Can Crusher From an Old Mountain Bike Sprocket

In this Instructable, we will be creating a can crusher out of a reused hub-assembly from a bike (the sprocket attached to the shaft in which the bike petals rotate). This project also utilizes plenty of material, primarily wood, that is likely to be found around the house.

1. Safety Glasses
2. An old bike, preferably a mountain bike.
3. 3/4-inch-thick wood that is at least 5 inches wide and 44 inches long.
4. A 4 inch by 4-inch wooden block, at least 12 inches in length.
5. Small, square wooden bar for railing.
6. Table saw
7. A die grinder (grinder with a circular-rotating blade)
8. At least 2 bolts and nuts
9. 2-inch screws (can be any length)
10. Electric drill
11. Nail gun and nails (optional but preferred) (pneumatic)
12. A metal strap (preferably has holes pre-drilled
13. A U-shaped bracket (bought or custom made)
14. Old metal pipe (3/4-inch diameter)
15. Measuring tool (tape measure)
16. Screwdriver
17. Large wooden plate as a base (recommended)
18. Trash Can (for the cans to fall into)

This is the most difficult and dangerous step of the process. Ensure you are using the proper safety measures like safety glasses. In order to remove these components, you must use a die grinder to cut off the metal surrounding them. This process will create an extraordinary number of sparks, so it is important to stand away from the direction they are falling.

1. Cut off all pieces connecting the shaft to the whole bike.
2. Cut the bike pedal off that is furthest from the sprocket at the point indicated. (The metal bar that connected the petal to the shaft will be cut later as necessary.)
3. Clean up the part so that the shaft is as round as possible.

This block is essential to cut early on because it will guide the build if different measurements are used. The driver should be long enough to stay steady within the can crusher as it is pushed forward.

1. Use the saw to cut the block to a length of 5 inches.

The walls are essential for encasing the driver block within the build. These side walls will be placed length-wise on the crusher. These pieces are made from 3/4-inch thick wood.

1. Cut the wood with a saw so that it is 19 1/2 inches long, and 5 inches wide.
2. Copy this action for the second piece of wood.

In this step we are going to be using the same step however, cutting the width to 3 1/2 inches, the same size as the driver block.

1. Cut the piece of wood to be 19 1/2 inches long and 3 1/2 inches wide.
2. Measure the size of a crushed can and cut that size into the end of this piece.

You can attach the can crusher floor with either a nail gun, screws, or both for the most structural integrity. Make sure that all edges line up, and that there is a blank spot where the can will be crushed into.

In this step we will add a third wall to the end of the can crusher where the hole is.

1. Cut a piece of wood that is the same thickness as the others, but attaches evenly to the end of the crusher
2. If your measurements are right, this piece should be a square that covers the entire front (5 in. by 5 in.)
3. Attach this wall to the end of the can crusher where the hole is.

In this step we will create a railing so that the driver block is able to stay within the crusher.

1. Simply find a piece of wood that does not take up too much space and like it up so that it touches the top of the driver block, as shown in the picture above. For this picture the length of the wood is 19 1/2 inches.
2. Make sure that the can is able to be placed into the machine still.

In this step we will create a post so that the bike sprocket/pedals are connected to the machine at the appropriate spot, and elevated.

1. Use the same piece/size of wood that we used for the driver. it is 4 in. by 4 in., and we will cut it to be 7 inches long.
2. Attach it to the end opposite of the hole, as shown in the picture above. Make sure that it is not placed any further than the railing

In this step we will simply be adding pieces of wood, or any other reusable materials you can find to upgrade this crusher, so that it can withstand the immense torque that the machine will be put through.

1. In this specific machine, multiple pieces of wood the same size as the railing was used.
2. Place them around the wooden post and attach them via nails or screws to the post and the main machine.

In this step we will prepare the pipe that we have found for the next step.

1. Use a hammer or other blunt object to flatten the end of the pipe so that it is easier to drill a hole through. Drill this hole inside of the flattened part as shown in the picture.
2. Follow this same step for the other side of the pipe, because this will be attached to the bike component.

In this step we will use the U-bracket (or alternatively another type of bracket or metal piece to form a U-bracket.)

1. Screw the bottom of the bracket onto the driver so that the 2 holes on each side are horizontal to one another.
2. Use on of the bolts and nut to feed through the hole of the pipe and attach the U-bracket to the pipe.

This step is the most complicated, however, is very important in ensuring that the pipe lines up appropriately to the bike as a turning mechanism.

1. Use the size of a non-crushed can to determine how far the driver block will be from the hole/wall. Make a mark where the pipe's hole and part of the bike component line up.
2. Once done, move the driver to where the crushed can hole is, and make sure that the mark that was placed before also lines up there.

In this step we will drill a hole where it was marked in the last step. Take the blunt end that is without the bike pedal drill a hole until it is completely through.

In this step we will cut off all of the metal of the bike component that is beyond the hole that was previously made.

Align the hole on the pipe with the driver attached to the hole just made with the bike component.

1. Use another nut and bolt to attach these two parts together. Make sure that the nut is loose to allow full rotation of the machine, otherwise it will lock-up.

In this step we will use the metal strap to attach the bike component to the wooden post. Make sure that the previous step remains stable as we attach these parts.

1. Take one end of the strap and screw it into the wood at any point. (Pre-Drill if necessary)
2. Wraps the strap around the bike component so that it is tight. (A hammer will be helpful in making sure the strap bends evenly.
3. Screw the other end of the strap. (Pre-Drill if necessary)
4. Add in more screws if required to make the part more stable.

If you have made the can crusher successfully, it should have a full rotation such that as you push the opposite side bike petal, the block will move back and forth consistently.

It is best to attach the machine to a wooden base, which improves its structure. Simply use a nail gun or screws to attach all important points to the base.

Provide any fine-tuning and the project is complete!