.jpg)
ALS "Build-a-Bike" Project
January - April 2022
In this endeavor, I helped lead an initiative to build a accessible, customized road bike for an Auburn Alumnus, Gary Godfrey, who was living in his 3rd year with ALS at the time of building. This bike allowed Gary to participate in "Bo Bikes Bama", a 20-mile road bike race in Auburn, AL on April 23, 2022.
The custom trike was designed, engineered, and built in just 3 short months with a budget of $28,000. Gary, who cannot move any muscles except for his eyes and a few others in his face, rode in the front of the bike as a passenger. His long standing biking partner, Chuck Smith, drove the bike during the race.
The 20-mile race was successfully completed in 1 hour 45 minutes with an average speed of 11 MPH and a top speed of 27 MPH! The bike performed perfectly, with no engineering issues to report. Following the ride, Gary stated: "The ride was beyond my wildest expectations! I must thank my riding partner, Chuck Smith, who tirelessly pedaled for me. We got the bike going 27 mph! I must also thank the Auburn Engineering students who built a bike that worked flawlessly. I am grateful they said "yes" to my crazy dream to feel the wind in my face again. I always say, 'Make Today Your Best Day.' Today was a Best Day for sure!"
​
In this role, I practiced using the following skills: project management, product management, leadership, CAD design (Solidworks), human factors engineering, and fabrication.
The "Good Stuff": Engineering Considerations
Weight: 700-750lbs
Designing a bike capable of safely carrying a former basketball player at 6ft 9in & nearly 300lbs was no easy task. Gary's ventilator weighed an additional 50lbs, the driver (Chuck) weighed nearly 200lbs, and the bike itself (unloaded)Â was estimated to be close to 150lbs.
Frame: Chromoly Steel
While it's not the lightest material option, our team chose to use 4130 Chromoly Steel over Aluminum because of its availability and its ease to work with using tools available to us
Brakes: Disc, Custom
Two 180mm disc brakes were used on the front wheels and one 200mm disc was used on the back wheel. Each disc was paired with one hydraulic, 4-piston Magura E-Stop caliper. The front wheels were not made for use with brakes, so custom adapters were machined to allow the wheel hubs to accept disc brakes.
Wheels: Custom
Finding bike wheels capable of accommodating our weight requirements was nearly impossible. We wanted to use bike wheels over car/motorcycle wheels because of their reduced rolling resistance. The front wheels were custom made by NYC based Worksman Cycles, each with a 500lb capacity. The wheels were not made for use with brakes, so custom adapters were machined to allow the wheel hubs to accept disc brakes.
Passenger Seat
A custom seat able to accommodate Gary's dimensions was provided by Simpson. The aluminum racing seat was outfitted with egg-crate cushions provided by Roho Cushions. To constrain Gary's midsection movements during the race, a racing harness was used. To help secure his head, both a Hans device and halo device were used to secure his head and neck. Velcro straps were used to hold his legs in place.
Motor: Bosch Cargo
The bike was equipped with a Bosch Cargo Line Motor, the strongest commercially available pedal assist motor. Without this motor, pedaling the bike for 20 miles, especially uphill, would have been nearly impossible. The motor utilized a Bosch Power Pack 500 to supply energy. Each fully-charged battery provided 10 miles of range; 3 batteries were used throughout the race.
