For a while there progress on the rollers was slowed..., but the work has picked back up! This week's work consisted of creating end plugs for the pipes to create the roller drums. I used some composite decking material that happened to be sitting in my shop (sorry Ralph for not getting this back to you!)
After about 9 cuts apiece on the miter saw, the blanks are marked for center and drilled for mounting on a face plate mandrel to turn the pieces on a lathe.
I borrowed a little wood lathe from a friend. These pieces nearly max out the size capacity of the lathe, and I was a little worried that it might not be powerful enough, but it's a gutsy little thing. The major issue has been to keep any tool sharp enough to work effectively. The composite material is pretty tough stuff.
There are two types of end plugs I am turning. The first has a little groove in it to accept the belt. The second does not need this, so the outer lip is smaller. 
I finished one of each today and loosely assembled the first roller drum. It takes me about 2 hours apiece to turn these plugs. I'm sizing them just right to be able to press into the pipe, and so the bearings will press into the plug. The key to this is to take it slowly!
I finished one of each today and loosely assembled the first roller drum. It takes me about 2 hours apiece to turn these plugs. I'm sizing them just right to be able to press into the pipe, and so the bearings will press into the plug. The key to this is to take it slowly!
Just 4 more plugs to go and I'll have the three roller drums ready to mount on the frame. Now if I could just find some time to ride my bike...
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