Video: Build a Wood Kicker Using Dartmoor's Bike Box

May 19, 2015
by Dartmoor-Bikes  
Views: 24,389    Faves: 206    Comments: 17

Is it possible to recycle your bike box into a wooden kicker? Yes, if you have the box after buying a 2015 Dartmoor jump bike. Watch this video and read the instructions below, prepared by the Dirt it more crew.

how to build wood kicker

You hear a lot of 'think outside the box' stuff, but today we go the opposite way and ask you to look inside of your brand new Dartmoor bike package box where you will find a complete kicker side wall profile printed on the cardboard. All you need to do is to cut it out, redraw all the pieces on wood, cut them out and put all of the pieces together like a pack of Lego! But to make your work easy and effective please follow these simple steps:

1. Start with collecting all the needed tools and materials

how to build wood kicker
An extra friend might be also very useful to help you with cutting the wood, carry heavy parts or shaping the plywood.

2. Now when you've got all of the stuff ready and a friend waiting for your orders you can start the construction process! Start with careful preparation of cutting templates and redrawing them to the plywood. We advise to use a long metal ruler for drawing long straight lines.

stencil on plawood

3. All the cardboard templates should be redrawn according to the scheme above. Spare plywood will be used in another steps. Now cut all drawn elements using a circular saw or jigsaw. Don't do this in a rush and take care on all the details - it is very important to make it as precisely as possible.

Using Dartmoor s Bike Box to Build a Wood Kicker

4. Now combine all the cut pieces together with boards according to this scheme below. Each connection needs to be secured with at least 6 screws.

Using Dartmoor s Bike Box to Build a Wood Kicker

Using Dartmoor s Bike Box to Build a Wood Kicker

5. When both side walls are completed connect them with 1230mm long boards starting in all three corners. Keep about 200mm space between each board. It should look like this when ready. Use 4 screws to connect each board with the side walls - 2 per side.

Using Dartmoor s Bike Box to Build a Wood Kicker

6. Now it's time to put the plywood on our wood skeleton. Carpenter clamps might be very usefull in this step to keep it tight at the top of our construction. Starting top to bottom remember to take special care on the sides of mounted plywood. It has to be straight and keep the edges of the whole construction in one place. Each plywood-board connection should be secured with 3 screws - on both sides and in the middle.

Using Dartmoor s Bike Box to Build a Wood Kicker

7. The last step is mounting the long diagonal board at the back of the construction. This one will keep the horizontal stiffness of the kicker. Put the board at the back of the construction and shorten the board on both sides to fit it to the kicker. Attach it to the side walls with screws.

Using Dartmoor s Bike Box to Build a Wood Kicker

Using Dartmoor s Bike Box to Build a Wood Kicker
Don't forget about proper impregnation if you want to keep the kicker outdoors!

Your brand new kicker is ready for your first jump up to 3m long. Now you "only" need to prepare a comfortable landing and your jump will be ready to ride. If you need a bigger kicker you may try to contact us for other designs. We're waiting for the pictures of your complete kickers built according to this guide. Best constructions will be awarded!

Use professional tools and handle them with special care when working with wood. If you don't know how to use those tools - ask someone experienced to make it for you. Always wear eye protection when cutting wood, otherwise you risk your health and life! When riding your bike always wear a proper protection gear and listen to your mother!


The idea for this project, photos and video by DIRT IT MORE
Supported by DARTMOOR-BIKES


