The "Loopschip" is an walking aid for Lukas, a 10 year old boy with a dissability. The aim was to make a product that is both fun for Lukas himself, as ergotherapeutic. This manual explains how to make one yourself!

1. http://designforeveryone.howest.be/

2. LOOPSCHIP 1.6
154 euro 32 hours - 24 minutes
http://loopschip2011.blogspot.com/ Filip Gerits/ Elena Martinez / Steven Verbrugge
http://designforeveryone.howest.be/

3. ASSEMBLY MANUAL
http://designforeveryone.howest.be/

4. LOOPSCHIP 1.6
BILL OF MATERIAL
1. Wooden frame
2. Wheelplate (2)
3. M5 bolts and nuts (20)
4. M6 bolts and nuts (4)
5. M5 Screw-in nut (6)
6. M6 threaded rod
7. 10mm tubes (3)
8. Castor wheels (4)
9. Cross beam
10. Wheel support plate (2)
11. Table
12. Seat
13. Foam parts (4)
14. Straps (different sizes)
15. Springs (2)
16. Chest support side plates (2)
17. Chest support main plate
18. Velcro strips (7)
19. Wooden plate (for seat)
20. Wooden pins (2)
21. Wood screws (2)
22. Custom toys
10 different tools needed
8 standard parts / 2 parts reused
14 parts tailor made

5. 1 8x
LOOPSCHIP 1.6
DESCRIPTION The first thing you
need to do is buy the wood. The structure is built
up of different layers of triplex wood glued
together. There are two main shapes you need
to cut out with a fretsaw . It’s easiest to cut out
two templates first. Use those to draw the
shapes with a pencil or the big triplex board. This
way you make sure each part has approximately
the same shape.
2x
Technical plan 1 and 2
2 hours
Pencil and a fret saw or belt saw
Two standard (120 x 240 ) triplex boards.
1 part added
30 euro

6. 2 LOOPSCHIP 1.6
DESCRIPTION The structure consists
of a triangular base. To make that base we’ll
need to bend the wood. We will start by gluing
the fixed part to each other. Apply regular wood
glue and press them together with clamps for
the time mentioned on the bottle (about one
hour).
Remember NOT to glue the long legs. These will
be glued later.
1 hour
6 glue clamps
A bottle of regular wood glue
1 euro

7. 3 LOOPSCHIP 1.6
DESCRIPTION To bend the two front
legs we must first attach some bolts to
strengthen the center and relieve the bending
stress from the glue surfaces. Therefore there
are two bolts at the longest leg. This is done by
drilling a hole with an electric drill and a 5mm
wood drill.
5mm 5 minutes
Electric drill/screwdriver
5 x M5 inbus bolts and 5 x M5 cap nuts.
5 part added
1 euro

8. 4 LOOPSCHIP 1.6
DESCRIPTION Now we need to apply
glue to the long legs. Four of them will make the
left leg, and the other four the right. Then bend
open the legs and insert a steel rod spacer (cut
with a metal saw on an angle) between the two
legs (1). Be fast! Make sure you insert the rod
before the glue has started to dry. Now use the
clamps to make sure the gaps between the
layers of triplex are closed. Spread them out
evenly (2).
After the glue has dried, saw away the excess
wood and use sanding paper to round and trim
all the edges. A sanding belt or electric circular
sander is recommended.
1
2 1 hour 30 minutes
Wood glue, metal saw and sanding paper.
10 mm steel tube
5 euro

9. 5 LOOPSCHIP 1.6
DESCRIPTION At the bottom of the
bent front legs we need a way to attach the
swivel wheels. This can be done by adding
triangular blocks of multiplex or triplex wood.
Those can then also be sanded to match the legs
and have a flat surface.
1 hour 30 minutes
Wood glue, belt saw, sanding paper.

10. 6 LOOPSCHIP 1.6
DESCRIPTION At the back of the
board the structure is widened with additional
layers of triplex wood. The number of additional
layers depends on the thickness of the wood and
the size of the back wheel.
Make sure the finished piece is as wide as the
axle of the wheel.
With a butterfly drill you drill out bigger wholes
for the seat pins.
1 hour 30 minutes
Wood glue, belt saw and sanding paper.

