>> Major funding for Design Squad Nation is provided by: >> The National Science Foundation, where discoveries begin.

Series funding is provided in part by NASA-- the National Aeronautics and Space Administration.

>> Northrop Grumman Foundation, supporting innovative education experiences for students and educators.

>> And the Lemelson Foundation.

The Foundation sparks, sustains, and celebrates innovation and the inventive spirit in the U.S. and developing countries.

Additional funding is provided by: United Engineering Foundation... >> ...Motorola Foundation.... >> ...and IEEE.

>> I'm Judy.

>> And I'm Adam.

We're engineers.

>> We work with kids... >> This is so cool!

>> ...to make their dreams come true through engineering.

>> ( speaking in Spanish ) >> If you can dream it, you can build it.

>> I never really thought I could do something like this.

>> That was really fun.

( laughing ) >> On Design Squad Nation.

>> My name is Beatriz, and I live in Emeryville, California.

I like to have a lot of fun.

I like to hang out with my family, my friends.

This is the school, Emery High School.

It's a really small school.

There's only 400 students.

You know that mural?

I helped make that mural.

I like expressing myself, especially through art and music.

So that's why I like to play the trumpet.

Right now I'm in the jazz band.

I never used to listen to jazz, but then, like, it's kind of different.

It's kind of, like, oldish, kind of.

So that's why I like it.

>> We'll come in with the hits.

They'll go (sings part) then we'll go (sings part).

Ready?

One, two, three, four.

>> Our teacher always says play what's in your heart.

So it's kind of like a way for you to express yourself and what you're feeling.

I like being creative and creating new things.

Like this bike.

When I finished this bike, I felt really proud, because I got to put in my ideas into something that I created.

Like, you never see anything like this, and creating it was art, so it expresses my artistic side.

We're having a block party on Friday at my school.

We're going to have, like, carnival games, and there's going to be music and food.

I'm really excited, because I'm sure everybody's going to have fun.

As you can tell, I have a love for music, but I also have a love for making bikes.

And I would like to somehow combine the two ideas and create something very, very special, so that it can be unveiled at the block party.

>> Wow, it is a beautiful day today.

>> Yeah, it's really nice outside.

>> Yeah, perfect day for a bike ride.

>> Yeah.

>> Oh, hey, Beatriz, how's your jazz band coming along?

>> It's going good.

We're just, like, practicing, because we're going to have a block party on Friday.

>> Cool.

>> And I was wondering if you guys could help me build something for the block party so I can show it off.

>> Nice, for sure.

>> What do you have in mind?

>> I'm thinking something music related, but also related to a bike, since I built this one.

>> What do you think?

Should we go figure out how this musical bike is going to work?

>> Yeah, let's go.

>> Nice.

>> I have the perfect place where we can build the bike.

It's called the Crucible.

>> Nice.

>> It's where I built my other bike.

The Crucible is, like, a fire arts organization.

So it's a lot of stuff with metalwork, welding, and blacksmithing.

It's a really cool place.

>> This place is amazing.

>> This is so cool.

>> I know.

>> This is my kind of workshop.

>> Look at this.

>> Yeah, it's going to be cool.

>> I think I'm going to like it here.

>> Yeah.

So I'm going to take you guys to the bike shop so we can create the plan.

>> Yeah.

>> All right, let's go.

>> So Beatriz, what are you thinking about for this musical bike?

>> So I was thinking maybe something that's pedal powered, like a pedal powered instrument.

>> Hmm.

>> What about an organ?

>> A pedal powered organ?

>> Yeah, a pedal powered organ.

>> Pedal powered pipe organ.

Say that three times fast.

>> Pedal powered pipe... >> Normally, right, we have our wheel here.

And here's the handlebar.

And then the other wheel's back here.

>> Mm-hmm.

>> But if we do that, it seems like there's not going to be enough space, right?

So what if we build a platform there?

>> Yeah.

>> What if it's a trike?

What if we kick it out, make it nice and wide?

>> That's a great idea.

>> Yeah, because then, like, you'll have two wheels in the back, and it'll carry more... like, it's more stronger in the back.

>> So where's our second person?

Where's our player?

>> So maybe the person should be, like, in the back of this one, like, their backs... yeah.

>> Oh, they're back to back.

>> Yeah, back to back.

>> So what if we... let's put a seat right there.

And let's see.

What drives an organ?

We need some sort of bellows, right?

>> Yeah.

>> Air, yeah.

That's what creates the air for the organ.

