Chapter 5

Parts Required

Version 2.3

Written by Rickey M. Horwitz

Below is a listing of all hardware and materials required to complete the Thunderbolt project. Although the listing has been scrutinized, some material may have been omitted from the list. If anyone finds a reasonable source for any of the materials below or has discovered an error on this list, please share your findings with us by E-mailing [email protected].   If a more accurate listing is needed, refer to the hardware requirements of each applicable chapter or section. 

The Thunderbolt can be fabricated using three types of braking. Each braking scheme require different parts. To reduce confusion, I have color coded the parts as follows:

 Standard common parts are shown as black

 Parts for rear brake only system are shown in Green.

 Parts for the steering stirrup and caliper brake system are shown in dark Blue.

 Parts for the Sachs Drum brakes are shown in Red.

All dimensions in SAE unless specified

Aluminum Tubing and Round Stock (all 6061 -T6)

 68" long, 1" x .083" round tubing. If frame is heat-treated .063 can be used.

 12" long, 1.125 x .063" round tubing.

 16" long, 1.75 x.083" round tubing.

 2.5" long, 1.75 x .250" round tubing*

 36" long, .875 (7/8") x .083" round tubing.

 16" long .4375" (7/16") round Aluminum stock.

 28" long, .375 (3/8) round Aluminum stock.

 2" x .083"x 84" round tubing. If frame is heat-treated, .063 can be used.

 16" long, 1" round Aluminum stock.

 10' long, 1"x1"x .083 or.125" Square Aluminum stock.

Aluminum Raw Stock

 4" x 14" x .250" Aluminum Plate Stock.

 16" x 14"x .125" Plate Stock.

 1" x 1" x .125"x 8" angle stock

 2" x 2"x .125" x 24" Angle Stock.

Delrin/Polypropylene

 4"x4"x.5" Derlrin Stock.

 1/2" x 80" Polypropylene Sprinkler Hose.

Miscellaneous Hardware

 6 ea. 5/16" Rod End Bearings (Baileys Catalog #170-303). See below

 4 ea. 3/8" Rod End Bearings (Baileys Catalog #170-305). See below

 5/16 All-Thread Rod, 24 TPI 1 ft long, Stainless Steel or #8 preferred.

 1/2 All Thread Rod, 20 TPI 1 ft long, Stainless Steel preferred.

 1 ea. 3/8" Universal Socket Adapter.

 Tie Wraps, various lengths

 1 ea. 60-72 mm Skate Wheel with a Durameter rating of 88 or harder. Bearings and spacers required.

 1 ea. 38-45 mm Skate Wheel with a Durameter rating of 88 or harder. Bearings and spacers required.

 Lightning P-38 or Stealth Seat Assembly

 3 ea. Seat Post Clamp, 1" diameter (Odyssey).

Fasteners

 4 ea. 3/8" fine thread Jam Nut.

 7 ea. 5/16" fine thread Jam Nut.

 2 ea. 1/2" fine thread Jam Nut.

 2 ea. 1/2" fine thread Nyloc Nut.

 2 ea. 5/16 fine thread Nyloc Nut.

 2 ea. 5/16" x 2.25", fine thread, Allen Cap Screw

 4 ea. 3/8"x 1.5", fine thread, Allen Cap Screw

 4 ea. 3/8" lock washer

Standard Bicycle Components

 Front Derailleur, non-compact, standard high clamp (Shimano RX100).

 Rear Derailleur, Long Cage, (Shimano RX100 or better).

 Chain, 3 sections, Sachs SC55 or better.

 Crank/Chainwheel Assembly, non-compact.

 Shifters, Shimano Bar-Cons

 2 ea. Sachs VT5000 Front Hub Brake Assemblies*

 2 ea. 20" ERTO 406 BMX front wheel assemblies

 2 ea. Wheel Chair Hubs, with .5" axles

 2 ea. 20" ERTO 406 AlloyRims, 36 spoke

 72 ea. Stainless Steel Spokes ~168 mm length (depends on type of rim and lace pattern)

 Rear Wheel Assembly, 32 or 36 Spoke with Alloy Rim, Stainless Steel Spokes, Cassette Hub

 Freewheel Assembly, Cassette type, 7 or 8 Speed, 12 to 30 teeth range

 Brake levers, MTB type

 Brake and Derailleur Cabling with Housing

 Rear Caliper Brake (Dia-Compe)

 2 ea.Front Caliper Brakes (Dia-Compe)

 

Bailey Sales Corporation Toll Free Number 1-800-800-1810

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