DIY bicycle toe clips
Part of my blogging strategy is to try and add bits of information to the internet that I could not previously find. When the old, plastic toe-clips on my Shimano 105 pedals broke, and I learned that the bike shop wanted $75 for a replacement set, I decided to make my own. I’ve used them for a few months now and they’re working great.
With the hope someone out there could use the info, here is a quick howto for building replacement toe clips from the lid of any old piece of electronic equipment.
Scrap aluminum sheet metal
Permanent marker for layout (silver sharpie for black sheet material)
jigsaw with metal-cutting blade
drill press (or hand-held drill and punch)
Dremel with cut-off and grinding (de-burring) blades
I used the lid from a broken audio electronics component. The case from an old DVD player or similar would be good. Most such cases are made of aluminum, which will be much easier to work with than steel.
Trace the shape of the original, plastic pedal on the sheet metal. As my original pedals were a bit small, I added an extra inch or so to the long tail of the shape. Use a punch to mark the locations for the screw slots, one at the center of each end of each slot. Cut the shape with a jigsaw and deburr the edges with a Dremel grinding wheel. Drill two holes for each slot and remove the metal between them with a Dremel cut-off wheel.
Use the original pedal to estimate the bend points for the new shape. I used my largest pair of shoes as a guide to make sure my toes had enough room.