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DIY Bike Rollers

by jcs7928 on July 5, 2011

Table of Contents

DIY Bike Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: DIY Bike Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Parts and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2: Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 4: Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Step 5: The frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 6: The missing link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 7: Putting it all Together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

http://www.instructables.com/id/DIY-Bike-Rollers/
Intro: DIY Bike Rollers
It is my personal belief that many people own bicycles, and that many of those people aren't interested in riding for pleasure / exercise when it is raining, snowing, dark,
etc. outside, and that many of those people would ride their bicycle indoors if they had a fun and challenging device that allowed them to do so, and that many of those
people would build such a device themselves if given the encouragement and advice to do so. Thus, if my calculations are correct, this Instructable my indeed be
appropriate for, and benefit many people.

DIY Bike Rollers from Jason Sauers on Vimeo.

Some people prefer stands and other types of trainers over rollers, but to me there are a few appealing aspects of rollers vs others:

More enjoyable
Faster / more intense Workouts
More challenging / engaging
Better all-over body workout
No adapting or installation - just set the bike on and go

Some may argue that it isn't worth the cost (a new set can be bought ~ $200) and time to build your own, but that can be said about almost anything-
I enjoy building things, I had all the materials that I needed, and it only took a weekend to build.

The building isn't particularly challenging, so long as you are familiar with basic construction / projecting techniques, and have access to the necessary tools and
materials.
I would not however suggest this as a first project, or for someone who does not have experience with similar projects.

P.S. I do not intended for this to be a set of step-by-step construction plans, as I feel that those who will likely have success in completing a project like this will be able to
easily fill-in the b_a_ks that I may leave.

P.P.S. This is another homebuilt setup (much more sophisticated than mine) that I didn't find until writing this - however for me the free-motion feature isn't very important
:
http://www.bikeforums.net/showthread.php/196027-Home-Made-Free-Motion-Roller-Assembly?highlight=home%20made%20free%20motion%20rollers

http://www.instructables.com/id/DIY-Bike-Rollers/
Step 1: Parts and Materials
Again- my goal is not to create a set of building plans, but rather lay out some suggestions for others to build off of.
I know that there are improvements and tweaks that others will find as they build their own which will result in better and diverse versions.

Some material suggestions:

'
3" PVC pipe 3pcs @ 18"
8ft of low stretch webbing - or tubing, rope etc
6+ skateboard bearings
3/8" steel Rod 3pcs @ 21"
Screws
Plywood
Dimensional Lumber - or other material for frame
Traction tape

Step 2: Dimensions
The roller width can be as wide - or narrow as you'd like, but unless you have very good balance, I wouldn't recommend less than 14 or so inches. I built mine 18 inches
wide.

The distance between centers on most adult bikes are fairly similar - but you may want to build the rollers to the bike you plan on using on it. Making it adjustable is also
an option, but didn't seem necessary to me - I have rode four different bikes from full suspension downhill, to road racing on it and no adjustment was necessary

The rear tire will be centered halfway between the rear two rollers, and the center of the front wheel should be slightly behind the center of the front roller. So if your bike
is 51.5" center to center, add a couple inches and make it 53.5" or ( (11 / 2) + 38)

http://www.instructables.com/id/DIY-Bike-Rollers/
Step 3: Rollers
I used 3" PVC for the rollers, you will want something large enough to give decent traction between the tire and roller surface. Also, the larger the roller - the slower the
bearings have to spin. Again, I made mine 18" wide. You actually ony have a useable 16 or so inches with the webbing / cord that connects the front and mid roller.

You can also use logs if you like a rougher - more off-road feel
see: http://www.youtube.com/watch?v=AKEHoA_xl-U

I cut rings of the 3" pvc and used them to create a channel to restrict the webbing from walking around on the roller

Step 4: Bearings
The skate board bearings are pressed in to plywood discs that fit snugly into the PVC, and are then held in place with a few countersunk flat head screws.