11. 7 LOOPSCHIP 1.6
DESCRIPTION Cut off the top of the
structure, at the desired height for the table. Be
sure you sand off a flat levelled surface.
You will need to cut out a groove for the table
cross beam and add inserts later on.
30 minutes
Belt saw and sanding paper

12. 8 LOOPSCHIP 1.6
DESCRIPTION Further sand off the
wooden shape and drill 5mm diameter holes
where needed.
(1) Holes for the support beams.
(2) Hole for the front support brace
(3) Holes for the big rear wheel
2 hours
Drill, belt sanding machine, sandpaper

13. 9 LOOPSCHIP 1.6
DESCRIPTION Finished main shape.

14. 10 LOOPSCHIP 1.6
DESCRIPTION The metal tube you
used to bend the wood will now be used again to
make the construction more rigid. Through the
tube you need to add a threaded rod. In that
way you can screw bolts to fix it.
30 minutes
3 parts added.

15. 11 LOOPSCHIP 1.6
DESCRIPTION To give the
construction even more rigidity we are going to
add two support tubes. Use the same type of
steel tube we used between the front legs.
Saw off two equal lenghts of the steel bar and
flatten the tubes at both ends with a vice. Grind
the ends. Drill a 9mm hole through the metal
ends.
1 hour
metal saw , drill, grinder, vice
10 mm steel tube
10 euro

16. 12 LOOPSCHIP 1.6
DESCRIPTION Place the support bar
over the bottom axle, add a spacer and a washer
and bolt it on loosely. Do this at both sides.
10 minutes
M6 bolt and nut
8 parts added.
1 euro

17. 13 LOOPSCHIP 1.6
DESCRIPTION At the top we can now
connect the two by putting a bolt through the
wooden main part and the two support rods.
10 minutes
M5 bolt, washer and nut
3 parts added.

18. 14 LOOPSCHIP 1.6
DESCRIPTION Firmly tighten all the
bolts when everything is in place.
10 minutes

19. 15 LOOPSCHIP 1.6
DESCRIPTION Finished main shape.

20. 16 LOOPSCHIP 1.6
DESCRIPTION The big wheel is a
wheelbarrow wheel you can buy in a DIY store.
We chose for a bright yellow to add playfulness.
After having measured the height of the axle
(radius/2) and measuring the height of the main
structure when levelled we know how big the
connection pieces must be. Those pieces are
drawn out on triplex and glued together. We
took 4 layers each. Then 5mm holes are added
to attach to the main structure, and a bigger
hole with a butterfly drill to slide over the wheel
axle.
1 hour 10 minutes
Fretsaw, wood glue, drill, butterfly drill.
Yellow cartwheel wheel.
3 parts added.
32 euros

21. 17 LOOPSCHIP 1.6
DESCRIPTION The two fork parts can
be bolted on the axle of the wheel.
5 minutes

22. 18 LOOPSCHIP 1.6
DESCRIPTION To attach the fork to
the main structure you can cut 2 pieces off a M5
threaded rod. For the ends you can use M5
capped nuts.
30 minutes
metal saw
M5 threaded rod, M5 capped nuts

23. 19 LOOPSCHIP 1.6
DESCRIPTION We used cap nuts so
the user can’t cut him/herself on the exposed
rod.
4 parts added.

24. 20 LOOPSCHIP 1.6
DESCRIPTION To drive around you
will need more than one wheel. We have found
that three weels weren’t stable enough. We
added 2 extra wheels for support, this may not
be necessary in your case. Extra support can be
cut out of multiplex, or multiple layers of triplex
and glued together. The swivel wheel is a wheel
we recovered from an old walking aid, but any
strong swivel wheel will do.
You will also need a inbus bolt, a nut, and a few
washers. This may not be necessary with your
wheels.
X2
1 hour 30 minutes
Belt saw, drill and sanding paper.
14 parts added.

25. 21 LOOPSCHIP 1.6
DESCRIPTION First we attach the
wheel to the front wheel support plate. You will
have enough room to use an hex-key to tighten
the bolt.
X2
10 minutes
Hex-key
M5 bolt, nut and washer
1 euro

26. 22 LOOPSCHIP 1.6
DESCRIPTION In the attachment
blocks on the main shape make 9mm holes for
the metal threaded inserts.
These we now use for attaching the main plate
with one bolt. Make sure the holes correspond.
X2
30 minutes
Drill, screwdriver, hex-key
M5 bolts, nut and washers, M5 screw-in nut
4 parts added.
5 euro

27. 23 LOOPSCHIP 1.6
DESCRIPTION Use a washer for a
better force distribution. Make sure the bolts
aren’t too long. The length of the bolt must
somewhere between the thickness of the
wooden board and that thickness added with
the depth of the threaded insert.
X2

28. 24 LOOPSCHIP 1.6
DESCRIPTION For the fourth and fifth
wheel you will need the same bolts and washers.
8 parts added

29. 25 LOOPSCHIP 1.6
DESCRIPTION Attached the wheel in
the second hole made in the board and block. If
everything is aligned right this should go
perfectly.
10 minutes
Hex-key
M5 bolts, nuts and washers

30. 26 LOOPSCHIP 1.6
DESCRIPTION
move.
Now the structure can

31. 27 LOOPSCHIP 1.6
DESCRIPTION These are the parts we
need, to make the seat. From left to right: the
PC seat, an extra pc detail, wooden base,
wooden pins, wood screws and a leather back
strap at the top. The back strap is recovered
from a different support apparatus.
Wood screws

32. 28 LOOPSCHIP 1.6
DESCRIPTION The polycarbonate
chair is bent with a bending machine. We first
cut out the shape and drew the bend lines. Make
sure you let the sheet dry in an oven at 60 °C for
about 24 hours before bending it. Otherwise
there will be bubbles at the bends. The groove at
the top is made for adjustability. This can be 2
simple holes too.
Technical plan 3
1hour 30 minutes + 1 day drying time
Belt saw and bending-machine.
PC board 60x70 cm
9 euro

33. 29 LOOPSCHIP 1.6
DESCRIPTION The 6mm transparent
polycarbonate plate can be bent by using a
warm paint blower. Be sure to put the
polycarbonate plate in a drying oven (on 70 °C)
for about a day. If you don’t do that bubbles will
form during the bending process. Once you
have heated the plastic up to a point where it is
getting strecheable, you can start bending.
15 minutes + 1 day drying time
Belt saw, heat blower, drill

34. 30 LOOPSCHIP 1.6
DESCRIPTION Bend the plastic by
holding it or fixing it with clamps. Be sure to use
pliers for holding the heated tip to avoid getting
burnt.
1 minute
Pliers or a vice

35. 31 LOOPSCHIP 1.6
DESCRIPTION The seat base is made
out of multiplex wood in our case. This can be
any kind of firm material (we used wood
leftovers). We will add two wooden axles to slide
the seat into the wooden main structure. These
are cut off peaces of a broom stick. The reason
for this ‘slide in’ seat is to make our product
adjustable to the user, and especially because
grow.
1 hour
Belt saw and sanding paper
Wood screws and a recycled broomstick
5 parts added

36. 32 LOOPSCHIP 1.6
DESCRIPTION Use wood screws to
attach everything together. The leather part is a
strap we reused from a different aid. This was
added to give our user more back support but it
depends on who will use it.
5 minutes
Screwdriver
1 standard strap
1 part added
1 euro

37. 33 LOOPSCHIP 1.6
DESCRIPTION Before placing the
saddle on the main structure you can ad springs.
The springs we used are recycled from an old
bycicle saddle. By using higher springs you can
adjust the height of the saddle from ground up.
1 minute
2 springs recycled
2 parts added

38. 34 LOOPSCHIP 1.6
DESCRIPTION Place in the saddle.
1 minute

39. 35 LOOPSCHIP 1.6
DESCRIPTION Add an optional
cushion to the seat. This cushion is cut in shape
with a belt saw. Mind that this cushion also
alters the height of the seat.
15 minutes
Belt saw
Recycled foam cut to shape
1 part added

40. 36 LOOPSCHIP 1.6
DESCRIPTION
structure.
Front support

41. 37 LOOPSCHIP 1.6
DESCRIPTION Make the mold first!
Use scrapwood, or what you can find and
construct a mold as in the image. Cut out 6
identical square pieces. Draw the curve on these
6 plates, make sure that the 6 plates and the
curve are exactly the same and cut the square
pieces following the curve. Now you'll have the
2x6 identical halves of the mold.
Now screw them onto a base plate. Use enough
screws and make sure that they fit nicely.
1hour
belt saw, electrical screwdriver
Some screws (18x 4,5x35mm)
3 euro

