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Dutch Speed Bicycles KV4 Builder Manual

Velomobile kit
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Dutch Speed Bicycles
Builders manual KV4 Velomobile kit
Most pictures also on www.dutchbikes.nl
version: KV4_1.9 page 1
This kit was designed and produced with great care.
To turn it into a great and nice looking velomobile
you will have to finish it with care and attention.
Hasty work here can only lead to an unpleasant,
shabby looking bike that will bring you little pleasure.
So please give this project the attention and effort
it deserves. Finish all details careful and mount
everything rattle-free. This way you will make sure
that you will have many enjoyable rides in you Dutch
Speed Bicycle. Good luck!
Version, Pictures
Some details shown in the pictures may be different from what is
supplied or from what is shown on our site. Small improvements
are made almost every production run, be it to lower weight or to
improve ease of assembly.
Important! Make sure you have downloaded the last version of
the instruction manual. At the top of each page you can find
the version number. Most pictures can be studied in detail on
www.dutchbikes.nl/uk (see the instruction manual page) Some
pictures have altered colours to make the explanation easier.
Changes (compared to the previous version) to the text are
underlined
A new milling machine has made it possible to produce the sheets
more accurately, allowing to make more pre-drilled holes. On the
other end it has limited the largest possible sizes. Resulting in a few
more seams. Also the length of the MacPherson strut (suspension
on the front wheels) has been reduced to save weight.
About this builders instruction manual.
This manual explains how to build the Dutch Speed Bicycles KV4
velomobile. As the Alligt Alleweder a4 is basically the same, you
can use it also to put those together. However we have no control
over the Alligt products, so there may be differences in details. We
take no responsibility regarding building anything other than the
kits we supply. We do not support builders working on non Dutch
Speed Bicycles kits.
Packaging
The kit comes in two large boxes and a flat box. The flat box
contains all the larger aluminium sheets and the machined ribs.
Some larger tubing is also included
Take out the ribs and leave the sheet in the crate, using
the crate for storage. Especially in a not so huge workshop
a sheet is otherwise easily damaged at some point.

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Summary of Contents for Dutch Speed Bicycles KV4

  • Page 1 About this builders instruction manual. This manual explains how to build the Dutch Speed Bicycles KV4 velomobile. As the Alligt Alleweder a4 is basically the same, you can use it also to put those together. However we have no control over the Alligt products, so there may be differences in details.

  • Page 2: Left And Right

    Should you have any questions don’t hesitate to ask. (Customer or no customer) We will try to answer your question and may use it to improve on this manual. But have a look at our KV4 FAQ page first please.

  • Page 3: General Tools

    Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 3 General tools Wrenches, use open end wrenches or better still, ring spanners. These won’t damage the nuts and bolts. If you don’t have a fitting wrench you might use a adjustable wrench (bahco).
  • Page 4 In general the higher sheet is over the lower sheet, to prevent the rain from dripping in. If in doubt, have a look at the large photographs on the KV4 manual page on our website. B) Drill the hole using one of the supplied 3.3 mm drills, Remove any burr between the two parts C) Fasten the (supplied) pop rivet.
  • Page 5 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 5 Cutting sheets. In some places you need to cut the sheet to size. All sheet is pre cut, and for a large part pre drilled. But in some places there is some extra material to remove the need to work very precisely .

  • Page 6: Required Parts

    Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 6 The Seat Required parts Use the seat to practice your skills. Any mistake can be corrected here. It will not show in the end result. The seat will be covered anyway.
  • Page 7 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 7 Bend the flaps inward to shape the seat. Start at the long sides and work your way down. You will find the complex shape will form easy...

  • Page 8: Head Rest (Optional)

    Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 8 Remove the first two rivets. (1 and 2) Insert the thick tube. Drill in the tube using the holes of the removed rivets as a mould. Rivet the tube with the two rivets.

