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Homemade Ab Roller, By Ulma Doctor

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Ulma Doctor

Infinitely Curious
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Feb 2, 2013
Messages
507
A flash of inspiration came over me, this weekend past.
from my mind, came the idea of constructing an ab roller from materials i had laying around.
this is the progression,
enjoy!

I started with hot rolled steel, 3/4" diameter.
the bearings 2) 6303-RS C3, i had chosen them for sheer abundance in my shop.
a 6303-2zz C3 is a double dust shielded (the 2zz part of the part #), C3 precision bearing.
the dimensions: 17mm Id x 47 mm Od x 14mm thick.
I needed to reduce the shaft to 17mm.
here's a video of part of the process


the finished shaft with 2 6303-2zz bearings installed
FullSizeRender.jpg
i made the shaft to exactly 17mm and froze the shaft for a couple hours.
i warmed the bearing to approximately 100*f and banged the bearings on the shaft.
the end result is a strong press fit upon temperature equalization.

i cut out a 6"rim from scrap 2x8 construction fir with a 6" holesaw.
then milled the stepped center hole with a rotary table on my vertical mill.
i used a 4 flute HSS endmill and a small rotary table to achieve the 47mm bore, to accept the shaft and bearing assembly.
2016-02-20.jpg

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I turned a pair of delrin thrust washers to keep the bearings at zero thrust clearance

ab%2Broller%2Bfiller%2Bwashers.jpg ab%2Broller%2Bthrust%2Bwashers%2B2.jpg
and the opposing side,
ab%2Broller%2Bthrust%2Bwashers%2B3.jpg
i reclaimed a bearing support from a PVC overwrap machine.
i bisected the flange and turned the 2 halves to make 2 stepped bearing retainers.


here's a couple pictures post bisection of the flange,
ab%2Broller%2Bretainers%2B2.jpg
ab%2Broller%2Bretainers%2B1.jpg

i installed the bearing retainers and secured them with #10 drywall screws.

Every rim needs a tire,
so i thought of a way of doing just that with what i had on hand...
ab%2Broller%2Btire%2B1.jpg

i used the drop from the rim rendering operation as a form to clamp the tire during the glue up
prior to glue up i drove a antique tack into the tread to keep the tread centered.
i also skived and joined the belt ends to make a continuous tire surface.

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg
and a shot of the glue up, clamped in the strangest way- but it worked!!!

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

after a 2hr cure the clamps were removed and the tire was ready.
i used 3/4" shrink tubing to cover the hot rolled shaft to give a more finished look.

Ab%2BRoller%2BDONE.jpg

thank you very much for looking!

i hope that these words and images inspire others to do something, out of the ordinary,
whenever possible:)

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ab%2Broller%2Bfiller%2Bwashers.jpg

ab%2Broller%2Bfiller%2Bwashers.jpg

2016-02-20.jpg

ab%2Broller%2Bfiller%2Bwashers.jpg

ab%2Broller%2Bthrust%2Bwashers%2B2.jpg

ab%2Broller%2Bthrust%2Bwashers%2B2.jpg

ab%2Broller%2Bthrust%2Bwashers%2B2.jpg

ab%2Broller%2Bthrust%2Bwashers%2B3.jpg

ab%2Broller%2Bthrust%2Bwashers%2B3.jpg

ab%2Broller%2Bthrust%2Bwashers%2B3.jpg

ab%2Broller%2Bretainers%2B2.jpg

ab%2Broller%2Bretainers%2B2.jpg

ab%2Broller%2Bretainers%2B2.jpg

ab%2Broller%2Bretainers%2B1.jpg

ab%2Broller%2Bretainers%2B1.jpg

ab%2Broller%2Bretainers%2B1.jpg

ab%2Broller%2Btire%2B1.jpg

ab%2Broller%2Btire%2B1.jpg

ab%2Broller%2Btire%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

Ab%2BRoller%2BDONE.jpg

Ab%2BRoller%2BDONE.jpg

Ab%2BRoller%2BDONE.jpg

FullSizeRender.jpg

2016-02-20.jpg

2016-02-20.jpg

ab%2Broller%2Bfiller%2Bwashers.jpg

ab%2Broller%2Bthrust%2Bwashers%2B2.jpg

ab%2Broller%2Bthrust%2Bwashers%2B3.jpg

ab%2Broller%2Bretainers%2B2.jpg

ab%2Broller%2Bretainers%2B1.jpg

ab%2Broller%2Btire%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

Ab%2BRoller%2BDONE.jpg

FullSizeRender.jpg

2016-02-20.jpg

2016-02-20.jpg

ab%2Broller%2Bfiller%2Bwashers.jpg

ab%2Broller%2Bthrust%2Bwashers%2B2.jpg

ab%2Broller%2Bthrust%2Bwashers%2B3.jpg

ab%2Broller%2Bretainers%2B2.jpg

ab%2Broller%2Bretainers%2B1.jpg

ab%2Broller%2Btire%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B1.jpg

ab%2Broller%2Btire%2Bglue%2Bclamp%2B2.jpg

Ab%2BRoller%2BDONE.jpg
 
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Bob Korves

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When you said ab roller I was thinking about abalone and tenderizing it... 8^)

Nice job, Mike!
 

jpfabricator

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So how long will it be before the kids are trying to use it as a unicycle? It would take my kids about 20 seconds! LOL

sent from somewhere in East Texas!
 

