Recumbent Electric Assist Cycle Tadpole

Right, so now my blogging experience begins.. not so much on MySpace or Facebook (although I should probably just post there), but here on Blogger.
I may neglect this one from time to time, but I hope to keep up with it and add to it more than I do with some of the other social networking sites.

Now, about the project:
I decided some time ago that it would be practical/convenient/economic/healthy to bicycle to work whenever I could. Problem is, I want something that is good on even slightly rainy or cold days, and being exposed to the elements just would not do. I did some research and selected a full-fairing tadpole bicycle design with electric hub motor to assist with the hillclimb sections (as well as to help keep me from arriving at work in a full sweat).

Since most good tadpole road/touring bikes start out just under $2,000.00, I decided to build my own. That famous phrase that is normally the harbinger of doom, "How hard could it be?" ran through my head.

After some research, I felt I was ready to start looking for some raw material (donor bikes) for the project I lucked onto two thrashed mountain bikes at a local scrapyard that had similar frame tube cross section and proceded to disassemble them. After cutting the rear suspension triangle from one, I was left with the front parts of the other two.

I purchased a piece of 3" stainless steel exhaust pipe from a local shop and had them bend it 73 degrees for the main tube, then cut and ground the rear suspension to fit as close as possible, aligning it on a fabrication jig that I made from salvaged 1" square tubing.

Next, I was able to cut the excess material from the front down tube of both bikes and was left with nearly identical (but different colored) parts for the front cross beam.

I checked my kingpin and ride height on Google Sketchup (awesome program!) and was able to draw the geometry and cut points with alignment lines on a piece of plywood. This helped me cut and grind the front cross beam to make the individual sections line up exactly with nearly no gap whatsoever. The original plan was to me to either re-learn how to TIG weld, or have my friend Rob (or one of his minions at AutoCraft in Elkridge, MD) weld up the front cross beam using TIG. After an encouraging practice/learning session at his shop, I was frustrated by the Millermatic Squarewave that a friend had left in my shop for safekeeping. I gave my trusty Hobart Handler 135 a few practice rounds on some of the extra scrap that was in the metal bin, and became confident enough to tackle the welding on my own.

I welded the rear suspension, front cross beam, and entire main tube/cross beam "T", still using the jig to keep everything aligned properly.

Next Step: Mounting the Seat!