42. 38 LOOPSCHIP 1.6
DESCRIPTION When you have the
mold, make 3 identical curved plates by bending
and gluing pieces of plywood.
Use 3 layers of standard plywood (multiplex 3-
4mm thickness, 40 by 20 cm). Stretch the wood
first! Wet the pieces and put them in the mold
without glue! Fasten the clamps a little and leave
them for some time. Do this multiple times until
you’re sure that you can bend the wood without
breaking it.
When you're ready, put some glue between the
plates and clamp them again (as strong as
possible!). Wait for the glue to dry.
Multiple hours per plate (3x)
A set of clamps (6 or more)
Normal glue for wood
3 parts added
2 euro

43. 39 LOOPSCHIP 1.6
DESCRIPTION When the glue has
dried, open the mold and take out the curved
plate. Repeat until you have 3 pieces.
Now cut the plates to the desired shape. The
exact shape is not important and depends on
your patient. Maybe later on, you'll have to alter
the shape again to correct it.
Make sure, your patients legs fit between the
seat and the chest support, and that his arms fit
over it.
1h
Belt saw,

44. 40 LOOPSCHIP 1.6
DESCRIPTION
and slots in the plates.
Now cut out the holes
In the main plate, cut out 4 holes (diam. 5mm),
approximately 5 cm from the sides, and 5-8 cm
from the top and bottom.
In the 2 side plates make 2 slots, 5-6cm long,
5mm wide. Make sure they are positioned
relative to the holes in the main-plate.
To make the slots, we drilled 2 holes (5mm) and
cut out the part in between with a fretsaw.
Finish by sanding the plates.
30 min
Drill (5mm), fretsaw

45. 41 LOOPSCHIP 1.6
DESCRIPTION Attach the front
support bracket to the main plate. This bracket
consists of 2 slotted plates (slots 5mm wide)
hold apart by a piece of wood with the same
width of the main support structure.
The bracket is simply glued together, and
screwed onto the main plate. (center back, 5cm
from the bottom)
1h to glue the parts
Belt saw, drill, fretsaw, screwdriver
Screws (3x 3,5x30mm)
3 parts added
1 euro

46. 42 LOOPSCHIP 1.6
DESCRIPTION Position the straps
with the plastic connectors and the velcro strips
on to the plates. Use an old backpack for the
plastic connectors.
Position the straps according to the needs of
your patient. Remember that the position of the
plastic connectors, determine the position of the
back-support straps!
15 min
5 parts added

47. 43 LOOPSCHIP 1.6
DESCRIPTION When they are
positioned correctly, staple the straps and the
velcro to the plates.
You can use a pneumatic stapler, but a
mechanical one will do too.
15 min.
stapler
staples
1 euro

48. 44 LOOPSCHIP 1.6
DESCRIPTION Bolt the side plates to
the main plate, use bolts with a rounded head.
Use a washer at the back to prevent damaging
the wood.
10 min
wrench
4 bolts, nuts and washers (M5)
14 parts added
2 euro

49. 45 LOOPSCHIP 1.6
DESCRIPTION
cut the foam parts.
Now you're ready to
Find some old mattress, or foam-pillows to cut
them out.

50. 46 LOOPSCHIP 1.6
DESCRIPTION Use a sharp knife, an
electric knife or a belt saw to cut the foam.
We made 3 parts, one large thin part for the
main plate, and 2 triangular parts for the side
plates. We made them out of different types of
foam, but you can do it with the foam you can
find.
20 min
Belt saw or sharp knife

51. 47 LOOPSCHIP 1.6
DESCRIPTION Attach some velcro
strips to the back of the foam parts. Use self
adhesive-velcro for this.
Position the velcro strips relative to the strips on
the plates.
When necessary use some extra glue.
10 min.
Velcro
9 parts added
8 euro

52. 48 LOOPSCHIP 1.6
DESCRIPTION Now attach the foam
parts to the support, and you've finished this
part.

53. 49 LOOPSCHIP 1.6
DESCRIPTION Now you can attach
the chest-support to the main-frame.

54. 50 LOOPSCHIP 1.6
DESCRIPTION First drill a hole in the
main frame (5mm). Use the chest part to
determine where the hole should be. Make sure
you can height-adjust the chest-part as much as
possible.
Use a bolt, a nut an some washers to attach the
chest-part to the frame.
20 min
Drill
1 bolt, nut, 2 washers (M5x60)
3 parts added

55. 51 LOOPSCHIP 1.6
DESCRIPTION
support straps.
Now attach the back
We collected some straps from old wheelchairs
at the care institute of our patient.
You can use what you can find, according to your
patients needs.

56. 52 LOOPSCHIP 1.6
DESCRIPTION Now the chest-support
is completely finished and you can start with the
table.