Ulma Doctor

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When you said ab roller I was thinking about abalone and tenderizing it... 8^)Nice job, Mike!
Thanks Bob! Abalone does sound good though!!!

:encourage: Now we need a picture of you using it.:grin:
Thanks Jim!
If you'd really like to see some pictures, i'll post em' ,
but i can't be held responsible for any loss of lunch after viewing said photos!:eek::p


So how long will it be before the kids are trying to use it as a unicycle? It would take my kids about 20 seconds! LOL
sent from somewhere in East Texas!
Hi Jake,
Oh No, now you brought up stuff that reminds me of something i might have tried as a youngster.

i should probably let the boy know it's for exercising, not riding! (not that a warning from a grown up was always heeded, by yours truly:rolleyes:)

thanks guys!
 

eeler1

Dang, buggered that up too!!
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And before and after pics of your abs!
 

FOMOGO

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That's using the old noodle. Pretty cool. Perhaps some comely young thing for the demo would be a safer bet.:grin: Mike
 

Ulma Doctor

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And before and after pics of your abs!
in the interest of science, and because eeler1 asked.

i apologize in advance for my first selfies... i assure you the photos are unedited and not fit for human consumption!

Ab%2BBefore%2B2.jpg Ab%2BBefore%2B1.jpg

Yeah, I wanna see that in use video as well:chunky: And well done!
Thank You Chips!
i'll make a video when i get home from the salt mines and show you all how it works, and how silly i look using it :grin:

Ab%2BBefore%2B2.jpg

Ab%2BBefore%2B2.jpg

Ab%2BBefore%2B2.jpg

Ab%2BBefore%2B1.jpg

Ab%2BBefore%2B1.jpg

Ab%2BBefore%2B1.jpg

Ab%2BBefore%2B2.jpg

Ab%2BBefore%2B1.jpg

Ab%2BBefore%2B2.jpg

Ab%2BBefore%2B1.jpg
 

jpfabricator

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I threw up in my mouth a little. :(
Lol

Sent from somewhere in East Texas Jake Parker
 

kvt

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You trying to get the site on the ban list at work. Nice setup on it. And kids would never try something like that would they.
 

Ken S

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Good job Mike. I made one of those for my wife several years ago
but I would have to dig in the pile of bicycles ,treadmill,
ab cruncher, exercise ball, ankle weights, workout mats,
workout ball, mini tramp, thigh buster,
and hundreds of workout tapes to find it.
 

cathead

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MIke,

If you are into multi-tasking, you could use the AB-ROLLER to make tortillas or lefse:encourage: or possibly gold leaf with a little modification.....:grin:


:boxed in: Keep thinking outside the box..................(KTOTB):encourage:
 

Ray C

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Pretty sure that in recent times, if I were to use that thing, the bar might not be big enough in diameter or the bearings might fail. :blue:
 

Uglydog

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In the interests of over-complicating and overbuilding I'm wondering if changing the diamter of the wheel changes the effort or strength required.
I'm guessing that the smaller wheel requires greater flexibility as it would put your shoulders closer to the floor.
How about adding back-gears or intentionally increasing the drag requiring you to push or plow when going out.
Perhaps even a clutch which would have separate in and out drag intensities.
Would a very very narrow wheel require more balance?

Daryl
MN
 
R

Robert LaLonde

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I have to say I really like your "run flat" wheel barrel tire and axle. Nice job. Might be a bit tough in sand or mud, but should be fine on hard pack or pavement.
 

Ulma Doctor

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MIke,
If you are into multi-tasking, you could use the AB-ROLLER to make tortillas or lefse:encourage: or possibly gold leaf with a little modification.....:grin:
:boxed in: Keep thinking outside the box..................(KTOTB):encourage:
Thank you very much cathead, i like your thinking!!! :grin:

Pretty sure that in recent times, if I were to use that thing, the bar might not be big enough in diameter or the bearings might fail. :blue:
Thanks for looking Ray, you got me laughing here!
Great Job! I love the shrink tube idea.
thank you very much for reading, the shrink tube seemed better than bicycle handlebar wrap
In the interests of over-complicating and overbuilding I'm wondering if changing the diamter of the wheel changes the effort or strength required.
I'm guessing that the smaller wheel requires greater flexibility as it would put your shoulders closer to the floor.
How about adding back-gears or intentionally increasing the drag requiring you to push or plow when going out.
Perhaps even a clutch which would have separate in and out drag intensities.
Would a very very narrow wheel require more balance?
Daryl
MN
Hi Daryl,
I suppose a change of diameter would alter the resistance!
the smaller wheel would also take a longer period of time to roll a set distance, giving more workout time per stroke! i like it!!! :grin:
I have to say I really like your "run flat" wheel barrel tire and axle. Nice job. Might be a bit tough in sand or mud, but should be fine on hard pack or pavement.
Thank you very much Bob, i was trying to use materials that i had on hand.
i don't think the tire will ever go flat, but i have not tested it in offroad situations yet! LOL:grin:
 
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