>> Pipe organ's there.

>> That'll look really cool with the pipes there.

>> Yeah.

>> What do you think?

>> Looks cool.

>> I like it.

>> Here's how the bike organ will work.

When you turn the pedals, the bike crank pushes and pulls a bar that is connected to a pump called a bellows.

The bellows has two valves that let air in and out.

When the bar pulls on the bellows, it expands, drawing air in through the inlet valve, and sucking the outlet valve closed.

When the bellows is completely expanded, the bar starts to push on the bellows.

This decreases the volume inside the bellows, which increases the air pressure.

The high pressure air inside the bellows pushes the inlet valve closed and forces the outlet valve open, releasing the pressurized air into the pressure regulator box.

The pressure regulator box stores pressurized air from the bellows.

It has a heavy top that pushes down on the air inside the box to keep a steady flow of air to the pipes, so the organ can keep playing while the bellows is refilling with air.

Each organ pipe is connected to the regulator box through a valve that is also connected to a key on the keyboard.

So when a key is pressed, its valve opens up, sending air from the regulator box into a specific pipe to play a specific note.

>> We have a lot of work.

>> What do you think you're going to do first?

>> I think we should go look at the bikes.

>> Yeah?

Okay.

>> All right, you guys want to do that?

I'm going to look at the shop, look around.

>> Okay.

>> See you in a bit.

>> Okay.

>> Whoa, you guys have a huge stash of bikes.

>> I know.

There are so many.

I like this one because it's yellow.

I like the color.

Oh, a trike.

>> Tell me why you like this one.

>> It looks like it could be comfortable, with the handlebars.

>> So you think this is the one?

>> I think this is it.

>> Should we take it?

>> Yeah, let's take it.

>> So I think this is the perfect bike.

So we're going to have to build a platform that goes from the seat to about where I'm standing.

All right, you ready for a ride?

>> Yeah.

>> Looks like a smooth ride.

Judy, Beatriz, I want you guys to meet Rusty.

Rusty's a bike builder here at the Crucible.

>> Hi, guys, good to meet you.

>> Good to meet you too.

>> Good to meet you.

>> He's going to be helping us turn this guy into our creation.

Should we start chopping?

>> Yeah.

>> Yeah?

>> Get to it.

>> Let's do it.

>> Cool.

Let's do it.

>> Okay.

>> See you in a bit.

>> Rusty and Beatriz today are going to work on the bike while Judy and I work on the organ.

>> So we're going to weld a platform where the organs are going to be in the back.

I think the plan that we've come up with is very cool, because it's like something that you've never seen before, and I'm glad that I was able to combine both music and combine my like for welding things together and putting things together.

So I'm really excited about that.

>> Looks great.

>> And now we weld.

>> Now, that's a nice strong weld.

>> Okay.

>> You're a good welder.

>> Thanks.

>> That's really good.

>> Thanks.

>> So we've got to make basically two projects for the price of one.

Bike and organ, put them together.

First off, got to make this whole, like, mechanical bellows.

This is just a thick, heavy paper, like a card stock.

So what I'm doing is I'm folding this whole thing, and eventually this is going to turn into a big accordion.

Man, I've got a long way to go.

All right, this is almost done.

Mmm, look at that.

That was a bit of work.

Well, I made these valves.

It's just a little piece of rubber that flaps up and down.

So what a valve does is a valve lets air go one way and not the other way.

That's all it is.

It's just sort of a one way yes, one way no.

So here's a hole right there.

And all I'm doing is holding it here so it can flap back and forth to open that up.

So watch what's going on right here.

You're going to see this flap back and forth.

>> Did you just hyperventilate?

>> Yeah, I did.

I've got to take a breath.

Whew!

This is tough work.

Watch that flap.

This is great.

This is really, really, really good.

>> You think I could use this for a hair dryer?

This box is going to be a pressure regulator.

When air goes in, this is going to raise up to maintain the pressure to the pipe.

What I'm doing here is cutting out the hole that the bellows is going to sit on.

We're going to be working pretty hard to get this done, but we kind of just have to at this point.

>> This is a real axle.

>> Does that fit on?

>> Yep.

>> Nice.

There we go.

>> Oh, that's pretty cool.

So we're going to stand right here, the seat's going to be right here, and the organ is going to be right here.

Somebody's going to go like... >> So the silver stuff here is just going to make the bellows a lot stronger.

We don't want any air to leak out, so it's going to help prevent air from leaking.

