This is possibly Part One of a series on the construction of this bike.  If construction actually starts, it will be some time in the future, as schedule and shop space permits. Construction is entirely feasible, however. This design is presented as a thought aid to get you thinking about the possibilities inherent in this construction method. It is hoped that you will take advantage of this method, and build your own masterpiece. Be sure to send us pictures!

As normally seen, applying the Kustom Aesthetic to machines does not  necessarily make them any more efficient. This especially holds true with bicycles. Most radical kustom treatment applications or radical frame constructions add weight to the basic load. Fortunately, this mostly applies to welded-tubing construction. Utilizing current composite bike construction techniques, as seen in the recent composite bike coverage in BR&K, it is possible to build extremely radical bike designs without paying much of a weight penalty for their extreme koolness. The current approach to garage-composite bike construction ( as seen in Damon Rinard's work, for example), is to carve the bike's basic forms from plastic foam, then cover the foam with carbon fiber and resin. Usually, metal hard points are combined with the composite form at dropouts, steerer, bottom bracket, etc. Usually, these interface points are made in a machine shop, using lathes, milling machines, drill presses, etc.

Jim Wilson: Project Minotaur Part One of a series, maybe.

As normally seen, applying the Kustom Aesthetic to machines does not  necessarily make them any more efficient. This especially holds true with bicycles. Most radical kustom treatment applications or radical frame constructions add weight to the basic load. Fortunately, this mostly applies to welded-tubing construction. Utilizing current composite bike construction techniques, as seen in the recent composite bike coverage in BR&K, it is possible to build extremely radical bike designs without paying much of a weight penalty for their extreme koolness. The current approach to garage-composite bike construction ( as seen in Damon Rinard's work, for example), is to carve the bike's basic forms from plastic foam, then cover the foam with carbon fiber and resin. Usually, metal hard points are combined with the composite form at dropouts, steerer, bottom bracket, etc. Usually, these interface points are made in a machine shop, using lathes, milling machines, drill presses, etc.

The foam forming and composite lay-up can be done in the home garage or backyard. This is a very low-tech approach to high-tech engineering- ideal for the Bike Kustomizer. This design project's goal is the realization in composites of a kustom bicycle form normally made from steel tubing- the Stretch Kruiser. As principal reference for the form, I chose one of the ReeCycles Stretched Moto-Kruisers.

This one is an especially fine example of the Russell family's designs. The frame's form bears strong resemblance to an exaggerated male human torso, terminating at handlebars; has always reminded me of the Minotaur, the half-man-half-bull monster of Greek mythology. Thus, Minotaur is the working title of this design project- to transform the heavy metal Russell design into lightweight composite-over-foam form.

(Above) A 3-D digital model of the Minotaur form, transposed over the original bike.. This form could be done as a fiberglass "costume" fairing, however there would be a weight penalty in addition to the original frame's already-substantial weight. Composite over solid foam can have much less weight and greater stiffness. It may be presumed that the finished bike would have a chainguard and tank. If engine is retained, an aluminum-lined opening would be made in the frame,  shaped to the engine. The frame form would be shaped foam 1.5" thick. The same thickness would be laminated on to form rear stay. Full-valence fender  arc is 1.5" foam, with side panels of 1/8" paper clad foam board. When finished, the bike's form could be laid-up with carbon fiber and  resin, or  alternatively, stretched kevlar/spandex (Wearforce TM ) fabric and epoxy  resin.

(Above) Welded-tube frames, with thin frame members do not allow much surface area for kustom graphics. Composite-over-foam frames can be visually solid, with no weight penalty. This gives many more creative possibilities when designing a paint job.

This is possibly Part One of a series on the construction of this bike.  If construction actually starts, it will be some time in the future, as schedule and shop space permits. Construction is entirely feasible, however. This design is presented as a thought aid to get you thinking about the possibilities inherent in this construction method. It is hoped that you will take advantage of this method, and build your own masterpiece. Be sure to send us pictures!