The Smell of Molten Projects in the Morning

Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.

Category: Recumbent Bicycling

Cruisin’ the streets

  • Bicycle Mobile Rebuild

    Bicycle Mobile Rebuild

    A long-lost repair finally made it to the top of the list:

    Bicycle Mobile - bottom view
    Bicycle Mobile – bottom view

    The original string had long since rotted out, but everything else was in a plastic bag just waiting for this occasion.

    The colorful cylinders are stacks of laser-cut 6 mm disks with a 2 mm hole, held to the wire & string with a tiny dot of high-viscosity cyanoacrylate glue at each end:

    Bicycle Mobile - detail
    Bicycle Mobile – detail

    The disks came from acrylic leftovers:

    Bicycle Mobile - laser-cut acrylic
    Bicycle Mobile – laser-cut acrylic

    The motion you can’t see makes the shiny bikes much more visible out there:

    Bicycle Mobile - side view
    Bicycle Mobile – side view

    The string came from dismantled badge reels providing spiral springs for the auto-retracting spools in the PolyDryer boxes.

    The weight ball had a 2 mm hole filled by a wood plug which I cleaned out piecemeal with a 1.5 mm drill bit in a pin vise; a short length of wood skewer holds the new string in place.

    Because the upper arms support more weight, their disk stacks need fewer disks for the same leverage. The original mobile had (at most) four 6 mm chromed plastic balls at each level, so I started with eight 3 mm disks, adjusted the stack length as needed, glued them in place, then removed the surplus disks by crushing them with a Vise-Grip.

    I should rip off the design (“© otagiri 1979”) to build another with recumbent bikes.

  • Dutchess Rail Trail: Brush Trimming & Pruner Repair

    Dutchess Rail Trail: Brush Trimming & Pruner Repair

    The bushes & trees along the Dutchess Rail Trail were reaching out to touch us again, so I took some slow rides with many stops.

    Maple Oak trees along Page Park Drive:

    DCRT Brush Trimming - oak - 2025-07
    DCRT Brush Trimming – oak – 2025-07

    Blackthorn encroaching through the fence at Overocker:

    DCRT Brush Trimming - blackthorn - 2025-07
    DCRT Brush Trimming – blackthorn – 2025-07

    A tree somebody tossed down the trail bank near Morgan Lake:

    DCRT Brush Trimming - discarded tree - 2025-07
    DCRT Brush Trimming – discarded tree – 2025-07

    The slide lock on my trusty rehabilitated Fiskars bypass pruner worked loose and began sliding into the LOCK position when held overhead, then fell apart during disassembly:

    Fiskars pruner - lock rebuild
    Fiskars pruner – lock rebuild

    The lock now consists of:

    • An M4 × 12 mm nut from a Chicago Screw that exactly matched the 5 mm OD cylinder passing through the pruner body
    • A laser-cut fluorescent acrylic disk for thumb grippiness
    • A washer just because
    • An M4 hex-head screw
    • A dab of Loctite bonding screw to nut

    Clean the blades with alcohol and it’s ready for the rest of the season.

    I should have put a wave washer in the stack for some springiness, but it works surprisingly well for what it is.

    Now: discover how long acrylic lasts out there in the wild.

    Update: Yeah, the lock needed a wave washer for more friction, which became apparent after the first overhead branch.

  • Newmowa NP-BX1: 2025 Batteries

    Newmowa NP-BX1: 2025 Batteries

    A new sextet of NP-BX1 batteries for the Sony AS-30V helmet camera arrived:

    Newmowa NP-BX1 - 2022 vs 2025
    Newmowa NP-BX1 – 2022 vs 2025

    The traces:

    • Blue = 2025 batteries
    • Red = 2022 batteries when new

    I don’t know what the bump in the middle of the new battery discharge curve means. Something weird in the chemistry, I suppose. Getting good batteries from Amazon surely remains a crapshoot and I now have four chargers.

    Recharging all six batteries required 5488 mA·hr, just over 900 mA·hr apiece. Running the camera on a one-hour bike ride burns 600-ish mA·hr, so that’s comforting.

    Comparing the new results with the 2022 batteries tested last month:

    NP-BX1 - Newmowa 2022 in 2025-06
    NP-BX1 – Newmowa 2022 in 2025-06

    The upper traces appear in red in the first plot, the lower curves come from three years of use.