I cut the plywood discs using a jigsaw, and then sanded them to the compass mark

The recess can be made using a paddle bit of forstner bit

I then made retainers out of big fender washers to hold the bearings tightly

If possible, the bearings should be pressed into the discs tightly, if the bit you use doesn't allow for this, epoxy may be necessary to keep them from potentially wearing or
slipping in the wood

http://www.instructables.com/id/DIY-Bike-Rollers/
Step 5: The frame
The frame is pretty simple - you need two long pieces of material to hold the axles off the ground, and something to separate them the appropriate distance from one
another.

I added a little standing platform on both sides just to make it easier to get on and off - but it isn't necessary

2x4 studs or other common materials will work fine - you certainly don't need to use hardwood like is pictured in mine

You will also want a way of pinning the axles so that they don't turn or try working their way out while moving.

Note the notch in the middle cross pieces to accommodate the webbing

http://www.instructables.com/id/DIY-Bike-Rollers/
Step 6: The missing link
The front roller should be connected to the middle roller so that it in turn spins the front wheel.

I chose to use some 1" webbing, since I had some lying around. Lots of different things could be used for this however, rope, rubber tubing, rubber strapping, etc. The
important thing is that you can get it tight, and so that it doesn't slip on the rollers.

It is easiest to figure out how long it needs to be by assembling the frame and rollers, and then measuring and marking directly. It is also better to make it a touch small so
that it will be tight when you put it together

Step 7: Putting it all Together

A clamp may help with stretching the strap to get everything to go together properly - a test assembly with-out the strap should tell you that everything is lining up properly
before taking it apart and installing the strap.

I built mine without the stepping plates first, and then decided to add them afterword
They aren't necessary, but are nice

Some people also like the security of wheels on top to prevent the bike tire from tracking off the edge of the rollers - often seen on the free-motion setups - I didn't feel
them necessary

It is nice to assemble the frame with strictly screws or bolts - as you may want to take it apart later to adjust, transport, etc.

Hope you found this helpful - Have fun if you do decide to build your own, and go get some exercise. For both your body and your creativity.

http://www.instructables.com/id/DIY-Bike-Rollers/
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Comments
17 comments Add Comment

Mr.Sanchez says: Aug 3, 2011. 9:24 AM REPLY

Keep up the Good work...BTW...congrats for wining that XBox...

rgbarnes says: Jul 12, 2011. 9:38 AM REPLY

Those of you who would like to connect a fan or generator to a set of rollers have never ridden rollers. Rollers are a workout in themselves. No added
resistance is needed or desireable. As mentioned above rollers teach you to pedal properly, that is they teach you to spin not tork through the entire cycle.
Speed is desireable because the speed of the rear rollers determines the speed of the front roller. Your front wheel is the gyroscope that keep you upright.
the faster it turns the more stable your ride. Riding rollers is often compared to riding on an ice covered road. Good balance and control are not just nice they
are required. They are easy to learn to use if someone holds your hadlebars for the first few times so you can get used to the fact that the bike will stand
upright on its own. I took mine to a Boy Scout Camporee and taught hundreds of kids to ride them.

mjohnson21 says: Jul 19, 2011. 12:13 PM REPLY

You can also add bumpers. Seen a couple of models where people have added skateboard wheels (mounted on their sides) at the end of the rollers. If
wheel goes to far in either direction is bumps the skateboard wheel and you don't fall off. Very nice addition IMHO.

jcs7928 says: Jul 12, 2011. 12:58 PM REPLY

Practicing next to a wall, or even between a doorway is also a good way to learn.
I personally didn't like the feeling of a person holding the bars while I got the feel for balancing on them - but it is just personal preference. There are also
downsides to using a wall, like the fact that you can only use one hand on the bars while balancing against the wall - so if anyone is trying to learn, my
advice is try lots of different methods and use whatever works best for you.

