XR2 Construction Manual

The 80-page manual that comes with the Ground Hugger XR2 plans is printed on 8-1/2 x 11-inch presentation-quality paper. It contains approximately 100 photographs and renderings, and covers design factors as well as the actual construction.

Click on the image to see a large preview of the cover.

Scroll down to see the Table of Contents.

Table of Contents

Introduction
    The CD-ROM
    About Recumbent Bicycles
    Inherent Hazards of Mixing with Motorized Traffic
    Where to Get Parts and Materials

Technical Overview
    Fitting the XR2 to You
    Seat-to-Pedals Dimension
    Handlebar Location
    Controls
    Consider the Trickledown Effects of Design Changes
    Steering Geometry
    Fork Design
    Steering System Design
    Hydrostatic Steering
    Under-Seat Steering
    Floating Front Head Bearing Cup
    Rear Suspension Design
    Rear Stay Design

Bicycle Components
    Front Wheel
    Rear Wheel
    Gearing
    Headset
    Bottom Bracket and Shell
    Crank Set
    Pedals
    Brakes
    Handlebars and Stem

Building the Ground Hugger XR2
    Construction Tips and Techniques
    Getting Prepared

Building the Ground Hugger XR2 (cont.)
    Tools & Equipment
    Precautions
    Fork Assembly
    Rear Stay Assembly
    Rear Stay Hanger
    Headpiece
    Steering Housing
    Steering Tube
    Handlebars and Stem
    Building the Frame
    Urethane Foam Core
    Tips on Using Carbon Fiber and Vinylester Resin
    Stabilize the Foam With Carbon
    Fiber Lay-Ups
    Install Headpiece
    Install Bottom Bracket
    Install Stay Hanger
    Make Cable Cavity
    Install Upper Shock Bracket
    Install Seat Brackets
    Front Derailleur
    Finish the Laminations
    Seat
    Finishing
    Assembly Tips
    Accessories

Riding the XR2

Materials List

Vendors