I recently embarked on creating a wheel system upgrade for Ion’s marvellous portable boom box - the Block Rocker.
The current wheel system that the Block Rocker is issued with works well when being pulled on flat surfaces and make an excellent use of space. The issue arrises when pulling the Block Rocker over uneven pavement or hard ground. The weight of the Block Rocker can very easily crack the standard issue wheel system, greatly impairing it’s portability.
Using SketchUp and an Ultimaker 2, I prototyped an alternative wheel system, consisting of two 3D printable brackets and a number of off the shelf parts. The bracket system is designed to fit into the original wheel system’s place using the same threaded bolt holes. These brackets then hold wheels with a larger diameter at the sides of the Block Rocker to create a smoother ride, capable of being pulled over slightly rougher terrain.
Here is the list of parts needed for the upgrade:
1 x 460mm (approx.) length of M8 stainless steel rod
2 x M8 standard nuts
2 x M8 lock nuts
6 x M8 washers
4 x M4 round headed bolts (15mm long)
4x M4 washers
2 x scooter wheels (approx. 100mm - 130mm diameter) including bearings.
1x Left 3D printable bracket
1 x Right 3D printable bracket
For 3D printable bracket files see: https://www.youmagine.com/designs/ion-block-rocker-wheel-hack
And a little secret… I couldn’t resist fitting this Block Rocker with some scooter wheels that double up as disco lights when on the move: