If you’re looking for a serious cardio and conditioning tool, learning how to build air bike totk is a fantastic DIY project. An air bike, often called an assault bike or fan bike, provides brutal full-body workouts, and building one yourself can be a rewarding challenge.
This guide breaks down the process into simple, manageable steps. We’ll cover everything from gathering materials to final assembly, ensuring you end up with a sturdy, functional piece of equipment. It requires some mechanical aptitude and effort, but the result is a cost-effective way to add this powerful tool to your home gym.
How To Build Air Bike Totk
Before you start, it’s crucial to understand what an air bike is. It uses a large fan for resistance—the harder you pedal and push/pull the handles, the more air you move and the greater the resistance. The “totk” here stands for “Tears of the Kingdom,” a popular video game, but in the fitness DIY community, it’s often used to describe a custom, from-the-ground-up build. This project is about constructing the physical bike itself.
You’ll need a dedicated workspace, like a garage, and a basic set of tools. Safety is paramount, so always wear protective gear like gloves and safety glasses during construction.
Gathering Your Tools and Materials
Having everything ready before you start will make the process smoother. Here’s a comprehensive list of what you’ll likely need.
Tools Required:
* Welder (MIG is preferable for beginners)
* Angle grinder with cutting and grinding discs
* Drill and a set of metal drill bits
* Measuring tape, square, and marker
* Wrenches and socket set
* Vice or strong clamps
* File for smoothing rough edges
Main Materials and Parts:
* Steel tubing (1.5 to 2-inch square tubing for the main frame)
* Steel plate (for brackets and joints)
* A bicycle crankset with pedals
* Two sturdy handle levers (can be salvaged from an old rower or made from tubing)
* A large fan blade and housing (industrial fan or heavy-duty floor fan)
* Bearings and axles for the fan and crank assembly
* A sturdy seat and seat post
* Chain or belt drive system
* Bolts, nuts, and washers
* Paint or sealant for finishing
Sourcing parts can be part of the fun. Look at scrap yards, online marketplaces, or old fitness equipment for the fan and mechanical parts. Make sure the fan is balanced and the bearings are in good condition, as this is core to the bikes function.
Step 1: Design and Planning
Don’t skip this step. A clear plan prevents wasted materials.
First, decide on the dimensions. A standard air bike is about 50 inches long, 30 inches wide, and 50 inches tall. Sketch your design on paper or use simple CAD software. Key measurements include the distance from the seat to the pedals and the height and reach of the handles.
The critical mechanical link is connecting the fan to the pedals and handles. When you pedal and move the handles, both actions should turn the same fan axle. This dual-input system is what makes an air bike unique. Your design must incorporate this.
Step 2: Building the Main Frame
This is the foundation. Your frame must be incredibly strong to handle dynamic force.
1. Cut the main steel tubing according to your plan. You’ll need pieces for the base (a rectangular footprint), the vertical post for the seat, and the forward section that will house the fan.
2. Thoroughly clean and deburr all cut ends with a file or grinder.
3. Clamp your pieces together and tack-weld the base rectangle. Check for squareness with your measuring square. Once square, complete the welds.
4. Weld the vertical seat tube to the rear of the base. Reinforce it with gussets (triangular steel plates) at the bottom for extra stability.
5. Attach the forward frame section that will extend out to hold the fan assembly. This often involves angling two pieces of tubing upward from the front of the base to meet a horizontal bar. Double-check all angles before final welding.
A sturdy, square frame is non-negotiable. Take your time here. A wobbly frame will make the final bike unsafe and unpleasant to use.
Step 3: Assembling the Fan and Drive System
This is the heart of your air bike. The goal is to have the fan spin freely on bearings, with the crank and handles connected to it.
1. Mount your fan housing securely to the front of the frame. You may need to fabricate a custom bracket from steel plate.
2. Install the bearings on either side of the fan axle. The axle should protrude from both sides of the fan hub.
3. Attach the bicycle crankset to one end of the fan axle. You might need a custom adapter or sprocket to make this connection secure.
4. On the opposite end of the fan axle, attach the linkage for the handle levers. This usually involves a second crank arm or a welded bar that pivots as the axle turns.