Last piece, last bellow.

Judy, I can't wait to be done with bellows.

>> But you've gotten so good at it.

>> I know.

>> Should we try to put it on the box yet?

>> Do you want to do it?

>> Yeah.

>> I'm a little nervous, because we haven't tried the whole thing out yet.

So we're ready for a moment.

This is a scary moment.

>> This is a very big moment.

>> Oh, okay.

>> Here's what we hope will happen.

>> Here's what we hope.

>> So as we pump, as we pump all three, this is going to rise up.

>> Okay.

>> Right, and when it rises up, it should kind of stay up.

>> Okay.

>> That means we've got... that whole box is full of pressurized air that's going to go out the pipes in our organ.

So what you want to do is kind of just make sure that this thing just goes right in the center of that hole.

>> Okay.

>> So I'm just going to put the bottom on there.

>> Like that.

>> There you go.

My heart is racing here.

>> Yeah, I know.

>> Start to pump.

Yeah!

>> Okay, it works.

>> It works.

All right, that's a big step.

>> You have no idea.

I was like, "I hope this thing works."

>> There's a lot of pressure in there, actually.

I'm pushing pretty hard on that.

>> It's so cool.

I love it.

It's going to be perfect for the block party, because it's so unique.

>> Nice job today, guys.

>> Yeah, good job.

>> So I'm starting to drill the holes that's going to hold the organ pipes.

Today is going to be a huge day.

We still have a ton of stuff to do.

Rusty and Beatriz working on the bike frame, and making sure everything was ready to go, and then Adam and I have been working on the organ parts itself.

So today everything comes together.

And it's going to have to happen fast.

So with the very little time that we have to make this, what we decided to do was go ahead and buy organ pipes.

So imagine trying to make almost 40 of these.

That would just take up a lot of time.

So we went ahead and bought it.

These are going to get mounted together.

So we're going to see something like this.

Nothing's glued yet.

It's a little wobbly, including this, because we haven't screwed this down.

But you get an idea.

So if you can imagine, this whole thing would be like that.

>> We're going to weld the platform to the bike.

Ready?

>> Yep.

>> Okay.

Is that okay?

>> Yeah, that's great.

Good job.

>> Okay.

>> Hey, you've got the welding skills.

>> And it's ready to take it for a ride.

This is fun.

Are you tired?

>> A little bit.

>> This thing is solid.

>> (sings opening of Beethoven's Fifth Symphony) >> Whee!

>> Looky!

>> Oh, we've got a keyboard.

>> Keyboard time.

>> Yeah, Judy.

Sweet.

>> Yes.

So we went and found an old keyboard that we're going to hack apart.

We're going to use the keys.

And the keys, as you press, is going to hit an electronic switch.

It's going to send a signal to this right here.

This is a solenoid.

So what the solenoid acts like is basically a valve.

It's going to control the air going in and out of the organ pipes.

This is going to get mounted here.

It's mounted like this, underneath.

And when a key is pushed, this solenoid is going to open up and allow air to go through to enter the pipes and play a note.

>> There's 37 different switches that have to get wired up to trigger with each of those piano keys to power each solenoid.

It's just a lot of stuff.

>> About 400 feet.

>> Nice.

>> I finished my part by doing a frame, and it's really, really strong.

I'm going to have Adam and Judy finish the rest of the organ parts.

How's the organ going?

>> Well, it's going well, but Judy and I will definitely be working late, late, late tonight, well after you take off.

But we'll see you tomorrow at the block party, and I think we'll have a big surprise.

This thing will be working awesome.

>> Okay.

So I really wish I could stay with Adam and Judy to finish the bike, but unfortunately I can't, because I have a lot of homework to do, and I have school tomorrow, and tomorrow's the block party.

But hopefully everything turns out really good.

Bye, you guys.

See you tomorrow.

>> Bye, Beatriz.

See you tomorrow.

>> Bye.

>> Good night.

>> It's the night before this thing has got to be out at the block party.

And there's a lot left to be done.

We are working late night.

Tonight is going to be a lot of wiring.

We have to get all of the keys wired up.

>> We've still got a ton of work.

We're all just absolutely exhausted.

I'm waiting for the birds to come out and start tweeting, and then I'll know, like, it's official.

It'll be an all-nighter.

>> Mm-hmm.

>> Look at that.

>> Mm-hmm.

Want to just go down the line?

>> Cool.

>> Yeah, let's put it together.

We're going to put the bellows on for real.

