JC Coker Handle (revision Beta 2)

I have been making myself a handlebar extension for my new Coker. I wanted something modular so I could adjust things to make it fit right and also add and change things for different riding. I got a lot of inspiration from the handlebar setup in Will’s gallery.

Pictures of my JC Coker Handle are in my Miscellaneous Stuff gallery

The handlebar is mounted to the frame using part of an adjustable stoker stem for a tandem bicycle. I got the stoker stem off eBay for around $30, but you can also get them from a place like aebike for about $48.

The boom is a 400 mm x 28.6 mm Rockwerks seatpost. I cut the seat guts off with a hacksaw.

The stem is a MTB stem with about a 25 degree rise.

I got some used MTB bar ends and mounted them on a straight piece of 22.2 mm handlebar with a 25.4 mm shim. The Coda bar ends have a weird bend in them that makes them more comfortable than regular bar ends for this riding position. I had to cut the bar ends down to get them to fit the way I wanted.

The 400 mm long boom was not quite long enough so I grafted on an extension. The extension is a piece of 25.4 mm chromoly seatpost that I had laying around. It is held in place using a big double bolt BMX clamp similar to the Primo Viking. I used an XS clamp but you can’t get those any more. The clamp is designed to fit a 28.6 mm (1 1/8") seat tube and 25.5 mm (1") seat post. Half the clamp grips the seat tube and half the clamp grips the seat post.

On the extension I have mounted my computer and a bell. The computer is mounted on a stubby extension designed so you can mount a computer on aero bars. A bike shop that knows about bikes for triathletes would know about these little computer mounts.

At the end of the extension I have a “T” shaped bar to protect the computer in the event that the unicycle hits the ground after a UPD. It is a
Minoura Space Grip. aebike has them. I haven’t crashed with it yet so I don’t know how it will hold up after a UPD. It is part plastic so it may not survive. I have some ideas for a different way to protect the computer without using the Space Grip as a crash bumper. I’ll have to play around and see what works. The JC Coker Handle is still in the Beta stage and this is one of the reasons why.

The boom required some shims to get it to fit in the stoker stem holder. The stoker stem was designed to fit something close to 30 mm and the boom is only 28.6 mm. I consumed several cans of Coca-Cola and used the empty cans as shim material. I think it is possible to get a 28.6 mm to 29.8 mm shim. I’ll give that shim a try when I can get it.

The stoker stem is designed to fit a 29.8 mm seat post. My frame is only about 28.6mm in diameter where the stoker stem is mounted so this area also required the use of some shimming material. Fortunately the tandem folks make a 28.6 mm to 29.8 mm shim for mounting a stoker stem on smaller seat posts. Now I need to get two of those fancy tandem stoker stem shims.

Overall, I like the JC Coker Handle. It’s a modular setup which allows me to move the handlebar pieces to get it to fit right. I can also add new things like maybe an aero bar instead of the bar ends. Lots of possibilities. Most of the JC Coker Handle is aluminum which keeps it fairly light.

I need to figure out a better way to protect the computer without using the Minoura Space Grip as a bumper, and I’d also like to mount a water bottle somewhere. I could mount it out front like Nathan has, or I could figure out a way to mount a single water bottle under my seat. The JC Coker Handle revision Beta 3 will be out once I get these details figured out.

jc_coker_handle.jpg

Cool and sweet.

Your one is especially good on the point that having adjustable joints to adjust and can be personalize the need for any individuals.
Also beta 2 will be attractive if you find a decent place to attache water bottle. Waiting for revision Beta 3…

Sweet. That’s a hoopy bit of engineering John! I especially like how you used commonly available pieces and parts to construct it. It really looks great.

One of my design goals is to use commonly available parts with a minimum of machining. So far the only machining I’ve needed is just a hacksaw and a file.

It would be nice to have a longer boom. The longest 28.6 mm seatpost that you can get are about 400 mm and that’s just a bit short. A 600 mm or 700 mm long boom would be better. I may look in to getting a boom custom machined even though that would violate one of my design goals. With a custom made boom I could make it longer and have the end that fits in the stoker stem be about 30 mm in diameter so I wouldn’t have to use a shim. The machining would be simple, just turning an aluminum tube on a lathe. But I’d have to find a machinist to do it and the end result would be more expensive than buying a Rockwerks seatpost and a shim.

The Coke can shims that hold the boom in the stoker stem are also problematic. They don’t hold the boom really tight. It doesn’t slip while riding, but it will twist when it hits the ground after a UPD. The Coke can shims get chewed up when the boom twists like that after a UPD. It’s not ideal, but not a critical problem either. Hopefully the tandem stem shims will fix that problem.

So I don’t know whether to go the custom machining route for the boom or add a better shim. I’ll probably go the shim route. But I’m also curious about how much it would be to have a machinist make a custom boom.

One other problem I’ve noticed with the JC Coker Handle is that it is harder to fit the Coker in the back of my Subaru Impreza wagon now. It still fits just fine, but it’s harder to get it in and out of the car.

Nice pictures John,

Instead of buying a longer seatpost, you could just order 1.125" aluminum tubing in any length you want. Shapiro supply has a good selection and no minimum order. Ideally you could find a local source and not pay shipping, but failing that:

Nice work, John! I’m just a step behind you on this one :angry:

For crash protection, you might try using a cane tip on the end of the boom and get rid of the space grip. That has worked for me so far.

Coke can aluminum is very squishy stuff. The formula was created to allow rapid forming of sheet into cans.

It’s really an amazing formula when you think of it - taking a 3" disk of aluminum sheet and reliably stretching it into the shape of a coke can in a fraction of a second without tearing. However, it’s not really a structural material. Ditto for aluminum foil, for the same reasons.

on edit: OOPs! Almost forgot… Very nice design.

I agree, very nice John. --chirokid–

Do you wonder any more why we call him “JC”?

Excellent, clean design. Simple and elegant and produced without exotic tools or materials. And done by the guy who can ride it on water.

I’m curious to see what you come up with for a handle system when you get it finished.

I got my initial idea from Will’s gallery. Then I saw an adjustable stoker stem on a tandem and the whole idea came together right there. It has been several months since that initial idea to use a stoker stem. Now I finally have a working version (I’m a bit lazy and slow about these things).

One problem with my design is that it may not work well with the Hunter Coker frames because there is not as much neck on the frame to mount the stoker stem. It may work on a Hunter frame or it may not. It would depend on how much room there is on the neck or on the exposed seat post to mount the stoker stem. And then there is also the possible issue of the angle that the stoker stem puts the boom at. Would the angle be too steep to clear the front of the seat? I’m going to be putting a Magura brake lever below my seat (just like a muni setup) so I need clearance area under my seat for the brake lever.

I initially used a rubber tip similar to a cane tip on the end of the boom but my boom isn’t long enough to keep the computer from contacting the ground during a UPD with that design. I would need a longer boom for that to work. I have found that the further out on the boom that I put the computer the easier it is to read the computer while riding. So I have the computer out as far on the boom as possible (as far as the computer cable will allow). I may need to go to a wireless computer to put it any further out on the boom.

Cool! What kind of finish is there on the aluminum tubing like that? I really like the machined finish on my seatpost boom, but I could live without that machined finish.

I believe that the seat post I have is 6000 series aluminum. Don’t know for sure. The wall thickness is around 3/32" (0.09375") (about 2.4 mm). The closest in the stock tubing they have has a wall thickness of 0.125". Probably thicker than I need, but better to be too strong than too weak. UPDs can be violent events for a Coker unicycle and I want the boom to survive my crashes.

The finish is just “as extruded”, not machined. It’s easily polished with Mother’s Mag and Aluminum Polish (check Napa). An angle die grinder with a buffing wheel can have really nice effects.

I think you could get a larger OD tube machined down pretty reasonably too, especially if you bring in your pre cut tube and say “Here, face both ends, then turn down XX inches to XX diameter”. I would think around $10 for machining. Shop rates are usually around $40 an hour for stuff like this, if they want more than that, go somewhere else.

polished_al.jpg

Yes. Soda cans and beer cans are squishy stuff. Not the best shim material. I can get some proper shim stock but it is much more expensive than soda cans.

I’m going to look into getting the shims that are designed specifically for the stoker stems. They seem to be, very conveniently, just the right size for what I need.

Now that the design has proven itself I’ll splurge on the shims.

That looks good. The polished aluminum look should do well. I’ll look into the round aluminum tubing and see what I can come up with for revision Beta 3 of my handle.

Beta testing can be fun. :slight_smile:

Electric glue works pretty well, too.

What is electric glue? A Google search turns up everything from software to glue guns.

: )

Wow I wish I knew what you guys were talking about, nice pictures of shinny objects though.

Hey whats the advantage of having a handlebar on a coker, and whats the computer do?

I’ve thought of putting a water bottle on my uni, or a horn or something. I also want to get a steering wheel, not to attach it, but to hold it and look silly, I gotta start doing stuff while unicycling, thats part of the beaty of not riding a b*ke : )

Andrew

It’s Navy slang for arc welding. Sorry, thought it would be obvious.

Now that’s Beautiful !!!
inspiration to start on my onw very soon

You should have put a smiley after your comment about the electric glue. :slight_smile: