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Old 10-09-2017, 08:59 AM
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Default 2017 - !Arriba!

Picked up some 1/2" schedule 40 water pipe from Home Depot
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Old 10-09-2017, 09:11 AM
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and we'll see what you're going to do with it hopefully

'sid
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Old 10-09-2017, 10:18 AM
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Old 10-09-2017, 03:55 PM
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So

...here's the plan


Cut it up into several pieces

...(2) side rails

...(1) rollbar/seatback

...(1) steering support


Next

...dig out the pipe bender
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Old 10-09-2017, 10:42 PM
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Side rails (2 @ 56" ea.)

Left Rail

measure 12" - mark
measure 10" - mark
measure 20" - mark


put in bender
1. @ 12" do - 35 pumps

2. @ 22"do - 20 pumps
(inverted 180* from 1st bend)

3. @ 42" do - 75 pumps
(leaning inwards, toward 1st bend ~20*)


Right Rail

Do everything the exact same but, exactly opposite
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Old 10-10-2017, 07:44 AM
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Bends came out pretty good

Welded the rollbar/seat back down to the (2) side rails

& welded the curled up parts to the back side of the rollbar/seat back
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Old 10-10-2017, 03:50 PM
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Used a ratchet strap to precisely draw the sides together

Tack welded the ends of the sides to the front axle bar

That'll hold it together for now

Next, we'll square up the rear end
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Old 10-11-2017, 03:34 AM
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Looking good so far!! Nice work
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Old 10-12-2017, 10:46 PM
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Welded a ~16" piece of 1 1/4" angle steel across & between the side rails right where the rollbar/seatback come together

This is where the rear axle will mount & will also be the front support for the battery box


The rear axle-

The original plan was to use (2) axles & (4) pillow block bearings


* RE-EVALUATE

Unnecessary & too heavy


* Exploring options
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Old 10-13-2017, 07:20 AM
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Huh. I figured the rear axle would be hanging off the back loops.
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Old 10-13-2017, 09:45 AM
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Quote:
Originally Posted by ezcome-ezgo View Post
Huh. I figured the rear axle would be hanging off the back loops.
That's where the power pack & propulsion unit(s) go

Goin'

...for little & big @ the same time

small foot print with lots of room

& lots of power


But, also


...lightweight & heavy duty @ the same time

I am using a minimalistic approach

& trying to make it strong by design


Goals-

easy to enter & exit

comfortable to drive

powerful - torquey & speedy (over 20 mph)

strong but, don't over build it (keep her ~100 lbs.)
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Old 10-13-2017, 12:31 PM
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Picked up some stuff

dual flanged hubs w/ 5/8" sealed bearings

6" drive wheels

72T #35 sprocket(s)


So, goin' with

15 x 6.00 - 6 rear tires & a 7.2:1 gear ratio
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Last edited by Functional Artist; 10-13-2017 at 03:01 PM. Reason: math error
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Old 10-13-2017, 01:50 PM
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I'm liking that Martin sprocket, they've got a plant just a few blocks from my house.
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Old 10-13-2017, 09:29 PM
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Quote:
Originally Posted by ezcome-ezgo View Post
I'm liking that Martin sprocket, they've got a plant just a few blocks from my house.
Yup! looks like good, quality stuff & made in U.S.A.
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Old 10-14-2017, 11:49 PM
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Next on the agenda

Motor mount plate 3/16" x 5 1/2" x 18"

used handy dandy cut off tool to whack off the excess material


WOW! 5 lbs. just for the motor mount plate


trim the corners & clean 'er up a bit

layout a grid pattern to help keep everything square

mark & drill (2) holes for each slot

(16) holes for (8) slots

used a Dremel to connect the holes

& a 5 1/16" drill bit to smooth 'em out
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Old 10-15-2017, 12:21 AM
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Made up a solid axle to mount the dual flanged hubs to

1 - 30" piece of 5/8" rod
2 - ~2" pieces of 3/16" angle steel (mounting brackets)
2 - ~1" pieces of 7/8" pipe (mount to hub spacer)

started by threading ~1" of each end of the rod

cleaned up a bit on wire wheel

drilled 5/8" holes in each mounting bracket to run the axle thru & 1/2" holes for mounting it to the kart


bolted the mounting brackets to the frame

run the axle thru (roughly centered)

slide a spacer on each end

slide a hub on each side

snug up with a fine threaded nut on each end


Now that everything is where it's supposed to be we can weld 'er up

just spot welds to tack everything in place

disassembled & welded 'er up good

(don't want to get our new hubs all discolored from welding)
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Old 10-15-2017, 12:35 AM
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Now

that we know where the rear wheels go

we can get the motor mount mounted

drilled (2) 1/8" holes to tack the plate in place

to be sure nothing moves while welding


after welding

I removed the screws

& welded them holes up too
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Old 10-15-2017, 08:26 AM
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Next up is the steering support


think were gonna go a little different direction

...than our original drawing/concept


using the same piece we bent

...just not

a big looping nose piece

...more of just a simple support


~12" seems to be about the right height

made a couple of marks

then lined up the angle, & marked

gonna split it in half

round em' up a bit

& weld a piece of pipe between

* got some pipe that will hold these grease able bushings
they are (originally) for riding lawn mower front wheels
should work good & never squeak
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Old 10-16-2017, 02:04 AM
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Wow!! Awesome work so far. You should be finished in a week
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Old 10-16-2017, 07:44 AM
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Quote:
Originally Posted by landuse View Post
Wow!! Awesome work so far. You should be finished in a week
Thanks!

It's mid-October already

Winter here in Toledo (my busy season)

could show up @ anytime


So, gotta move it along
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