Treadmills conform to a basic design that consists of a steel frame, a running deck, rollers and a running belt. In addition, manual and motorized treadmills have a feature that allows the treadmill handrails to be folded for storage. Bolts at the base of the handrails serve as hinges and secure the rails in the upright position for workouts. Building a treadmill includes welding a steel frame and installing rollers, the running deck and running belt. From that point, aluminum tubing is used to fabricate a folding handrail.
Step 1
Measure the width across the front of the treadmill frame. Add 1/4-inch for nylon spacers that are installed later and note the measurement. Measure the overall length of the treadmill and double this measurement. Add the width as noted to the doubled measurement. Cut a length of 1-inch diameter aluminum tubing to the total length using a hacksaw.
Step 2
Smooth the ends of the aluminum tubing with a flat file. Wet the tubing with water and slide the foam handlebar grip on to the center of the tubing. Use a tubing bender to bend the piece into the three-sided handrail configuration. Make sure to have the correct width at the section with the handlebar grip.
Step 3
Place the handrail on a workbench. Use a mallet to flatten 3 inches of the tubing at the ends of both uprights. The flattened portions will reside against the sides of the treadmill. Use an electric drill with a 3/8-inch drill bit and drill a hole in each end of the flattened portions of the tubing. The holes should be 1 inch from the ends.
Step 4
Position the handrail against the sides of the treadmill frame at the front of the treadmill. Hold the ends of the handrail and lower it over the treadmill. Adjust the handrail so the foam grip is just beyond the end of the treadmill frame. Mark each side of the treadmill frame at the locations of the 3/8-inch holes in the handrail. Adjust each of the marks so they are 1/2-inch from the bottom of the frame
Step 5
Drill 3/8-inch holes into each side of the treadmill frame at the marked locations. Turn the treadmill over. Center a 1/4-inch machine nut on a 3/8-inch hole at the inside of the treadmill frame. Use a random 1/4-inch machine bolt threaded into the nut from the outside of the frame to hold the nut in place.
Step 6
Use a soldering tool and steel solder to attach the 1/4-inch nut to the inside of the treadmill frame. Repeat this at the opposite side of the treadmill frame and allow the soldered attachments to cool completely. Remove the random machine bolts and turn the treadmill upright.
Step 7
Insert the threaded ends of the locking levers into each of the holes at the ends of the aluminum handrails. Put nylon spacers or washers on the threaded ends of the locking levers. Align the aluminum handrails on the treadmill frame. Thread the locking levers through the frame and into the soldered nuts on each side. Tighten the levers to secure the handrail upright. Loosen the levers to fold the treadmill.
Things You'll Need
- 1-inch diameter aluminum tubing
- Hacksaw
- Flat file
- Foam handlebar grips
- Tubing bender
- Mallet
- Electric drill
- 3/8-inch drill bit
- 1/4-inch machine nuts
- Soldering tool and steel solder
- Locking levers with 1/4-inch diameter threads
- Nylon spacers
Member Comments