>> When you're tired, lots of mistakes are going to start happening.

>> What happened?

>> I put them on backwards.

This is the back side.

>> Yep.

>> Wow.

This is like being in the last leg of a marathon and spraining your ankle and crawling, and then getting a splinter in your finger and crawling on one hand.

This is familiar.

I just feel like we did this before.

>> At least twice.

>> It's going to be nice to have this one behind us.

Moving on.

Let's put this guy on the bike.

We are hooking up the bellows, which we just assembled, to the crankshaft, which is a piece that is connected to the pedals, and drives the bellows.

So there's going to be, like, a big pushrod pushing it back and forth.

>> But that's the permanent connection, with tape?

It's going to break tomorrow.

>> So this is the first time.

What we are hopefully going to see is what happens when you spin this crankshaft, whether we move these bellows.

I'm pretty excited to see this work out.

Judy, you ready for this?

Let's celebrate.

I love it.

It's pretty cool.

And there's a lot left to be done.

>> I think this is good, but it's still... yeah.

And we can pull it out this way, right?

>> Last little check.

>> All right, getting glued.

This is actually a pretty cool moment, because this is when it actually looks like a pipe organ now.

Before it just looked like, you know, boxes.

Now it's coming together.

>> Judy, check it out.

>> Nice.

>> Adam, what do you think about this?

>> Oh, yeah, the bike handlebar.

>> How cool is that?

>> That's inspired, Judy.

That's awesome.

>> Let's do that.

>> Weld that right in the middle there?

That's simple.

That's easy to do.

>> Yeah.

>> Yes, let's do that.

This is going to look cool.

>> The block party is officially started, so have fun.

>> All right, Adam, I think we're out of time.

We've got to go.

It's just... we're going to be... we're going to totally miss the block party.

>> What if we just have just the bellows pedal powered?

>> I think that's the best compromise we have right now.

Because we can't just not show up, right?

So what that means is the bike itself is not going to move, but the organ will be pedal powered.

>> Let's put a chain on that.

>> I'm wearing out really, really, really fast.

Okay.

>> Give it a spin, see what happens.

>> Wow.

It's pretty hard to pedal.

Ready?

Two, three.

There you go.

You okay?

>> Yep.

>> Okay, up.

All right, Adam, we've got to go.

>> All right, guys.

>> Got the front.

>> Nice job, guys.

>> It's coming.

Wow, I can't believe this.

It's cool.

>> Check it out.

>> Wow.

>> This is your bike.

>> Come, step up.

>> Okay.

>> Step right up.

>> Wow.

This is so awesome.

>> You ready to play?

>> Yeah.

>> Wow!

>> This is so cool.

>> I know.

>> I feel like we're at the carnival.

Sounds good to me.

>> I know.

>> So this is my brother, Gerardo.

It was a good experience for me, and I learned a lot.

And I was part of, like, a bigger team.

That also felt really good.

>> Girl's got skills.

>> Yeah.

Oh, you guys, this is Mr. Brown.

He's my band teacher.

>> This is awesome.

>> Yeah.

>> I think engineering is fun.

I didn't know that engineers built, like, cool stuff like this, so that was pretty eye-opening for me.

>> Guys, dirty hands.

Dirty high five.

This is awesome.

This really... this feels good.

>> We still have a little bit of work to do.

You could take it back to the Crucible and finish up the last little bits.

>> Okay, that's cool.

So as you can see we finished the bike organ, and it looks really, really good, but it sounds even better.

Hit it, Malik.

(organ playing) >> Major funding for Design Squad Nation is provided by: >> The National Science Foundation, where discoveries begin.

Series funding is provided in part by NASA, the National Aeronautics and Space Administration.

>> Northrop Grumman Foundation, supporting innovative education experiences for students and educators.

>> And the Lemelson Foundation.

The Foundation sparks, sustains, and celebrates innovation and the inventive spirit in the U.S. and developing countries.

Additional funding is provided by: United Engineering Foundation.

>> Motorola Foundation.

>> And IEEE.

>> Hey, Adam, check this out.

It's the Design Squad Nation Web site.

You can play games on it.

>> Whoa, sweet!

Hey, look at this.

You can watch videos from the show and you can sketch your own new designs.

>> And there's a ton of amazing designs on here from kids at home.

This is a hat that plays music.

>> This instrument makes sounds when you squeeze water though its tubes.

>> And here's a wild combination that five people can play at once.

>> So join Design Squad Nation at pbskidsgo.org.