Made my own cuffs + Tutorial added!

[Jason]

I E-mailed germany to check if they would sell me a set of the cuffs
No way pedro was the answer (nicely put I might say ) patent problems
but they said they may be available soon

Now I'm an inpatient type so I've made my own it's taken me nearly a month of trial and error But I tried the mark 1 out last week end and just walked in the latest and last mark 3 (don't ask about mark 2 )

Anyway heres some pics what do you lot think

[Jason]

Another view
by the way all parts velcro together so can be washed

[bewildered monkey]

Ahh machine washable.


Very useful for getting those pesky blood-stains out 

[woodsy_1984]

and do they work as well as the bar? r u going to put up details of how to make this?

[Athoul]

Very nice, you should definatly put up a simple tutorial so others can learn from you.

[Demondrex]

verry nice
i congratulate you..
im gunna be making some verry soon (same problem as you)
could you give me some advice please??
thanks

Demon

[webmaster]

Wow

Looks fantastic, actually looks like its more comfy than the actual ones!

[BuzzCobain]

o wow, awesome, when are you gonna start sellin em? 

[Jason]

Right last first I won't be selling them (don't want a law suit from powerizer )
Sorry

I will take some pics and measurements of the parts and post

The only part that I had to use a lathe to make is a small nut behind the bar
this was to keep the bar close to the leg as in the mark 1 they were wide and
I knocked them together only made a 4mm a side differance but on each leg

I'll start tonight and try to get some pics up soon

And yes the seem to work as well as if not better than the bar (more adjustment )

And finally No Guarantees you all make them at your own risk they may be dangerous if something fails so please be carefull and if you do hurt yourself don't blame me

[webmaster]

Hey

The only people that may tell you off is the Boecks if you sold some!

However a tutorial would probably be great for all those that would like them. They look excellent Jason.

The cuffs do provide more comfort however I would recommend using Pads otherwise you may get some sore knees!

[Jason]

Thanks Webmaster
Yes I agree about the pads I'll be using the Pit Dirt ones I got from PJ they make it easier to get the cuffs really tight

OK first the metal bits If you cant make these give up now you will need 4 of each

The bolt is a 6mm x 50mm long cut down to size

The washer is 25mm with a 6mm hole

the strange little nut can be replaced with a 6mm nut but makes the thing 4mm wider

The large square plate is next

[Jason]

I made the square plate of ally it's 40mm x 30mm x 2.5mm thick (approx )

I cut the plate to size drilled a 6mm hole in the middle put the bolt through and tightened a nut on the other side

now the hard bit if you take a bit of tube that is about 25mm ( I used an old socket set ) place the plate bolt head side down on a flat metal surface (a vice or similar ) put the tube over the bolt center it and hit it hard with a hammer it will form into the shape shown

then if you want to be able to angle it file the hole into a slot (only needed if you have a dodgy leg like me )

[Jason]

Side view

[Jason]

Next have you got a sewing machine as if not it's gonna take you a long time

I used an old singer hand cranked one as it can sew 2 layers of webbing and 2 layers of velcro all in one

The webbing needs to be strong but fairly thin dont use the really thick stuff or you'll never get it through the machine

You need 8 bits of 50mm webbing 150mm long burn the ends with a lighter to stop them running
You need 20mm velcro good stuff not the cheep ones 8 bits 150mm long of both sides ( hook and Loop )

[Jason]

now you cut a small hole in the center of 2 bits of web and using a hot bit of wire burn it out to about 6mm then the same in the other 2 but larger and oval to take the bolt head

next sew the loop velcro (the soft one ) to the 6mm holed webs as in pic and the hook velcro to the other 2

[Jason]

other side

[Jason]

now take one hook web and one loop web and sew them back to back but not all the way round Its hard to explain but you must leave a pocket to put the square washer into

[Jason]

A diagramme to make it clear the dotted line is where to sew and the pocket should make the square plate center on the hole

[Jason]

Ok thats one pad done now the bad news you need 3 more exactly the same

Next you slip the square plate into the pocket with the hollow to the large hole side.
 push the bolt through from the side with the large hole put a washer on and run either the strange nut ( made on a lathe ) or a 6mm nut and tighten

It should look like this

Do the same with the other 4

[Jason]

Thats all the hard bits done

You now need four x 700mm long 25mm webbing
Four 350mm long hook side 20mm velcro
and four of those rucksack buckles get good ones and test them remember they hold you in and if the fail it could hurt

sew the buckles to the end of the webbing ( burn the ends first to stop it running )
Then sew the velcro to the side (not the center ) as in pic all four are the same ( don't make them handed or they won't fit )

[Jason]

The whole strap

[Jason]

The actual Cuff bit is down to your choise of material

I used a heavy nylon and a letherette backed fleece

Cut the nylon 100mm x 520
cut the fleece 140mm x 520

also 4 bits of 20mm loop velcro 400mm long

Sew the velcro to the face of the nylon as in pic the same width apart as on the 50mm webbing pads

[Jason]

Now you have to sew the fleece to the nylon  If you do it inside out like a tube you can then turn it inside out and hide all the seems (If anyone in your house can sew the can explain it better )

I put 6mm foam in side mine and then sewed the ends shut
I also put 2 lines of stiches across the cufs to keep the foam still

[Jason]

Other side the fleece really makes it soft

[Jason]

Thats the lot next is the scarry bit I couldn't face cutting the hoops ( to much of a coward ) so I got some ally tube and bent and cut it

It is possable to cut your tubes and drill them to fit but remember if you get it wrong they are £18 each so do it right first time