If you’re looking to build serious core strength and conditioning, learning how to make the air bike totk is a fantastic project. This piece of equipment, often called an assault bike or fan bike, gives you a brutally effective full-body workout right at home.
Building your own saves a ton of money and lets you customize it to your space. It might seem complex, but with the right parts and some patience, you can do it. This guide will walk you through the process from start to finish.
How To Make The Air Bike TOTK
Before you start, it’s crucial to understand what you’re building. A DIY air bike uses a fan for resistance, which increases the harder you push. You’ll need to source a few key components, but many can be found online or even repurposed.
Gathering Your Tools and Materials
Having everything ready before you begin is the key to a smooth build. You don’t want to stop halfway because your missing a bolt. Here’s a comprehensive list of what you’ll need.
Essential Tools:
- Welder (MIG is easiest for beginners) or a very robust bolt-together plan
- Angle grinder with cutting and grinding discs
- Drill and various drill bits
- Measuring tape, square, and marker
- Wrenches and socket set
- Clamps
Main Materials:
- Steel tubing (1.5″ to 2″ square for main frame)
- Smaller diameter steel tube for handles and linkages
- A heavy-duty fan wheel (like from a car radiator or industrial fan)
- Bicycle crankset, bottom bracket, and chain
- Bicycle seat post and saddle
- Sturdy bearings and axles for the fan and moving arms
- Foot pedals and handlebar grips
- Bolts, nuts, and washers in various sizes
- Frame paint or primer
Design and Planning Phase
You can’t just start cutting metal. A clear plan prevents wasted materials and ensures the bike will be safe and functional. Sketch your design on paper or use simple CAD software.
Key measurements to decide:
- Overall height, length, and width.
- Seat position relative to the pedals.
- The distance the moving arms will travel.
- Placement of the fan and its housing.
Remember, the geometry affects how the bike feels. Look at pictures of commercial air bikes for refference. The linkage system that connects the arms to the fan is the most critical part to get right.
Finding a Suitable Fan Wheel
The fan is the heart of your air bike. It creates the wind resistance. Many DIY builders use a used automotive cooling fan or a industrial blower wheel.
Make sure it’s made of sturdy plastic or metal. You’ll need to attach it securely to a central axle that spins on bearings. The cage or housing around the fan is also important for safety and directing airflow.
Step-by-Step Assembly Guide
Now for the main build. Follow these steps in order for the best results. Work on a clean, flat surface and always prioritize safety—wear your goggles and gloves.
- Build the Main Frame: Cut your steel tubing to length according to your plan. Weld or bolt the base rectangle together, ensuring it’s perfectly square. Then add the vertical posts for the seat and the front column where the fan will mount. Double-check all your angles.
- Install the Bottom Bracket and Crankset: Weld or bolt a standard bicycle bottom bracket shell to the frame at the correct hight. Screw in the bottom bracket and attach the cranks and pedals. This is what your legs will power.
- Fabricate the Moving Arms: Cut the tubing for the long arms that you’ll push and pull. One end will have handles, the other will connect to the drive linkage. They must pivot smoothly on a strong axle near the front of the bike.
- Construct the Fan Assembly: Mount your bearings onto a strong plate. Attach the fan wheel to its axle and secure the axle in the bearings. Build a protective cage around the fan using welded rods or mesh. This whole assembly then gets attached to the front column.
- Create the Linkage System: This connects the arms and the cranks to the fan. You’ll need to make several connecting rods with holes at each end. Use heim joints or sturdy bolts as pivot points. When you move the arms or pedal, this linkage should turn the fan directly.
- Add the Seat and Handles: Insert the bicycle seat post into its tube and tighten. Attach comfortable grips to the ends of the moving arms. Make sure everything is adjustable to fit different users.
- Final Adjustments and Testing: Go over every weld and bolt. Apply paint to prevent rust. Now, test it slowly. Sit on the bike and move the arms and pedals gently. Check for smooth movement, strange noises, or any wobble. Tighten and adjust as needed.
Safety Checks and Final Touches
Never skip the safety inspection. A failure during intense exercise could cause injury. Look closely at all the high-stress points: the arm pivots, the fan axle, and the linkage connections.
Add rubber feet to the base to prevent floor scratches and improve stability. You might also add a small console mount to hold a phone or heart rate monitor. Give all moving parts a light coating of grease to ensure quiet, smooth operation.
Your first few workouts on the new bike should be light. This lets you identify any issues that only appear under load. Listen for creaks or feel for play in the joints that you might of missed.
Maintenance Tips for Your DIY Air Bike
Your homemade equipment needs a little care to last for years. A simple routine prevents most major problems and keeps your workouts safe.
- Every month, check and tighten all bolts and nuts.
- Lubricate all pivot points and bearing every couple months.
- Inspect the fan blades and cage for cracks or damage.
- Keep the bike clean and dry, especially if stored in a garage.
- If you hear a new noise, investigate it immediately—don’t ignore it.
Common Challenges and Solutions
You might run into a few hiccups. Here’s how to solve typical problems.
Problem: The fan wobbles or vibrates excessively.
Solution: The axle is likely bent or not seated properly in the bearings. Check the alignment and ensure the fan is balanced on the axle.
Problem: The linkage feels jerky or binds.
Solution: The pivot holes are probably misaligned. The connecting rods need to move freely without side-to-side play. Re-drill any problematic holes and use spacers.
Problem: The bike feels unstable during use.
Solution: The base frame might be to narrow or light. You can add weight to the base or weld on extended feet for a wider, more stable footprint.
FAQ Section
How much does it cost to make an air bike TOTK?
Costs vary, but a DIY build can range from $200 to $600, depending on if you source used parts. This is significantly cheaper than a commercial model.
Is a DIY air bike safe?
Yes, if built carefully with strong materials and proper welding. You must perform rigorous safety checks before each use, especially in the begining.
What’s the hardest part of making your own air bike?
The linkage system is the most technically challenging. Getting the geometry correct so the motion feels natural and directly powers the fan requires precise fabrication.
Can I use an exercise bike for the base?
You can modify an old exercise bike, but adding the moving arm mechanism is very complex. It’s often easier to build a dedicated frame from scratch.
How do you adjust the resistance on a homemade air bike?
Resistance is air-based, so it’s not adjustable in a traditional sense. It increases naturally with your speed. For more resistance, you simply push and pull harder.
Building your own air bike is a rewarding project that results in a premier piece of home fitness equipment. Take your time, focus on safety, and you’ll have a powerful tool for countless workouts. The sense of accomplishment when you finish your first intense session on a machine you built yourself is unbeatable.