    I’ll deploy the two best 2022 batteries (D and F) in the SJCAM M20 keeping watch from the Forester’s dashboard.

  • Newmowa NP-BX1: Three Years Later

    Newmowa NP-BX1: Three Years Later

    A pair of the 2022 batch of Newmowa NP-BX1 lithium batteries for the Sony AS-30V helmet camera no longer survive a typical hour-long bike ride:

    NP-BX1 - Newmowa 2022 in 2025-06
    NP-BX1 – Newmowa 2022 in 2025-06

    The best four have a capacity down 14% from the good old days and the weakest pair are down 29%.

    The camera uses 1.9 W, so a battery with 2.5 W·hr capacity should last 78 minutes, but about 400 mV of voltage depression causes the camera to give up before using its full capacity.

    So they have a useful lifetime of maybe two years in our regular bike riding schedule and I should have bought replacements last year. I hope the next batch isn’t New Old Stock or recycled cells.

  • Sandisk 64 GB High Endurance MicroSD Card: End of Life

    Sandisk 64 GB High Endurance MicroSD Card: End of Life

    After about 7.5 years (!) the 64 GB card in my Sony HDR-AS30V helmet camera breathed its last:

    SanDisk 64 GB MicroSD card - end of life
    SanDisk 64 GB MicroSD card – end of life

    Over the course of several rides I noticed many video files ended prematurely or would not play. I gave up attempting to reformat the card in overwrite mode using the Official SD Card formatter after four hours, which says the wear leveler in the card has no spare capacity.

    In round numbers, I ride 1700 miles a year at 12 mph, so the card recorded 1000 hours of 1920×1080 video at 60 frame/s, storing one 4.3 GB file every 22.75 minutes for a grand total of 12 TB of data.

    Although that’s 188 times the capacity of the card, it rarely held more than an hour or two of data at any one time, because I copy the camera video files to a 3 TB USB hard drive after each ride. I don’t know how the exFAT file system interacts with the card’s wear leveling, but overall it’s much better than the non-high-endurance cards I’d been using way back when.

    A new Sandisk 128 GB High Endurance card cost a third of what the 64 GB card did and, after setting the partition label to AS30V, it’s off to a good start:

    Street Lamp Pole - Rombout House Ln - 2025-05-07
    Street Lamp Pole – Rombout House Ln – 2025-05-07

    That’s the street lamp pole installed on the replaced base at the corner of Rt 376 and Rombout House Lane, with the barrels gradually being pushed closer and closer to the pole by turning traffic on the newly paved lane.

    That pole is not going to see the end of this year.

    Update: The barrels vanished this morning:

    Street Lamp Pole - Rombout House Ln - 2025-05-08
    Street Lamp Pole – Rombout House Ln – 2025-05-08

    Definitely the triumph of hope over experience.

  • Tour Easy: Broken Seat Parts

    Tour Easy: Broken Seat Parts

    So hardened socket head cap screws survive fifteen years of hard service on my Tour Easy’s seat stay:

    Tour Easy - broken seat stay screw
    Tour Easy – broken seat stay screw

    I replaced both screws with stainless steel 1-½ 10-32 socket head screws, with a reshaped head on the drive side, and we’ll see how long these last.

    A few days later the continuing creak led to finding a broken gear clamp on the left side of the seat back:

    Tour Easy - replacement seat frame clamp
    Tour Easy – replacement seat frame clamp

    Apart from the atypical lack of grime, you couldn’t tell that’s the replacement clamp, because the broken one looked exactly the same way. The clamp strap broke where it bent around the bottom edge of the seat pan bracket, probably due to the flexing caused by the broken seat stay screw.

    Riding season is in full effect!

  • Cycling Shoe Sole Carving

    Cycling Shoe Sole Carving

    As before, the sole & lugs on Mary’s new Specialized cycling shoes requires too much torque to release the cleat, so I once again carved off everything that got in the way:

    Cycling shoe sole carving
    Cycling shoe sole carving

    A field test prompted a little more carving, but you get the general idea.

    This surely affects the shoes’ lateral stability, but getting her feet out of the cleats when & where needed outweighs everything else.