in the luggage compartment. I noticed that when the cases were sliding around in the rental car's trunk. Rubberized bumpers should do the trick.

I decided to skip the stickers, but it did not make any difference. TSA inspected both cases both ways.
CJ
chojn1 is offline   Reply With Quote
Reply


Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off



All times are GMT -6. The time now is 05:54 AM.