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Old 12-20-2019, 07:26 AM
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Default Lunar Rover (prototype)

TOP SECRET (so don't tell anyone)

NASA Space Program

Mission:
Design & build a Lunar Rover (prototype)

Requirements:
Lightweight (gotta be shipped to the moon or ...)
Electric/battery powered (can't go around pollutin' other atmospheres)
Multi-terrain capable (gotta be able to climb into & then back out of craters)
Durable/reliable (can't be breakin' down 1,000,000,000 of miles away)

* NOT REALLY
...but, a kool "backstory" for a build
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Old 12-20-2019, 08:26 AM
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Rc car or are you building this thing to drive?
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Old 12-20-2019, 08:52 AM
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Old 12-20-2019, 10:19 AM
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Now, since you are Functional Artist, you also have to build an electric rocket for NASA so they can ship it there!

I'll be watching!
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Old 12-20-2019, 10:41 AM
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A "real" Lunar Rover (Moon Buggy) would IMO probably be constructed out of Aluminum, Titanium (or some other exotic metal), maybe even some type of composite material.

I'm thinkin' this "prototype" will be constructed mostly out of 1/8" steel
...1/2" schedule 40 "water" pipe (7/8" od. x 5/8" id. x 1/8" wall)
...& some 1/8" flat steel

Why?

Cause it's strong, affordable & easily workable with most standard tools.

So, after extensive research, thought & a little planning) I started drawin' on some 1/8" x 3" steel

Can ya tell where the inspiration for this/these ( spoiler alert) came from?

* No, it's NOT gonna be a Bat'leth
...if ya don't know, Google it
Attached Thumbnails
SAM_1593.JPG   SAM_1596.JPG  

SAM_1597.JPG  
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Old 12-20-2019, 11:26 AM
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Quote:
Originally Posted by Functional Artist View Post
Mission:
Design & build a Lunar Rover (prototype)

Requirements:
Lightweight (gotta be shipped it to the moon or ...)
Electric/battery powered (can't go around pollutin' other atmospheres)
*cough* lunar atmosphere ??
You need electric power on the moon because there is no combustible oxygen in moons nearly non existing atmosphere
(frankly even nasa considers the moon to surrounded by a vacuum for almost all considerations)
the few molecules of helium and radon are really not noteworthy.

so yeah... correct decision, wrong reason

side note:
the real lunar rover (LRV) was rather hefty with 200+ kgs (it's essentially a two seater go kart)
but it mustn't jump out into lunar orbit just because it hit a rock

'sid

PS pleaaaase make it a six wheeler
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Old 12-20-2019, 12:02 PM
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Kevin, are those panels modeled after a 1933 Bugatti Type 59, per chance?
Look at the chassis rails.
This picture is the mild street version, the swiss cheese was more evident on the racers.
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Old 12-20-2019, 12:54 PM
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Quote:
Originally Posted by Budget GoKart View Post
Rc car or are you building this thing to drive?
RC=boring
..I'ma gonna drive/ride 'er

---------- Post added at 02:44 PM ---------- Previous post was at 02:42 PM ----------

Quote:
Originally Posted by JTSpeedDemon View Post
Now, since you are Functional Artist, you also have to build an electric rocket for NASA so they can ship it there!

I'll be watching!
I'ma buildin' it
...they can worry about shippin' it

---------- Post added at 02:48 PM ---------- Previous post was at 02:44 PM ----------

Quote:
Originally Posted by itsid View Post
*cough* lunar atmosphere ??
You need electric power on the moon because there is no combustible oxygen in moons nearly non existing atmosphere
(frankly even nasa considers the moon to surrounded by a vacuum for almost all considerations)
the few molecules of helium and radon are really not noteworthy.

so yeah... correct decision, wrong reason

side note:
the real lunar rover (LRV) was rather hefty with 200+ kgs (it's essentially a two seater go kart)
but it mustn't jump out into lunar orbit just because it hit a rock

'sid

PS pleaaaase make it a six wheeler
Ya, I know
...just usin' the opportunity to "crack" on gassers

Six wheeler hummmm
...maybe next time, not the "look" I'ma goin' for ATM

---------- Post added at 02:54 PM ---------- Previous post was at 02:48 PM ----------

Quote:
Originally Posted by JTSpeedDemon View Post
Kevin, are those panels modeled after a 1933 Bugatti Type 59, per chance?
Look at the chassis rails.
This picture is the mild street version, the swiss cheese was more evident on the racers.
Nope,
Inspired by the designers/engineers of Percival's Hellcat (early '60's)
...look @ the "stress plates" on the rear

http://www.diygokarts.com/vb/showthread.php?t=24416
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Old 12-20-2019, 04:07 PM
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Default Drilling big holes in 1/8" steel

Well, after burnin' up several (plural) step bits

I did some research & found that as you "go bigger" in bit diameter (like ~3/8" & up)
...you gotta go slower (like ~500-600RPM's slow)
…& to drill holes over 1" you gotta go really slow (like 200-300 RPM's slow)

* These "really low" speeds seems to work well when using hole saws too
...think like hand powered hack saw speeds

** addin' a little cuttin' oil helps too
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Old 12-20-2019, 05:03 PM
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The original rovers were built with 2219 Aluminum alloy, with four 0.25hp series wound DC motors with a range of ~22.3mi.

