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  #41  
Old 01-27-2020, 07:55 AM
aka Larry aka Larry is offline
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For those still following along, here's and update from this weekend's progress.

I started by finishing up the right side fender. Once that was in place I was able to attach the front bumper as seen here:




Next I added a pair of gussets to support the fender struts and to house the front LED parking lights:




Since the bumper was in place, I went ahead and made provisions for the LED headlight and mocked it up:




I finally got around to fitment of the brake band and welded the pin in place that attaches it to the frame. Also I added a mounting plate for the battery holder as seen in the upper left of the pic.





The biggest progress was I finally made some headway on the steering. My initial plan was to use 3/4" EMT and weld up simple T-style handlebars. As it turned out, almost all handlebar mounted controls (brake levers, switches, etc) are sized for 22mm handlebars, and 3/4" EMT is too large for any of those to fit. I ended up ordering set of bars from Amazon and they arrived Sunday around lunch so I was able to get started.

The steering column is made from 3/4" EMT with a 1/2" brass bushing in each end. The actual steering rod is 1/2" dia rod that is welded to the handlebars and slides through the brass bushings. There will be a pitman arm on the bottom end that connects to the tie-rods, but it's not done yet because the tie-rods I purchased are too long. I'll have to modify those, but for now here's where it sits currently:

Attached Thumbnails
14_front_bumper.jpg   15_gussets_headlight.jpg  

16_front_parking_light.jpg   17_brake_pin.jpg  

18_steering column.jpg  
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  #42  
Old 02-10-2020, 08:37 AM
aka Larry aka Larry is offline
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Is this thing still on? Anyone still following along? I feel like I'm talking to myself, which to be honest, isn't all that unusual...LOL.

Anywho, yesterday afternoon I had a chance to spend a little more time on this project.

The main focus at this point was on the steering. The OTS tie-rods I bought were too long so I had to remove a section in the middle, sleeve it, and weld it back together. Once that was done I welded the pitman arm to the steering shaft and mocked it all up as seen here:





Planning ahead, I added a 1/2 tube through the frame to act as a conduit to run the wiring from front to back. I hate having wires hanging, and I'm trying to minimize the amount of exposed wiring. The tube can be seen here:






I did the finish welding on all the joints with the exception of the engine mount, which I will save for last. I need to be sure the engine and drive sprockets line up perfectly before locking that down. The next step is to mock up the throttle and brake, and hopefully take it out for a quick test ride.

Stay tuned....
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20_steering tie-rods.jpg   21_wire conduit.jpg  

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  #43  
Old 02-10-2020, 08:44 AM
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this thing is sick im following along
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  #44  
Old 02-10-2020, 04:13 PM
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Should be fun, any pics with cooler on it?
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  #45  
Old 02-10-2020, 11:51 PM
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I am definitely still following. I just have nothing to add to what you are already doing You are doing a great job
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  #46  
Old 02-13-2020, 03:31 PM
aka Larry aka Larry is offline
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Quote:
Originally Posted by Bansil View Post
Should be fun, any pics with cooler on it?

See my post #35 in this thread for pics with the cooler.

Update, I just ordered a custom laser-cut badge for the project.

I designed a 50's style automotive badge. Below is what I came up with. Note, the tabs at the bottom are for mounting and will be bent 90 degrees before installation. I added a pair of small notches to make sure I bend the tabs at the correct spot. The plan is to mount it on the rear bumper right above the taillights.


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Cooler_Kart_Logo.jpg  
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  #47  
Old 02-13-2020, 03:55 PM
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I just tuned in to this build. I dig it. Love the Fab and welding job your doing.

But one thing bugging me. Back to the tire ordeal. You got split rims and kept them bolted together and pressed them in the rubber.
The point of split rims is to take them apart and then each half goes from the out side of each bead and then bolt them back together.

I admire you tenacity.
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  #48  
Old 02-13-2020, 05:58 PM
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I total missed page 2
Love the build
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  #49  
Old 02-14-2020, 07:40 AM
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Quote:
Originally Posted by Whitetrashrocker View Post
I just tuned in to this build. I dig it. Love the Fab and welding job your doing.
Thanks! Feels like I'm never going to finish it though. Just not enough time with all the other stuff I have going on.

Quote:
Originally Posted by Whitetrashrocker View Post
But one thing bugging me. Back to the tire ordeal. You got split rims and kept them bolted together and pressed them in the rubber.
The point of split rims is to take them apart and then each half goes from the out side of each bead and then bolt them back together.

I admire you tenacity.

Re-read my post #30. The split rims were not bolted together when I pressed them into the tires. I pressed in one half, installed the tube, bolted the halves together, and then aired up the tube.
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  #50  
Old 02-14-2020, 08:28 AM
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Ok. I missed that part. I was pretty sure you were smarter than that by the rest of your work. But you never know.
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