  • Page 9: The Frame

    The main frame is made out of CNC milled aluminium parts. They are bolted together. Because of this you will have the main structure of your KV4 ready in no time. This is an important change compared to the old Alleweder The basic frame...
  • Page 10 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 10 Mount the middle sections of the frame. Keep all the open side to the rear Careful: the centre middle section can be mounted in many ways.
  • Page 11 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 11 The rear fork mounting struts (pivot points) Mount the struts to the rear of the frame. Put the rubber pivot units (a) in place.
  • Page 12 The chain protection part, coloured green in this picture is no longer used in newer versions of the KV4. A better and lighter construction using a chain tube replaces it. Please note the U shaped tube that forms the edge of the feet hole (as shown in some photographs) is replaced by two straight tubes that fit into the front rib.
  • Page 13 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 13 Make sure to position and rivet the fixation points for the wheel suspension correctly first. Hammer the front edges of into shape. Do this gently Make sure the tube is riveted firmly to the sheet before you start hammering.
  • Page 14 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 14 The inside plates off the wheel housings need to be drilled from the inside. You need a Right Angle Drill to do this.
  • Page 15 Please note: the bottom side plate goes underneath the bottom sheet. See enlarged picture. If it is difficult to see on you print have, a look at the large pictures on the KV4 manual page on our website...
  • Page 16 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 16 Hammer gently in A, right next to the fixation point for the suspension so that he plate can close the edge properly. Then rivet the rest of the sheet.
  • Page 17 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 17 The “shoulder struts” Attach the struts that will hold the rim tube (next to where your shoulders will be) of the cockpit opening first to the small sheets Rivet the thin tube on the opposite side of the sheet.
  • Page 18 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 18 Drill two rivet holes in the rim tube, both exactly in the middle. One in the front middle (F) at the op and one in the back middle at the top (R).
  • Page 19 Mount the tail rib. The tail rib is changed slightly to include a grip. On the left the original that is used in the KV4 that was built for the manual. On the right the new one. Cut away the surplus of the small side sheets at the top.
  • Page 20 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 20 Start riveting from the top of the tail rib. Then work your way down from the top of the rim tube. Use intervals of 40 mm. Use the self made tool to find the...
  • Page 21 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 21 Remove the rivets that connect the ‘top rear nose sheet’ to the main rib. This will create a gap between the ‘top rear nose sheet’ and the main rib.
  • Page 22 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 22 Where the side sheet, the nose side sheet and the top rear nose sheet meet (A) the shape gets more 3D. Stuff some material inside between the main rib and the sheeting to get the shape just right.
  • Page 23 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 23 Hammer the edges of the tail sheet around the tubes See “general techniques” in the first chapter. Hammer the front edge gently onto the rib.
  • Page 24 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 24 Trim the edge of the sheeting along the rim tube. Leave about 30 mm above the rivets to wrap around the tube. Hammer gently in shape . See “general techniques” in the first chapter.
  • Page 25 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 25 The fixation point of the front threaded bar. (Looking form the front, velomobile in upside down position) Put the handle bars in it’s position The brake handle goes to the front Assemble the steering rods.
  • Page 26 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 26 Dill a holes in the floor in A and B for the front brake cables. Behind the second row of rivets. Put the supplied rubber grommets (rings) in the holes to protect the cable.
  • Page 27 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 27 Mount the two rails for the chair. Alain the front with the edge of the floor, unless you are of unusual length. The rear end of the seat rest on a support made of two small ribs and a centre piece.

  • Page 28: Tail Light

    Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 28 Use masking tape to mark the proper shape of the tail. Cut away the surplus material (using for instance a right angle grinder with 0,8 mm blade) Use sand paper to make the resulting edge not sharp.

  • Page 29: Aligning The Wheels

    Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 29 Aligning the wheels Just like in a car the front wheels must be aligned. To begin with check of all the rods positioning the wheels are (in pairs) of identical length left and right.
  • Page 30 Dutch Speed Bicycles Builders manual KV4 Velomobile kit Most pictures also on www.dutchbikes.nl version: KV4_1.9 page 30 Painting Painting is not really required. The type of aluminium is sufficiently corrosion resistant to be use in normal conditions. If you live in cold...

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