So any plans for adding suspension to your version?
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Old 12-20-2019, 11:12 PM
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Default Dual 48V 1,000W powered AWD rover

Quote:
Originally Posted by Kartorbust View Post
The original rovers were built with 2219 Aluminum alloy, with four 0.25hp series wound DC motors with a range of ~22.3mi.

So any plans for adding suspension to your version?
Kool!

I'ma thinkin' AWD will be necessary for climbin' outta craters-n-such
* to test this capability, I'm thinkin' it should be able to climb up stairs
...maybe even "walk up a wall"
So, I'ma gonna go with the (2) small but, super powerful 48V 1,000W MY-1020 motors (~1 HP ea.)
…& put 'em on live axles

During plannin', I thought about incorporating suspension
...but, probably not on this one (tryin' to keep 'er kinda simple & relatively lightweight)
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Old 12-21-2019, 08:18 AM
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Default Machining the Bearing Brackets

So, after learnin'-n-figurin' the proper way (or at least a more successful way) of drillin' big holes, I got (16) holes drilled
...in each piece

Then, trimmed off the excess material

* Can ya tell where I messed up?
**HINT: it's visible in last the pic
(but, IMO not bad or visible enough to necessitate a redo)
Attached Thumbnails
SAM_1600.JPG   SAM_1601.JPG  

SAM_1604.JPG   SAM_1605.JPG  

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Old 12-22-2019, 07:39 AM
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Default 3D Bearing Brackets

Now, let's make these bearing brackets 3 dimensional

My HF metal bender is only rated to bend ~16g. steel
...but, these are made outta 1/8" (~11g.) steel

So, during the planning stage, I added some relief holes to aid in bending these brackets

I slid the piece most of the way in to do the "outer" bend first
...then, after the first bend I simply slid it out, to the "inner" line, & bent it again.

That seemed to come out pretty good
...so, I did the second one the exact same way but exactly opposite

I did a quick video too
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SAM_1609.JPG   SAM_1615.JPG  

SAM_1617.JPG   SAM_1628.JPG  

SAM_1630.JPG   SAM_1633.JPG  

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Old 12-23-2019, 09:33 AM
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Default Tail Section Upper Rail

Now let's bend some pipe

Here's the plan
…& here's the Upper Rail
Attached Thumbnails
SAM_1725.JPG   SAM_1637.JPG  

SAM_1638.JPG   SAM_1639.JPG  

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Old 12-24-2019, 07:36 AM
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Default Assembling the Tail

Next, we gotta align/attach the bearing brackets to the Upper rail

I used a 5/8" rod to help align the bearing brackets
…then, clamped 'er down good
…& then, tacked 'em down
Attached Thumbnails
SAM_1643.JPG   SAM_1642.JPG  

SAM_1644.JPG   SAM_1645.JPG  

SAM_1646.JPG   SAM_1647.JPG  

SAM_1648.JPG   SAM_1651.JPG  

SAM_1655.JPG   SAM_1656.JPG  

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Old 12-24-2019, 08:25 AM
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That thing is already looking wicked!
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Old 12-24-2019, 06:22 PM
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Default Thanks for sharing

Thank you, for making the rest of us with grinders and a welder seem somewhat inadequate.
And I'm handy.

Merry Christmas
MrC.
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Old 12-24-2019, 08:15 PM
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Quote:
Originally Posted by MrC. View Post
Thank you, for making the rest of us with grinders and a welder seem somewhat inadequate.
And I'm handy.

Merry Christmas
MrC.
Just doin' my thing

That's a pretty kool project
...but, when she finds out, your wife's gonna be pizzed
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Old 12-26-2019, 08:29 AM
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Next, I (temporarily) installed the bearings & axle to double check the symmetry & squareness
...just to be sure everything lines up properly

Then started workin' on/linin' up the "goose Neck"

My lower level stress plates ended up a little longer than necessary
...but, longer is "way better" than too short
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SAM_1659.JPG   SAM_1661.JPG  

SAM_1663.JPG   SAM_1667.JPG  

SAM_1669.JPG   SAM_1670.JPG  

SAM_1671.JPG   SAM_1673.JPG  

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Old 12-26-2019, 09:12 AM
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Shaping up to be a work of art!
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