Can You Really Ride A Cardboard Bicycle?

Sustainable materials are all around us. Now, it is just a matter of reformulating their original purpose and repurpose these materials into new and challenging solutions. Who woulda thunk that cardboard could be crafted into functional bicycle or that wood could be potentially stronger than kevlar or carbon fiber?

Necessity is the mother of invention and hearing about stories such as a bike being built from cardboard keeps us awake at night. We know of the amazing building properties within bamboo, concrete, hemp and an array of other materials, so now we are seeking out a plethora of interesting stories such as this.

Neil Fallon sings it best in the Clutch song You Can't Stop Progress

Link to short film on Vimeo

Izhar cardboard bike project from Giora Kariv on Vimeo.

Questions and answers, original post and info here

What was the biggest challenge in working with cardboard?

The biggest challenge of the Cardboard Bike project was to learn and develop a whole new know how of cardboard. Our challenge was to take the cardboard material, and pass it through a set of treatments, to replace the raw materials of plastic, wood or metal.

What did you learn from the experience?

What start up nation learned: That Nothing is impossible if you have patience and you are persistent.

How far along is the development of the Cardboard Bikes?

The development started 3 years ago. Since there was no know how with regards to the cardboard material, the first 2 years were devoted to learning the properties and behavior of the material; from all aspects of engineering tools, strength calculations and analysis and establishment of the IP that protects all of this know how. The "packaging box on wheels" as seen in our video was the third prototype, the Alfa commercial model (with the letter A on the chassis), is the first operational model that is made of a 100% recycled materials (with the electric motor as an add-on option).

Is it patented?

All know how, working procedures and production techniques are fully patent protected worldwide by Israel’s leading patent Reinhold-Cohen.

When will the company get to the point where it is manufacturing?

The Company is now in the process of raising funds that will bring the company within 6 months of investment to the point in which we will have a full and detailed manufacturing plan for the first 2 platforms. The commercial/Urban bikes (BOM – $9, 9 KG), and the kids/youth bike (BOM - $5, 3.5 KG). These models will be made of almost 100% recycled materials and will have the option of adding an electric motor. At this stage we have only the prototype for the commercial bikes as shown on the video.

How do you have the knowledge to take it from here to the market?

The inventor, Mr. Izhar Gafni, is a mechanical engineer and a multi-disciplinary systems developer. Izhar developed the recycled cardboard bikes combining his knowledge in 2 main areas: being an expert in building and designing custom made carbon fiber bikes for high end riders and his experience as a production line expert. Izhar is known for his former developments of the Pomegranate Peeling Machine (for which he has won a prize by the American Association of Engineers), a Smart Robot for sewing shoes, a Disabled Climbing Machine and more.We believe we have the knowledge and the ability to reach our goals and that nothing is impossible.

What is your vision?

Cardboard Technologies is all about making a better world for us to live in by two main principals: creating the ability to produce almost any daily product from at least 95% recycled materials and building auto production lines, with a simple post production assembly that will be performed by people with difficulties or disabilities.

Unlimited and incentivized raw materials and incentivized manpower will help us create working places in every location which we will find a local partner at. Our vision is also to bring the factories back from China (starting with the green ones).

What is your business model, and what will be the end user cost of your bikes?

The principals of our vision above, will allow our partners and manufactures to receive almost all of the of the production costs of our products back from governmental and global incentives, making our products available to almost any person in any philanthropic or commercial business model.

We can add any design or logo to the bike chassis for example and with by adding a simple electric motor, making it the most classical urban clean transportation.

This will allow our bikes to be given away as a commercial transportation or as a gift for Christmas from your Mayor.

Another important attribute of our bikes, is that they need no adjustment or maintenance, making them available directly to consumer at low price, and not through the regular marketing chains that will bring it to an end cost of X5 post assembly."

Backyard Black Smithing With A Home Built Power Hammer

Characters like MacGyver and the fellas from Mythbusters continue to inspire, for one very specific reason. They think through a problem and create a solution. By painting their way out of a corner, clever ideas resolve an issue at hand or help to further expand their quiver of tools.

Ingenuity comes in many forms and creating your own tools is a particular fascination of ours. When it comes to metal, we are all ears and hands in this scenario. Have a look at this video about a home made black smith power hammer. Did you ever think about making an engine block for a table stand? Yep, we sure have many times and even made one. Below is also a fabrication table made from the crankshaft of the donor engine we bought. These guys upped the ante and for that clever solution and we salute you.

Find out more on blacksmithing tools from the Naked Anvil youtube page

Crank shaft as base for a portable fabrication table

Proportionate size with our old Cafe Racer in the process of being rebuilt

TWT Motorcycle Parts - Interview

As soon as you learn that life is all about who ya know, things get much easier. We had such a damn good time at the Timonium Motorcycle Show and were able to meet and hang out with Mike over at TWT Motorcycle Parts. He is a solid dude and is quite the artisan when it comes to working with metal.

