Dutch Speed Bicycles KV4 Bedienungsanleitung
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 1
This kit was designed and produced with great care.
To turn it into a great and nice looking velomobile
you will have to nish it with care and attention.
Hasty work here can only lead to an unpleasant,
shabby looking bike that will bring you little pleasure.
So please give this project the attention and effort
it deserves. Finish all details careful and mount
everything rattle-free. This way you will make sure
that you will have many enjoyable rides in you Dutch
Speed Bicycle. Good luck!
Version, Pictures
Some details shown in the pictures may be different from what is
supplied or from what is shown on our site. Small improvements
are made almost every production run, be it to lower weight or to
improve ease of assembly.
Important! Make sure you have downloaded the last version of
the instruction manual. At the top of each page you can nd
the version number. Most pictures can be studied in detail on
www.dutchbikes.nl/uk (see the instruction manual page) Some
pictures have altered colours to make the explanation easier.
Changes (compared to the previous version) to the text are
underlined
A new milling machine has made it possible to produce the sheets
more accurately, allowing to make more pre-drilled holes. On the
other end it has limited the largest possible sizes. Resulting in a few
more seams. Also the length of the MacPherson strut (suspension
on the front wheels) has been reduced to save weight.
About this builders instruction manual.
This manual explains how to build the Dutch Speed Bicycles KV4
velomobile. As the Alligt Alleweder a4 is basically the same, you
can use it also to put those together. However we have no control
over the Alligt products, so there may be differences in details. We
take no responsibility regarding building anything other than the
kits we supply. We do not support builders working on non Dutch
Speed Bicycles kits.
Packaging
The kit comes in two large boxes and a at box. The at box
contains all the larger aluminium sheets and the machined ribs.
Some larger tubing is also included
Take out the ribs and leave the sheet in the crate, using
the crate for storage. Especially in a not so huge workshop
a sheet is otherwise easily damaged at some point.
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 2
Skills
We assume that you are familiar with working on a bike and that
you have the basic DIY skills and that your have only one left
hand. Read a good book on bicycle maintenance if you think that
will help you.
Left and right
If we talk about left and right we assume to be looking from the
rear to the front of the bike. With the velomobile standing on it’s
wheels.
Front and rear
Naming front and rear we observe the direction of travel.
Questions
Should you have any questions don’t hesitate to ask. (Customer or
no customer) We will try to answer your question and may use
it to improve on this manual. But have a look at our KV4 FAQ
page rst please.
Sizes
All non-bicycle specic parts we supply are metric.
A bolt of M6 x 70 means the thread is approximately 6 mm
in diameter and the length below the head is 70 mm. For a
countersunk bolt the head is included in the length.
What you will need:
Enough room
Choose a place to work where you have enough room to work on
the velomobile. It will grow while are working on it. Also you will
need a safe place for the parts you have not yet used. You don’t
want to nd yourself standing on them from time to time! Make
sure you have enough light to see what you are doing.
It is not a dirty job, it is nice clean work. (except for the polishing
and mounting of the chains) so it could be done in the house.
Make sure you talk this through, it is a nice project but not worth
a divorce or something..
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 3
General tools
Wrenches, use open end wrenches or better still, ring spanners.
These won’t damage the nuts and bolts. If you don’t have a tting
wrench you might use a adjustable wrench (bahco). Never use
water pump pliers, they will damage or destroy the nuts and bolds
It is not nice to work with and it ruins the looks of your bike.
Set of Allen keys
An electric hand drill/screwing machine (a cordless is easy to
handle and works well)
A right angle head or Right angle drill (could be borrowed, you
will not need it often) (Cheapest solution is a separate head, we
bought this one in a DHY sales for 5 Euro)
Right angle grinder with 0,8 mm cutting disk
Heat gun of burner. (gas cooker will do too)
Ø 3.3 (supplied) Ø 6 and Ø 9 mm steel drills
Rubber hammer
Hammer
Safety goggles
Measuring tape
Optional: Cloth polishing wheel and polishing agent. A cloth and
brass polish will do ne, it will just take longer. (The polishing is
optional anyway)
Grease, Oil
Bicycle tools
Screw Type Chain Tool This is an inexpensive but very useful
tool that lets you remove chain rivets. This is also needed when
adjusting a bike to a much longer or shorter cyclist.
