12.23 Studios

Lab Notes 02

(05/03/20)

[Note: This page will now only feature lab notes from the current episode. Previous notes are in the Archive...]

While waiting for the new granny cart wheels I played around with how to set up the two biggest pieces of gear for camp, the bike and the cart, and seeing that I can make my own tent...

These pics start right after putting out the latest episode...


The weakest part of the $20 granny cart, wheels with plastic spokes. I doubt these would carry more than 50 lbs...


Ace Hardware has the same size replacement steel and rubber wheels that the sales copy says has 150 lb. carry capacity. The steel spokes here are properly attached to the rim. The upgrade will make the granny cart a real cargo trailer...


The steel wheels came in a few days early, so I rode over to the Haight-Ashbury Cole Hardware store (which reminded me that I need to do more riding regardless of the lockdown) and picked them up...


The new wheel installed. When I checked the old plastic spoke wheel with the magnet again to compare, I discovered that there is a metal something in that plastic, but the spokes are thinner and the magnetic pull is much weaker than the actual steel spokes. The side weld on the rims, however, are much sloppier than the cheap wheels, even though the new rims are thicker...


With the wheels installed, the cart can supposedly handle well over 100 lbs. now, so it should handle my sculpture studio and power plant just fine...


The store itself seemed very well equipped, so I checked and found a 15A SPDT On-Off-On toggle switch for the mobile power plant control panel. I'll have to make another trip to see what electronic gear they may have...


The solid rubber tires from the cheap wheels are perfectly good spares...


Re: the mobile power plant, the remaining components are the batteries and solar chargers. A good 12V 22Ah leisure battery is the Universal Power Group 12220, sold under Apex and a few other names...


This is a good example of a 50W hikers and backpackers type solar panel. This could fully charge a 22Ah battery from 50% to full in 4 Hrs. of sun, so the power plant should always be available for a few hours each night...


Since the power plant is mostly for the laptop, the smartphone or tablet should be a separate 10W 5V portable unit that would be charging the phone while in use all day. This portable folding panel could hang from a light backpack or be attached to the handlebar sling...


This generic solar power bank charger is more compact and a bit more expensive; some have two USB ports...


After another hardware store run, I replaced the long eyebolt with a restocked shorty that allows the rack bag to just fit...


The handlebar extension bracket only extends 2.5 in...


The PVC bar now fits the sling...


The too short carbon fiber bar was replaced by a 9 in. PVC section wrapped in one layer of tape to provide bite...


Example of an old school Baker Tent, from Boy Scouts 'Handbook for Patrol Leaders 1949'...


A 9 x 12 ft. painter's drop cloth draped over the bike and cart as a mockup for a custom tent...


A rough approximation of the space taken up by the bike and cart to be covered by the DIY low profile tent...


A tent jig of sorts, 3.5 ft. H, 3.0 ft. W, to mark the rear sides of the tent...


The simplest design would use a box tarp (original size 12 ft. W and anywhere from 12 - 16 ft. L), providing a sleep space of a minimum 2.5 ft. to a max of 6 ft. W. I left the sides off to show the sleep space...


A design with the sides down, with an extra tarp as a rainfly/porch (8x10 or 10x10, for ex.)...


The non-box end by itself just needs a few stakes and guy lines on the tarp grommets to have the tent open or closed...


The tent jig laid out on the tarp. There's just barely enough floor space to work with...


Lining up the corner for marking...


I put tape on the 3 corners and marked the cut and fold lines with a sharpie...


After refolding the tarp to double check the sides, I taped and marked off the other corner. This is a good place to stop for the show; after taping the sides up, testing the mockup tent will require taking it to a park with mockup tent poles and setting it up to see what's what...


Two other mockups of a one-tarp bivy design. The proportional size of the tarp on the left is 12 x 12 ft., 12 x 16 ft. on the right, leaving a sleep space of 6 x 2.75 ft. and 6 x 4 ft. with the front closed...

(05/25/20)


For a couple days after doing the show I played around with the 'Baker Bivy' designs. You can go from three pairs of tent poles to no poles, just guy lines and stakes. Six poles allows a small Baker-style rocket stove campfire...


This is the 14 x 16 ft. scale design that has 4 x 6 x 8 ft. inside. A heavy duty tarp would make this an all-weather shelter...


While shopping for the tarps, next up is the mobile power control panel. These cheap plastic dollar store tubs tend to crack and split easily, so I cut a piece of Plastruct to hold the actual components. This is the last piece from my ill-conceived powerbox project (I don't remember what I was gonna do with 600V DC strapped to my hip once the Ac part stopped working...)


The DC outlet mount...


The components placed with enough room for labels...


The instrument mounts had to be done using millimeters to stay within a 1mm margin...


The starting templates for the ugly top...


Dry fitting components one at a time...


After trimming the top with an exacto, the switches snap in snug, the meters very snug, so much that taking them out cracked the lid between them...


The dremel helped shape the toggle switch holes...


Complete control panel dry mounted...


Inside view - plenty of room for the hardware and wiring...


An example of uncut tarps using only two poles, placed between the rear 'vestibule' and the sleeping space, with back, sides and front staked and guyed down. A pair of two or three ft. poles placed at four feet provides more encolsed headroom in the 12 x 14 bivy; a 10 x 12 rain tarp works as well as it would be more openly staked...


The 14 x 16 design done this way wastes a lot of tarp, but this one shows the bike and cart 'vestibule' area - 4 x 6 x 3 ft., and how the tarp would be staked, guy lines not shown...


The control box with installed outlet...


Instead of bolts, a couple zip ties and duct tape could secure the outlet...


On the left side, the ports for the backup battery cable to the backup switch...


The front ports for the battery lines...


The charge controller can be mounted this way, with a big slot cut to fit the terminal block through...


Instead of the side, I'll put the controller in front, next to the outlet. The access port should be high enough to accomodate the thick wires...


Access port cleared...


12V outlet ports cleared...


Backup battery port cleared...


Battery cable ports cleared...


Reinforcing the plastic with duct tape patches inside and out...


All cable ports reinforced...


Last Tues. my sleeping pad came in a day early, so after washing hands, unboxing, washing hands, I fit it to the handlebar sling...


The support strap buckles fixed with duct tape braces...


Second fitting...


The sling mounted to the bar, not too wide up front. The pad is 14 oz...


A standoff will be needed to keep the sling off the front cables...


Last Wed. I got a foot of 2" wide plumbing PVC, marked, cut and sanded two 3" standoffs for the sling...


Detail...


Dry fitting...


The standoffs clear 2.75" from the bar, enough to move the sling body off the brake and shifting levers, though it still rests against the cables...


The cables need their own standoff...


There's enough clearance for the eventual fender, straps aside...


I got two bottles of yellow Heet, the most efficient and economical alcohol fuel...


10 aluminum tent stakes for the tarp...