For quite a few years we have been looking at making custom metal pieces for a few projects we had cooking up, but machining them out just seemed overly engineered and lacked the detail we were after. Luckily Mike walked into the picture and completed the ideas in our head, through his crafty techniques with metal etching. Dig into his work and see the possibilities for what type of custom work he could do for you. Imagination is the only limit you have as he also works in a variety of metals and can school ya quick on the best way to achieve your idea.

Be on the lookout for a whole lot of projects with TWT Motorcycle Parts and us in the future.

Keep up to date with TWT Motorcycle Parts blog

Buy products from TWT Motorcycle Parts

Rusty Knuckles gear logo for Sportsters, created by TWT Motorcycle Parts

Wilkinson Bros metal emblems created by TWT Motorcycle Parts

1. Tell us about yourself, have ya always been into all things mechanical?

Yah, I’ve always loved mechanical things. Lego blocks and an erector set were my

two favorite toys as a young kid. As I got older I started taking things apart to see

how they worked, I even managed to put them back together sometimes. My mom

would never let me have a mini bike or go cart “they’re too dangerous”. So I had to

stick to building crazy bicycles and soap box cars. Nothing dangerous about adding

½” black iron pipe to the forks of a bicycle to build a chopper right?

Cafe Racer style tank emblems created by TWT Motorcycle Parts for Front Street Cycle

2. How did you get into metal etching? Mad scientist yearnings, comic book ideas

involving dangerous chemicals or did ya find it on the internet?

I saw an article once in a woodworking magazine that talked about making etched

brass builder plates you could attached to finished woodworking projects and I

thought that was cool. The idea was in my head for a long time. Years later a friend

asked me to make a wooden plaque for a small battle axle he got at a renaissance

fair. He’s a tattoo artist and wanted to hang it in his station. He was going to have

an engraved plate made that said “Tattoo Remover”. I told him to hold off on the

plate, that I wanted to try something. That’s how it started. I did find some valuable

information on the internet as I was stumbling through the beginning stages of

learning how to do this and I’m still learning as I go.

3. Knowing the chemical reactions that cause the metal to be dissolved, are there any

special concerns about your process?

Any time you are dealing with chemical reactions you need to be careful. A lot of

etching processes use acids. I quickly got away from that at the beginning do to the

dangerous nature of acids and the problems disposing of it. I use a combination of

salts which are a lot more user friendly and easily disposed of.

Matchless logo belt buckle by TWT Motorcycle Parts

TWT Motorcycle Parts ready to ship

TWT Motorcycle Parts can etch any part you send them

4. With the type of work you are doing what type of companies can you see working

with?

I have a small line of motorcycle parts, belt buckles and accessories that I sell online.

You can see that stuff at http://twtmotorcycleparts.bigcartel.com/. I also do custom

signs. I’ve done signs for some companies in the motorcycle industry like Biltwell,

Lick’s Cycles, Cleveland Cycle Werks and a few others. Custom work is a big part

of what I do. I’ve made custom parts for a bunch of companies like Mutiny Cycle

Works, Shortbus Customs and Go Fast to name a few. Oh and let’s not forget Rusty

Knuckles. Stay tuned folks there’s some nice stuff coming from them soon.

5. Knowing that you are creating one off custom pieces, would your process be able

to scale to handle large orders?

Absolutely whether it’s a single piece or a large orders of pieces the process is the

same. It’s kind of like making cookies; whether you’re making a dozen or twelve

dozen you make them the same way it just takes more time. The key is to know how

to put it all together to make it flow efficiently.

6. Any other artisans working with a similar process you dig checking out?

I haven’t found anyone doing the kind of stuff I’m doing. I’d love to find some other

artisans doing it. So if your out there hit me up. There are two processes similar to

what I’m doing called Intaglio and photo etching. Intaglio is a form of printmaking

that uses etched metal plates to make prints and photo etching is used in a lot of

different ways. Jewelry making uses photo etching often to create details in the piece

being made. There are a lot of talented people in both fields. I’d like to meet some of

them and pick their brains.

Aluminum keychain for country band Hellbound Glory

Weld in oil cap with etched top by TWT Motorcycle Parts

7. What are the future plans for TWT?

I have a ton of ideas for different products rolling around in my head. So as time

permits I’ll be getting them out of my head and into physical form. I like working

with other creative people on different projects so I hope to continue to build on that.

I also want to do some one off pieces of wall art. So keep an eye out for that. I guess

you could say the future plans are to keep creating and make a little money along the

way.

Railroad Spike, Custom Knives

Over the last few years I have really been interested in learning more on the science and craftsmanship behind forged steel and blacksmithing. Our logo of the wrench knife was created by a local blacksmith as a gift and that set the ball in motion to learn more about this ancient craft. One area that I have been particularly paying attention to is custom swords and knives as the amount of craftsmanship to create such a type of blade can be done in many stages, such as with a Japanese sword or a bit quicker of a process with railroad spike knives.

