Recumbent exercise bikes provide comfort and support not afforded with traditional exercise bikes. Typical designs includes a steel frame with a seat pad and backrest at one end. The resistance flywheel with pedal cranks attaches at the other end of the frame. Building your own recumbent exercise bike provides options, such as custom sizing and selecting colors for the seat and backrest covering. Welded connections at the tube steel frame and supports are more reliable than bolted connections. The flywheel assembly and manual adjustment brakes are obtained from an accessory catalog or parts supplier. You can build a recumbent exercise bike using basic hand and power tools.
Step 1
Cut a piece of 2-inch-by-2-inch polished steel tubing 60 inches long using a miter saw with a steel cutting blade. This will be the main frame rail of the recumbent exercise bike. Cut another piece of tubing 30 inches long as the rear upright. Cut two, additional pieces of tubing 16 inches long as front and rear stabilizers.
Step 2
Position the 30-inch upright perpendicular at one end of the main frame rail. There should be 12 inches below the frame and 18 inches above as the backrest support. Weld the upright at the end of the frame rail.
Step 3
Weld the lower end of the upright to the center of a 16-inch stabilizer to form a "T" configuration. Weld the remaining 16-inch piece of tubing perpendicular at the opposite end of the main frame rail as the front stabilizer. Put 2-inch plastic end caps on the ends of each support.
Step 4
Use an electric drill with a 2-inch steel cutting wheel attachment and cut a 12-inch square piece of 1/8-inch aluminum plate as the seat plate. Measure 14 inches from the vertical backrest support and center the plate on the main frame rail at this location. Use the electric drill with a 3/16-inch bit and drill two holes to attach the seat support to the frame rail. Make the attachment with 3/16-inch carriage bolts and nylon lock nuts. Tighten the nuts with a hex wrench.
Step 5
Cut an additional piece of 1/8-inch aluminum plate 14 inches long and 12 inches wide as the backrest plate. Position the support at the center line of the rear upright. Drill a 3/16-inch hole at the upper and lower edges of the plate, and into the tube steel upright for attachment bolts.
Step 6
Test the angle of the backrest plate for the maximum comfort angle. Cut a short length of 1/2-inch aluminum tubing as a spacer that supports the lower edge of the backrest at the comfort angle. Use 3/16-inch carriage bolts with nylon lock nuts to attach the backrest plate with spacer to the upright.
Step 7
Use a utility knife to cut pieces of 2-inch foam pad for the seat and backrest. Cut pieces of vinyl upholstery fabric to cover the seat and backrest. Allow 1-inch additional each way to fold the fabric at the underside of the pads. Attach the fabric to the pads using spray contact adhesive. Apply contact adhesive to the seat and backrest plates, and attach the covered pads.
Step 8
Sit in the recumbent exercise seat with your back against the backrest. Have an assistant stabilize the flywheel assembly on the frame rail. Take several revolutions of the pedals with your feet to establish the optimum position of the flywheel assembly on the frame. Use 3/16-inch carriage bolts with nylon lock nuts to attach the flywheel assembly to the frame rail.
Step 9
Use 3/16-inch carriage bolts with nylon lock nuts to attach the flywheel assembly to the frame rail. Slide the manual adjustment brake assembly onto the front edge of the flywheel so the adjustment knob is facing the recumbent seat. Drill a 3/16-inch hole in the rail and attach the brake assembly with a carriage bolt and nylon lock nut.
Tips and Warnings
- Apply metallic primer and epoxy paint on the steel frame.
- Wear proper protection when cutting and welding steel tubing. Allow all welds to cool before proceeding.
Things You'll Need
- 2-inch-by-2-inch polished steel tubing
- Miter saw with steel cutting blade
- Welding equipment
- 2-inch plastic end caps
- 1/8-inch aluminum plate
- Electric drill
- 2-inch metal cutting wheel attachment
- 3/16-inch drill bit
- 3/16-inch carriage bolts with nylon lock washers
- Hex wrench
- 1/2-inch aluminum tubing
- 1-inch foam pad
- Utility knife
- Vinyl upholstery fabric
- Scissors
- Spray contact adhesive
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