Rick Wianecki builds the frank-n-liner recumbent hpv streamliner bicycle
Rick Wianecki builds 
the Frank-n-liner

By Rick Wianecki

 1-Design and mold     2-Fairing    3-Subframe    4-Tub    5-Drivetrain    6-Attach Top   7-Bodywork   8-PreRace
Body Work
Nov 26, 2006
The back section is placed on the tub to determine how it will be mounted. I considered different mounting schemes and decided to use some bungee cords that will hook on to the rear subframe.
To attach the bungee cords to the tail fairing, I first formed some aluminum brackets. These will be bonded to the fairing so I have something to attach the bungee cords to.
I also formed an aluminum bracket that is attached at the tail. This bracket will be used to keep the top and bottom of the body aligned at the rear. 
The side brackets were glued in place with some 5-min. epoxy. A steel bar holds them in place until the epoxy cures, then some fiberglass and Kevlar pieces were added to secure the clips. 
This picture shows the side clips installed and the the lips that were added to the rear section to align the top and bottom..
Next some ½” X Ύ” strips of foam were notched along their length to make them easer to bend and follow a contour.
These strips were then glued to the front section of the canopy to form the lip that will seal the front section to the rear section.
Frank came over to see if he still fits in the bike since I sectioned 1 ½” out of the top. Things are a little tighter now with some interference of the hands and the knees on the top of the fairing. The inner layer if Kevlar and the remainder of the foam is removed to increase the clearances where the knees and hands rub.
The handlebars were also modified to lower the right hand at the shifter by 7/8” 
A thin wedge of balsa wood had to be added to the tail section to adjust the tail section slightly. This was needed to improve the fit of the front and back sections of the canopy.
I then removed all the steering parts and cleaned and painted everything silver. 
Next it is time to fabricate the parts to make the front section of the canopy sliding and tilting. To support the front, two brackets were fabricated and bonded to the front section of the tub. 
5/8” cromoly tubing was cut and bent to make the supports and track for the front support. 
The parts were attached to the front of the sub-frame and to the supports bonded to the front of the tub.  
 A 2 ½” Delrin roller was cut to roll on the 5/8” support. When the roller reaches the front the 180-degree bend in the support tube captures the roller and allows the front section to tilt up. That is the theory, we will see if it will really work that way. A rear support and roller and the rest of the front roller mount brackets still need to be fabricated.
Dec 17, 2006
Frank has the rollers and it is time to move the vehicle over to his place so he can start working on the engine and breaking in the rear Rohlhoff hub. I first removed the seats from my Van. When I was designing the vehicle one of the design constraints was that the bike had to fit in my van and allow for one extra person.
The vehicle was rolled outside and positioned at the back of the van. 
Once the bike was slid in the van some rags were placed between the nose and the dashboard. 
The bike fits nicely along one side of the van. The tailgate just clears the rear of the fairing. 
The new home the vehicle for the next several months is Frank’s training room in his basement. I will get the vehicle back in April to finish the last of the canopy hinging and attach the wheel fairings.

Next - Pre-Race Construction

Back to the HPV projects page