Below is a cool video on how one guy is creating knives in a back yard forge and getting quite the results. If you want to know more about the science of metalurgy and sword making, check out a post we did a while back.

Link to article on sword making from an earlier post:

Custom knife made from railroad spike with leather sheath

Railroad spike knife with twisted handles

Railroad spike knife custom made

Railroad spike knife forged with black oxide and wood handle

Sculptures From Welded Chain

Form and shape are all around but it is up to us to interpret what we see, to become something new. Call it the creative process or maybe just working through ideas. Whatever the case may be, the curious mind will continue to find new ways to interpret concepts. 

A contemporary sculptor from Korea, by the name of Yeong-Deok Seo has found a way to give subtle hints of humanity to what might be considered just masses of chain. Within the lines of the these sculptures exudes a quiet and subtle presence. Due to the notion of what we assume chains provide, the depictions are endowed with pure strength. Mixing those elements together to create sculpture that contains the human forms allows this work to go to another level of appreciation. 

Another element that we enjoy is the fact that these two forms of chain have vastly different functions. To be able to assemble those two styles of a purely functional tool, begs backyard wrenchers everywhere to stop and stare at how a chain can be used in a new way. 

Art can come in many facets and be made from anything, it just takes a creative and analytical mind, to see an everyday object in a new way. Indian Larry consistently spoke on how building a chopper was the ultimate art form as it portrayed design, sculpture, painting and most of all, usability. We couldn't agree more, just have a look at his famous "Chain of Mystery" bike at the bottom.

Indian Larry's - Chain of Mystery

How To Build A Custom Stage and Booth

A crazy idea struck us earlier this summer. We figured that building a new setup for all the shows we do at motorcycle, hot rod and music events would be a good idea. Of course this was all on the fly and didn't even really think on drawing up a fully fleshed out idea as our clever concept entailed obtaining all recycled material or at least mostly refurbished steel and wood.

Several sketches and quite a few beers later we posted a note up on the local craigslist looking for scrap steel. Within a few days we got an email from a couple about an hour away that had an old steel staircase that needed tearing down and offered the steel for free if we hauled it away. How could we pass up on the opportunity to spend ten hours and over 30 cut off wheels cutting down an entire staircase? Yes, we are gluttons for punishment as this was all accomplished in close to a hundred degree heat and southern humidity, our normal operating temperature.

With all the steel finally at the shop we could take measurements and really see what we had to work with. The beams were our main interest along with the pipe as that would be our main structural support for the floor deck and poles to support the roof. The steel was under a huge amount of tension with the step supports that were welded on as they had begin to flex over the forty years that the stairs had been in use. As we we were cutting off the support brackets the steel was snapping back into its original shape. If that won't rattle your nerves handling big beams, not sure what else will, as you can guess this stuff isn't light.

Knowing how big our projects can get I cast out a blank series of text messages for "volunteers". One lone ranger opted to show up and help and we thank none other than Jukebox Hank for rolling down for three days for some sweat equity. Without his help in getting all the grinding and metal prep done on the box frame, we truly would have been up shits creek. The setup of the beams should have been a three man job to line things up and weld in the brackets to hold the corner bolts but we did it with two and several cinder blocks. The beams now lock into place with a series of four large bolts and the supports of the crossmember wood and steel pipe hold it all together so its easy to assemble and disassemble. In all actuality, one person can build the entire platform now without any other help as I had to do close to seven times to really dial in the construction of it on the fly.

One of the last pieces that we needed was refurbished floor planks. Luckily we have a Habitat for Humanity a couple of miles down the road and was able to purchase a stack of eighteen 2 x 6 x 10's in a variety of lengths. With the planks, our floor could now be completed and we cut those all to length and placed them in a specific alignment to lock the wood in tight and employed a few shims to really tighten it up.

Our plan is that now with a solid floor we can also use this for indoor shows as a bike platform or a raised deck for a variety of setups. We dig having an old country store feel as it matches the vibe we are going for. This stage has been truly labor intensive to build, but it solidifies exactly what we are doing and doesn't look like a lame cookie cutter tent at outdoor festivals. Add in our wrench knives flags and a variety of roof options and we are set for just about any damn show we need to do. 2012, here we come!

Total Cost, just under $180 bucks with excess cut off wheels, bolts, welding wire, etc. etc. Who says cool things have to cost a lot of money, go out and make life happen.

Soundtrack to stage building 101 provided by Antiseen and Crank County Daredevils

Antiseen - Broke Down Blues by RustyKnuckles

Crank County Daredevils - That's How We Roll by RustyKnuckles
Crank County Daredevils - Coming Down by RustyKnuckles