57. 53 LOOPSCHIP 1.6
DESCRIPTION First thing to do is to
make a slot for the table cross beam. This slot
should be the same width as the thickness of the
cross-beam (24 mm see also next step) and 2-3
cm deep. Make the slot by cutting the sides with
a thin saw, and then chopping out the part in
between with a chisel.
Make a hole at the bottom of the slot, and one
at the tip of the frame (9mm). Screw in a “screw-
in nut” in each hole.
1 hour
Hammer, chisel, thin saw, drill, screwdriver
2x “screw-in nut”
2 parts added
1 euro

58. 54 LOOPSCHIP 1.6
DESCRIPTION Now cut out the cross-
beam. We started by gluing two plates of
plywood together to make a plate with thickness
of 24 mm.
Make sure your cross-beam is big enough to
support the table. Make it 40 to 50 cm long
depending on the width of your table.
Cut out a rectangular part where the frame fits
in (same way as before) and drill 3 holes: One for
the connection to the frame and 2 for the table.
(5mm)
1,5 hours
Belt saw, hammer, chisel, drill

59. 55 LOOPSCHIP 1.6
DESCRIPTION
beam to the frame.
Now bolt the cross-
5 min
Hex-key
1 M5x25 bolt
2 parts added
1 euro

60. 56 LOOPSCHIP 1.6
DESCRIPTION Now drill holes in the
table relative to the holes in the cross-beam and
the frame.
We used the table from an old standing aid
belonging to our patient. Again, you can use or
make any table you want.
Use rounded or sunken bolts, so they don't stick
out of the table.
20 min.
Drill, wrench
3 bolts and nuts
6 parts added
1 euro

61. 57 LOOPSCHIP 1.6
DESCRIPTION Draw in Illustrator the
table and the 3 circles, different sizes, repeat the
big one twice and the other two 4 times each
one and one without any cut inside.
45 minutes.
Computer with Illustrator.

62. 58 LOOPSCHIP 1.6
DESCRIPTION
laser cut.
Send the file to the
1 hour 30 minutes
Laser cut
2 layers of multiplex wood
2 euro

63. 59 LOOPSCHIP 1.6
DESCRIPTION Make the toys.
3 hours
Little cars, plastic figures, foam, wire, wood
colored balls , springs and paint.
24 euro

64. 60 LOOPSCHIP 1.6
DESCRIPTION Glue together all the
circles that are equal, putting the toys in their
places.
40 minutes
clamps
Wood glue
4 euro

65. 61 LOOPSCHIP 1.6
DESCRIPTION
figures.
Glue together all the
40 minutes
Clamps
Wood glue
2 euro

66. 62 LOOPSCHIP 1.6
DESCRIPTION Cut the foam with the
form of the push figures and put it under each
figure and glue it to the base, the circle with all
the figures cut, to create the button effect, then
Velcro under each figure to attach to the foam.
1 hours 30minutes
Band saw and cutter
Foam, velcro and paint
1 euro

67. 63 LOOPSCHIP 1.6
DESCRIPTION Drill three M4 holes in
the wood table to place the three circles,
without touching each other.
10 minutes
Drill

68. 64 LOOPSCHIP 1.6
DESCRIPTION Put on each hole one
screw from the back to the front. After the
wood, put on each screw one sheave to make it
stay still and firm.
5 minutes
Screwdriver and pliers
Screws and sheaves
5 euro

69. 65 LOOPSCHIP 1.6
DESCRIPTION Place each circle in
their respective screw. Place another shave in
the end of each screw to avoid the circles to
come out when they turn.
1 hour 30 minutes

70. 66 LOOPSCHIP 1.6
DESCRIPTION Finished peace.

71. 67 LOOPSCHIP 1.6
DESCRIPTION Finished piece.

72. TECHNICAL ADDENDUM
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73. 1
70
90 70

74. 2
Height of the table -
wheelheight
(70)
(40)
Height of the legs – (wheelheight +
seat height)

75. 3
(30)
(10)
(40)
(10)

76. TEAM CONTACTS
http://designforeveryone.howest.be/

77. sucobona@gmail.com
TEL +52 14 42 35 99 0 34
stevenverbrugge@hotmail.com
TEL +32 474 66 72 50
filipgerits@yahoo.com
TEL +32 485 82 70 83
mpi@zonnebloem.telenet.be
http://designforeveryone.howest.be/