Crank arm puller for removing crank arm xing bolts and nuts.
You need also
A workbench with a vice or a workmate You will begin working
on this.
Two simple trestles. Very useful for supporting the Velomobile in
all sorts of positions
Special tools
A useful tool can be easily made of plywood. It will help you mark
the centre of the tubes when drilling the holes through the sheet
into the tube.
Naturally different markings are needed for different sizes of tube.
Check this on the tube without the sheet.
With the use of a piece of tape and marker you can even nd the distance
between each rivet. Or from one hole to the next
trestle
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 4
General techniques
Using Tape.
We supply a roll of strong packaging tape with the kit. Tape is
very useful to preposition things. Actually this is - literally- a very
powerful tool. If you stretch the tape while applying it, the tape will
exert a pulling force once it is applied. By applying a second tape
in the same position you will double that force. This is very useful
in bending the aluminium sheets in the proper position and getting
them to t nicely. You may regard it as a very exible clamp. But
be careful, you can actually overdo it an damage stuff! It really
is a powerful tool.
Pop riveting
For most of the pop rivet connections one of the two parts is pre
drilled. In those cases you can use these holes as a mould to drill
the opposite hole. The kit is supplied with 2000 good quality pop
rivets.
A) Position the two parts carefully, make sure the right sheet is on
top. In general the higher sheet is over the lower sheet, to prevent
the rain from dripping in. If in doubt, have a look at the large
photographs on the KV4 manual page on our website.
B) Drill the hole using one of the supplied 3.3 mm drills,
Remove any burr between the two parts
C) Fasten the (supplied) pop rivet.
D) You can not use pop rivets in solid sections
The wonderful thing about pop rivet is that it is a permanent connection and
a not permanent connection at the same time. It can be removed. Simply drill
through the head of the pop rivet and the complete rivet will be removed. The
hole can be used again. This can be repeated several times.
Make sure to drill in the right spot though, a hole can not be un-drilled.
Bending tubes
Some pre-bent tubes need to be corrected to match the exact form.
This is done easiest with the aid of a wooden plank with a gently rounded hole.
Do this carefully. Little by little at the time. Make a small change and check on
the assembly. Be careful not to buckle the tube!
There is a small but helpful lm on the site, showing the
process.
A
B
C
D
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 5
Cutting sheets.
In some places you need to cut the sheet to size. All sheet is pre cut,
and for a large part pre drilled. But in some places there is some
extra material to remove the need to work very precisely .
A good way to cut it is using a right angel grinder using a thin (we
use 0.8 mm) cut-off blades. This allows you to make a smooth
cut.
An another way is to use a “Dremel”- type high speed unit with a
ex-shaft attachment. This works well, but is slower and does not
give such a smooth line. Make sure to use the real “Dremel” brand
cut-off blades. One set will do.
(Be careful - in both cases - to take precautionary measures like
safety goggles hearing protection and proper clothing)
Remove burrs with sandpaper. Do this carefully in spots where
there is a risk that you might cut yourself, while using the
velomobile. Be careful not the touch the surface of the sheet wit the
sandpaper. This will leave ugly scratches.
Finishing tube edges
Many edges of sheets are nished with tubes. These allow you to
form the sheet around these edges.
To make this possible the sheet must be riveted properly to the
tube.
A) Cut the sheet at the proper length. In most cases this is just
over 90º around the tube counting from the rivets. In sharp corners
60º is better. The best position for the rivet is just where the
sheet touches the tube or even better, slightly above that point.
(A rivet below that point would deform the sheet in an ugly way)
B) Use a rubber hammer to bend the sheet gently around the tube.
C) Use a small metal hammer to get the sheet more tightly around
the tube.
Support the tube when hammering. If you cannot support it, then
support it by holding a heavier hammer against the tube’s opposite
side.
Use a piece of wood in difcult to reach spots. Avoid damage.
Do the rim tube edge (around the cockpit) at the end, this is the
most visible edge. Do it when you have gained most experience.