MENTIONS: @dart-bikes



Posted In:
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60 Comments

  • 16 0
 They only give the kicker, seems like Fail Friday videos submission will be tripled.
  • 62 1
 My mom doesn't want me to jump my bikes. So I would probably use the kicker to launch hotwheels. Is that safe?
  • 33 0
 Not if they're limited edition, then they're made of lead and will break it
  • 35 1
 Run away from home. Leave the hot wheels. Take your bike.
  • 3 1
 get lots of hay for the landing, she may say yes. Build it with friends and choose a location with a soft impact area
  • 16 0
 When I was like 10 I got mad at my mom and decided to "run away" all I took was my bike. I rode around for like 10 minutes then got thirsty and came back for water then left again. I was out of the house riding on a trail for like 3 hours then decided I had made my point and came home.
  • 54 1
 Not going to lie, I was kinda hoping that you could just fold the box up and make a kicker... This takes work! Fun idea, though.
  • 18 1
 I thought so, too. Imagined the Napolean Dynamite scene when he jumped the "Sledgehammer" HAHA
  • 17 0
 "Don't forget about proper impregnation if you want to keep the kicker outdoors!"
  • 6 1
 haha!! Google translation is AWESOME!
  • 13 0
 If your using a circular saw, remember to watch for knots, or you end up with less fingers than you started with. Pretty impressive saw work if they used a circular saw to cut those round shapes.
  • 18 0
 The key to cutting a radius with a circular saw is to have the blade depth set fractionally over the thickness of the material, it reduces the amount of contact between the saw and the material and makes it easier to create curves.
  • 8 0
 What scouse said. Many years of construction experience will teach you little things. If your not comfortable cutting a curve with a circ saw, you can use a jigsaw instead.
  • 5 0
 the key to keeping all your fingers is holding the saw firmly and looking at what you are doing!
  • 14 0
 Can Dartmoor just send me a box. I've got a bike. Now I need jumps
  • 10 1
 If you are building this get Torx screws and NOT Phillip head screws, it will save u a ton of bits and make ur life a whole lot easier, you can thank me later Smile
  • 8 0
 Why Robertson's haven't become an international standard is beyond me. Even better than torx for not stripping.
  • 11 1
 I got one of these in my Kellogg's Corn Flakes box...Smile
  • 7 0
 very original packaging for re-using haha loved it!
  • 6 0
 Was waiting for Laurel & Hardy to rock up and give it a test ride ... haha
  • 5 0
 I thought the final thing to see in the vid would have been someone actually using the kicker .... the music was funny though Smile
  • 7 1
 Henry Ford would be proud.
  • 5 3
 It's hardly recycling when you've got to use a load of new wood. Like RedBurn said, it'd be quicker and greener to make it from dirt. So thanks Dartmoor for giving us the template to make a nicely shaped dirt kicker!!!
  • 9 1
 i completely agree with you on this being hardly recycling, but this is way easier than digging an building a kicker out of dirt. Especially if there is only one guy digging with a shovel. You could do this alone in an afternoon. Good luck trying to build anything close to this size alone with just a shovel.
  • 23 0
 Challenge Accepted! Big Grin
  • 2 1
 yeah, given the right dirt this could be pretty easy to dig/build...

pretty certain the material for that box can be recycled anyway too, so Dartmoor should just ship their bikes with free tools instead!
  • 1 0
 At least you can burn this if you get cold!
  • 2 2
 omg yes, Dartmoor have a great idea in that this is fuel for a winter fire when you're out building your (extra emphasis) DIRT jumps ;D
  • 5 2
 Now THAT..............is doing the whole recycling thing proud! Go Mother Earth.
  • 1 0
 hehe
  • 3 0
 It's idiot proof! build a kicker as per instructions, what could go wrong....
  • 7 0
 Haha! Fingers. Who needs them anyway!
  • 4 0
 Was that the music from Mario 2?
  • 3 0
 Hopefully it says you need a landing for it. Otherwise I hope they don't sell it to us Big Grin
  • 1 0
 actually get dirt for landing without tractor is damn hard ! Big Grin
  • 4 0
 lovely music!
  • 1 0
 Does anyone have some good dimensions of such a kicker?
Height and length?
Thanks guys! Smile
  • 8 0
 Just buy the bike and you'll get the box with all the dimensions you need.

You already have a bike you say. Sorry, I should have known, was just trying to be funny. I recall Billy (Trailstar) Thackray did an article in Dirt mag a long while ago. Not sure whether it was the edition dedicated to backyard pumptracks. If you have it, you may want to dig it out. When working with wood, you'd probably just go with a constant radius as it is easiest to construct. So check your favourite dirts how high they are and how steep the lip is.

Say:
h = height
a = angle of the lip relative to horizontal

then:
r = radius = h/(1-cos(a))
l = length = radius*sin(a)

Does that help?
  • 3 0
 Helped for my maths GCSE! Thanks Salute
  • 2 0
 Awesome!! Beer
  • 2 0
 great idea !!!
  • 1 0
 The music from the vid makes me want to go play super mario bros. 2!
  • 1 0
 Is it just me or is that dude working at Super Sonic Elf speed???
  • 1 0
 how much did it cost to build ??
  • 1 0
 That`s not a 10mm ply on the build pictures. (transitions)
  • 1 0
 it is Smile
  • 1 0
 I'm on that this weekend!
  • 1 0
 that was great!
  • 1 0
 Yes!
  • 1 0
 This is GENIUS!!!!!
  • 1 0
 Great idea !! Smile
  • 1 0
 excellent advertising
  • 1 0
 so good
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