Freemotion Elliptical Roller Wheel Replacement

thingiverse

UPDATE: After light use over the last year, yes I know, I should exercise more!, this thing failed spectacularly (broke along one of the layer seams), causing me to fall off the elliptical again....the moral of this story is that you can't fix the design flaw with just a 3D print... BOTTOM LINE - DO NOT PRINT/PUT WEIGHT ON THIS - it will NOT work for the long term! Check out my YouTube channel https://www.youtube.com/channel/UC82xXciVxsQKthONKeYbhnw for how-to videos about 3D modeling, printing and home automation. I own a Freemotion 545 Elliptical, which has a pretty bad design flaw - there's a single track per foot, with a roller wheel that rides along it. On several occasions during exercise, one of my roller wheels fell off the track, almost causing me to fall off the machine and hurt myself. I decided to try designing a solution for this problem, and here it is. This replacement wheel has the same internal diameter (i.e., the part that sits on the track), but a more aggressive curve, and the walls of the curve are larger, helping keep the wheel more securely in place. I've printed this from PETG, for the strength and flexibility that material offers (with 80% infill, since it'll be bearing a lot of weight). Use with two R10ZZ bearings. All in all, about $15 worth of plastic and bearings (replacement units online go for ~$120), and solves the problem pretty well! Check out my (mostly functional) 3D designs - https://www.thingiverse.com/bkpsu/designs! If you like them and want to support my projects, use one of the links below when you're planning to buy anything from these sites (it won't cost you anything extra!). Thank you in advance! Banggood: https://goo.gl/uXGg84 AliExpress: https://goo.gl/KRNurW Amazon: https://goo.gl/nWhmjJ