5. Connect the handle levers themselves. They should be on pivots mounted to the frame, with connecting rods running down to the linkage on the fan axle. As you push and pull the handles, these rods should turn the fan axle.
Test the movement without the fan blade attached. The pedals and handles should both rotate the axle smoothly and without binding. If something feels stiff, adjust the linkages now.
Step 4: Installing Pedals, Seat, and Handles
Now you’ll add the points of contact.
Attach the pedals to the cranks. Make sure they are tight and thread correctly. Install the seat post into the vertical tube and secure it with a clamp. Add your chosen seat.
The handle levers need comfortable grips. Use foam bike grips, tape, or padded handles. Ensure there is no sharp or rough metal where your hands will be. The handles should have a natural, ergonomic range of motion that feels comfortable in both the push and pull phases.
Step 5: Final Adjustments and Safety Check
Before you test the bike under load, do a thorough safety inspection.
* Check every weld for cracks or incomplete penetration.
* Tighten every single bolt and nut. Apply thread-locker to critical fasteners.
* Ensure the fan blade is perfectly centered and securely fastened to its hub. An unbalanced fan will cause violent shaking.
* Verify that all moving parts clear the frame and eachother with plenty of space.
* Smooth out any sharp edges with a grinder or file.
Once satisfied, apply a coat of paint or rust-preventative sealant to the frame to protect your work. Let it dry completely.
Step 6: Your First Test Ride
Start cautiously. Sit on the bike and gently pedal with your hands on the stable part of the handles, not pushing the levers. Feel for smooth rotation and listen for unusual noises.
Next, incorporate the handles gently. Begin with slow, controlled movements. The resistance will feel directly proportional to your effort—the faster you go, the harder it gets. This is normal and the intended effect.
Pay attention for any creaking, grinding, or wobbling. If you detect an issue, stop immediately and identify the source. It might just be a loose bolt, or it could require a more significant adjustment. Don’t ignore it.
Common Issues and Troubleshooting
* Wobbly Fan or Frame: Re-check bearing alignment and frame weld integrity. An unbalanced fan is a common culprit.
* Chain/Belt Slippage: Increase tension or ensure the sprockets are aligned properly.
* Sticking Handles: Lubricate pivot points and check linkage alignment for binding.
* Uneven Resistance: This is almost always due to the fan blade being off-center. Re-center and balance it.
Maintaining Your DIY Air Bike
Your homemade equipment needs regular care to last.
Every few weeks, check all bolts for tightness. Lubricate the chain, bearings, and all pivot points periodically. Wipe down the frame and seat after sweaty workouts to prevent corrosion. Listen for new noises and adress them promptly to prevent small problems from becoming big ones.
Building your own air bike is a significant undertaking, but it provides immense satisfaction and a uniquely effective piece of fitness gear. You gain a deep understanding of how the machine works, which makes you appreciate the workout even more. Remember, the quality of your build directly impacts your safety and enjoyment, so never compromise on the key steps.
FAQ About Building an Air Bike
How much does it cost to build an air bike TOTK?
Costs vary widely based on part sources. If you salvage most parts, you might spend $150-$300. Buying all new components could push it over $500, which is still often cheaper than a commercial model.
What is the hardest part of the build?
For most people, fabricating the dual-drive linkage system—where the handles and pedals both connect to the fan axle—is the most technically challenging step. Precise measurement and welding are required.
Can I use a different fan?
Yes, but it must be heavy-duty. A lightweight plastic fan will not provide adequate resistance and could shatter. Look for metal-bladed industrial fans.
Is welding absolutely necessary?
For a safe and durable frame, yes. Bolted-together frames generally cannot handle the intense, oscillating forces an air bike produces. Proper welding is non-negotiable for the main structure.
How do I ensure the bike is safe?
Follow the safety check list in Step 5 meticulously. Never skip checking welds and bolt tightness. Always test at low intensity first and wear proper safety gear during construction.
My finished bike feels shaky at high intensity. What should I do?
This is usually a balance issue. First, ensure the frame is on level ground. Then, check that the fan blade is perfectly centered and secured. Adding small weights to the fan blades opposite the heavy side can help balance it—this process is called dynamic balancing.