Introduction

For this week we had to:
test runout, alignment, speeds, feeds, and toolpaths for your machine (group assignment)

individual assignment
make (design+mill+assemble) something big

wanted to make something really ambitious and big, after five hours of discussions with our local
instructor I decided to make the wooden replica of Vespa Italian scooter (bike).
Unfortunately, I couldn’t make it this week because our lab was closed, the reason was the coronavirus.
But anyway that gave me more time to make bikes design better and more functional.

Experience


First of all, I start researching if there is something close made. Actually I didn’t find Vespa made from fly wood but find a nice
example of wooden Vespa. then I start searching for wooden bicycles as they are the closest relatives of bikes And the research showed
me a lot of examples which after helped me to solve some technical problems which I faced.
For starting the drawing I download .jpg photo with dimensions and import it to Fusion 360 to make my work easier.
To be honest, Firstly I choose Solidworks as a CAD/CAM program but because of the short time, I changed my decision to go back to Fusion.
The result of that all become two beta versions and one final version.
The Vespa was going to be made with joints and be assembled only with the use of hummer and because it was a big project
I needed to much dog bone joints. to make my task easier our Instructor finds and suggests me fusion 360 addin that creates dog
bone joints for wooden joinery, that addin was created by MIT students, thanks to them.

The first beta version was a simple scooter that didn’t have steering. After finishing the drawing I didn’t like how it looks. To make it I spent 4-5 hours.

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For Beta two version I spent 1 hour the challenge for me in the second version was to make steering. As all of that was done before going to sleep.
I had all night to think about how it’s going to look the next day I start a new drawing.

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The final version of my wooden Vespa was drowned in scale 1:1 and will be made as a full replica. I think some
details will be added and changed, also I’m going to buy the normal wheels from the shop rather than make it from wood.
And the steering system will contain some steel construction as well.The most used tool in this project was extrusion, then press and pull.
In the drawing, I had only one parameter that is the thickness of the material.

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The mnufacturing part

Forst of all I need to put the details in ose surface an then make the toolpath. So first I put the parts on one face(xy), than make the setup which has the 1525 x 110 x 16.5 mm. the next step was to creat the toolpath I choose the contour toolpath, creat the end mill for the program 1/4 inch end mill, chose the contours and regulate the step downs after I generate the program. then done some simulation.

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After quarantine

cutting proces

For the cutting the Vespa I need 2 shits of plywood and some smaller pieces as well.

I put on the end mill, set the Z axis zero.

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We were putting the plywood sheets on the machine, fixing it with clamps, starting the program and after first pass fixing it with the screws as well.

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Assembling

The only tool I need for the assembling process is the hammer bigger better. actually there were issues which improve with sandpaper but in general, it was okay. At first I was using the nylon hammer and the process was going to slow because I made the joints small to mkae the construction stronger. after 2 hours of bumping I took tje metal hammer and that solve all my problems actually then I foudn the the bigger one and start use it.
Warning don't hit straight to wood put something on it

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bicycle parts

The next step was to put some wheels on the Vespa for that I took an old bicycle ant took the steering and the wheels from it.

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Files


wooden Vespa
wooden Vespa shop bot files

Conclusion


of course, there will be some improvement as this is the base of my final project.
At this point, it can be driven only with the use of gravity but in the future, I will
put some motor and electronics on it