As far a a generator goes - there are roller setups that incorporate a variable resistance feature. However, as rgbarnes points out, rollers are fairly difficult
without any additional resistance. So, im not sure how useful they would be if your goal is power generation.
My goal in building this was exercise / training equipment - so as Phil B suggested, a small electric fan would likely be a easier / more practical solution.
You can still vary the difficulty of the rollers by shifting gears. Never-the-less, if you decide to build one I would be interested in seeing it!

Phil B says: Jul 8, 2011. 5:26 AM REPLY

Thank you for this. It is a well-done Instructable. I have a set of rollers I purchased at a store for 2nd hand sports equipment. First I discovered that riding
rollers is more difficult than I thought. It takes more effort. I use a lower gear. My tires need to be at their full pressure always. It is more tiring. Second, it
takes a while to learn how to co-ordinate pressure to the pedals and maintaining balance in a way that is different from riding out on a road. Third, I added
some casters laid over on their sides and placed at the ends of the front rollers (at minimum) to steer the bicycle's wheel back onto the rollers. The used
rollers I bought were almost new. They had one giant rubber skid mark where the first owner's bicycle went off one side and he crashed on the floor. I like
the sideboards for placing your feet when mounting and dismounting. The only thing that might be helpful would be an adjustment for different bicycles with
longer or shorter distances between the front and rear axles.

Ev says: Jul 12, 2011. 9:10 AM REPLY

Riding on rollers gives a much different work out than a stationary bike. Balance, fine motor skills, core muscles, timing are all exercised. Smooth
pedaling is more efficient on the road, rollers are a great way to learn to be smooth.
Most cyclists push down on the pedals, nothing more. Efficient riders exert even pressure to the pedals on the down stroke, up stroke and the kick and
scrape strokes. It all becomes one smooth full circle effort.

greatpanda says: Jul 10, 2011. 10:08 AM REPLY

Yes the adjustment would also allow to tension the strap. Also, perhaps another strap for providing power for a fan? With a big enough or correctly
geared fan it might simulate air resistance, similar to commercial rowing machines.

pop88 says: Jul 11, 2011. 11:18 AM REPLY

hello
good idea
you can generate electricity

abaneyone says: Jul 10, 2011. 5:49 PM REPLY

Great instructable! It'd be neat to connect it to a small generator to power a fan or charge a battery. I use a resistance stand and get a great workout riding
for 30 minutes to 1 hour. It seems like it'd be more intense on a roller system like yours because you have to balance. However both the resistance stand
and roller system give great cardio workouts because you cannot coast while riding.

kiggs says: Jul 10, 2011. 10:50 AM REPLY

Make it power a fan!

susanrm says: Jul 9, 2011. 3:28 PM REPLY

Nice, nice, nice. Wish I had a wood shop, or the ex-boyfriend who had a wood shop. :-) I also like the idea of connecting it to power something.

http://www.instructables.com/id/DIY-Bike-Rollers/
 rimar2000 says: Jul 8, 2011. 4:52 AM REPLY
Very good. I make a lifter for the rear wheel, it functions, but is very boring to use.

Phil B says: Jul 8, 2011. 5:20 AM REPLY

Osvaldo, place an electric fan near you so it blows gently on you. Somehow it simulates the wind from riding outdoors and takes away much of the
boredom.

rimar2000 says: Jul 9, 2011. 4:55 AM REPLY

Good idea!

Now is winter here, I would put a hot air gun ;) Last weeks we had two "polar waves", too cold for us.

Phil B says: Jul 9, 2011. 5:22 AM REPLY

In a few minutes of riding, you will perspire enough that you will not need a heat gun, even though it is winter in the Southern Hemisphere, even
though you have a large air mass of cold air from the polar ice cap.

tinker234 says: Jul 8, 2011. 8:35 AM REPLY

wow now to make it power something hmmm

Kaptain Kool says: Jul 8, 2011. 6:30 AM REPLY

Very good instructable! I love the idea and the execution!

http://www.instructables.com/id/DIY-Bike-Rollers/