A
OK
OK
NOT OK
B
C
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 6
Required parts The Seat
Use the seat to practice your skills.
Any mistake can be corrected here. It will not
show in the end result. The seat will be covered
anyway.
Read general techniques rst.
Some details of the seat have been improved. It does not
effect the way of assembly .
Please note: The top end has been changed and is different
than in most pictures. The new top end is shown only as
the separate part and in the picture showing the nish of
the top.
Connect the two sheets with pop rivets
Use a table or a workmate
Drill a hole through the ribs at the location of the
hole.
This is the low end of the seat
Put the rst two rivets in.
Holding the rib you work on, in a workmate or similar, is
a good idea.
Make sure the distance between the two ribs is at least 151
mm (inside) otherwise the seat will not t over the main ribs
of the frame.
Make sure the ribs align with the holes in the sheet
x the position at the top.
Use tape or a clamp to hold it there.
Drill a hole in the ribs using the sheet as a mould
Work your way up from the bottom. Drill and
rivet, one at the time.
Do one rib rst then the other.
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 7
Bend the aps inward to shape the seat.
Start at the long sides and work your way down. You will
nd the complex shape will form easy
The description below is a bit different
form what is shown in the pictures, but is
much easier.
Rivet one side of the cross to the edge of the seat
and bend it over the ribs and rivet also on the
opposite side. Then rivet the cross to the back of
the ribs.
Careful, it is not as symmetric as you might expect. The
larger end ( B) goes at the bottom. Make sure the distance
between the two ribs is at least 151 mm (inside) otherwise
the seat will not t over the main ribs of the frame.
Fasten the aps with the separate pieces.
Fasten the top Tube and bend the remainder of the
ap around it (about 1/4 around the tube)
Use a rubber hammer, support the tube, let it rest on the
edge of a table.
The new top nish is shown on the right. Mount
the tube at the top and bend the ap around it. The
head rest is optional.
a
Old version
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 8
Remove the rst two rivets. (1 and 2) Insert the
thick tube. Drill in the tube using the holes of the
removed rivets as a mould. Rivet the tube with the
two rivets.
Drill holes in the tube trough the front at 40 to
50 mm interval.
To get the proper drilling positions: see general techniques
/ nishing tube edges
Bend the remainder of the sheet around the tube
Use a rubber hammer, support the tube, let it rest
on the edge of a table
Seat in this picture is an older version with one additional ap
on the low end corners
Congratulations, your rst part is
nished! Store it in a safe place
Head rest (optional)
To mount the optional head rest, use the pre
drilled holes in the seat. If you wish to bend the
stainless steel support, it is best to remove it form
the holders and bend it in a bench-vice. Do not
bend it in sharp corners.
1
2
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 9
The Frame
The main frame is made out of CNC milled
aluminium parts. They are bolted together.
Because of this you will have the main structure
of your KV4 ready in no time.
This is an important change compared to the old Alleweder
The basic frame
structure
Important
Work on a table
Fasten all the bolts with Loctite 2701 or Freebond
1305 (not included)
Use washers
Be careful; the steel bolts are harder than the aluminium
parts, make sure that the screw is in the proper position and
angle before fastening. Aluminium is a softer material, so it
is easy to damage the thread.
Fasten the front
Keep the open side of frame to the back
You may need to take (le) some material form the notches
to make them t nicely
Fasten the back
Keep the open side of frame to the back
Use the M5 x 12 mm screws.
Careful: holes with thread in the rib may not be 90º to
the surface.
Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 10
Mount the middle sections of the frame.
Keep all the open side to the rear
Careful: the centre middle section can be mounted in many
ways. Only one is OK
The one screw marked in red (A) should go in rst
Mount the main chain roll.
Use a washer .
Do not use Loctite or Freebond here.
Chain tube with pre mounted strut
Mount the chain tube.
You need to drill two holes in the frame.
Make sure the end of the tube is close to the chain roll, but
can never touch it. Make sure to align the strut with the top
of the frame. Use a ruler to check this.
Mount the chain tube strut using two pop rivets
Attention: Don’t forget to put in a pop rivet at the
end (B) later when the sheet is in place
B
A
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