Sam Barker’s garage is a haven for the over-ambitious, and his latest creation, a diwheel, proves that he’s able to turn half-baked ideas into working prototypes. This is a real twin-wheeled monster that will redefine transportation with a bit of chaos and a lot of steel.
Barker’s diwheel started as an expansion of his previous monowheel, a single-wheeled device he cobbled together in his kitchen four years ago. That first attempt, he admits, was a “janky” disaster that threw him off like a bull. Undeterred, he doubled down on the idea and connected two massive wheels to make a diwheel. Each wheel is a 5mm thick, 100mm wide mild steel tube rolled into a ring by a metal fabricator in Sheffield. These weigh about 60kg each, so they’re as unforgiving as they are strong. Barker wanted stability, so he overengineered them to stop the rings bending under stress. The result? A structure that can crush toes.
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A diwheel works on a different principle to a regular bicycle wheel, which has a hub and spokes. The outer rings revolve around a fixed inner frame, with four rollers per wheel. These rollers are attached to bearings, so the frame can fit snugly inside the rotating rings, with the rider in the middle. Barker’s inner frame is a beast in its own right, made from 5mm steel plates he drew up using 3D printed templates. He knows it’s overkill, but after his monowheel failed, he wasn’t taking any chances. The frame’s job is to keep everything together; the wheels, rollers, suspension and finally the rider from collapsing due to the diwheel’s massive inertia.
Suspension is key here, as it not only smooths out the ride, but also allows for adjustments to compensate for his not so perfect dimensions. H-brackets, and box sections welded to the frame, connect to the suspension, so the diwheel can flex with bumps and misalignments. The rollers are a big improvement over his monowheel days when 3D printed PLA ones lasted 10 minutes. This time, he designed them in Fusion 360 and had them SLS printed in nylon by JLC3DP, a service he recommends for its 48 hour turnaround and material options including metal and nylon. The rollers are press-fitted with 17mm bearings and are designed to support the diwheel’s weight and motion.
Cutting the steel rings into perfect circles was hard, as his measurements were wrong, and he had gaps to fill. He ended up clamping and welding under tension, which he described as a mix of pride and fear. His “Barker bodge” is reflected in his hand made lathe, 3D printed jig and drill setup for grinding down big rods for bearings. It’s the kind of hack that makes you root for him despite the danger.
The diwheel seat is a plastic bucket seat from Facebook Marketplace, which adds a bit of cheapness. He’ll add a 5 point harness for safety as the diwheel is as dangerous as it is fun. For now, the diwheel is a work in progress, he needs to make the top bracing, secure the seat and decide where to put the batteries and motors for the electric drive. Unlike the typical monowheels, powered by pedals, this one will be electric, so he’ll have tank like control without having to burn his thighs. When its finished, he’ll take it for a spin with 60kW of electric power.
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