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  #61  
Old 03-30-2020, 06:47 AM
aka Larry aka Larry is offline
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Update.

I was able to get the clear coat done this weekend. I also had to paint the handle bars, tie-rods, and hubs black, so I decided to get that done and let it all fully cure before starting assembly.

Here's a shot of one of the wheel halves with the clear coat done:


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30_clear.jpg  
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  #62  
Old 04-06-2020, 07:05 AM
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Update.

With the beautiful weather both days this weekend, I got off my @$$ and put in some quality hours on this thing.

I started out by reassembling the wheels. Yeah, it was kind of a PITA, but unlike the first time, I knew what to do, and had the jigs ready to go for the press. Since I didn't have the learning curve, and didn't have to stop, it took about 1/4th the time. I decided to paint the hubs gloss black for two reasons. First, for some contrast. Second because I didn't have any more of the blue paint.


Assembled wheel and hub assembly:






After the wheels were done and installed, I was ready to move on to the wiring. I started by mounting the battery holder. This is a 3D-printed piece designed to hold the 20V Dewalt batteries. It's attached with stainless-steel screws with rubber pads underneath to mitigate vibration. The wires pass through rubber grommets of course.





Dewalt 20V battery in place:





After routing all the wires for the lighting, I made the connections via a terminal block up front. I used the fabric wire loom to clean every thing up.





I wanted to be able to remove the cooler if needed for draining, cleaning, or whatever, so I used a pair of toggle clamps to secure the cooler to the frame. The stainless skin on the cooler is pretty thin (think beer can) so I used rivets to attach a 16GA stainless-steel plate to distribute the forces over a wider area.





I actually got further along, enough to make it mobile, but a snafu caused me to have to re-order a part that won't be here until Thursday. Once the part arrives, I should be able to finally ride this thing!

Stay tuned...
Attached Thumbnails
31_wheel.jpg   32_terminal_block.jpg  

34_battery holder_01.jpg   34_battery holder_02.jpg  

36_toggle_clamp_02.jpg  
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  #63  
Old 04-08-2020, 08:05 AM
aka Larry aka Larry is offline
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For those still following along...

It's done! Well almost, since I do plan to add a padded seat to the lid of the cooler, but otherwise it's 100% functional.

Here are a couple of short videos of me riding it yesterday. A day version and night version so I could test the lighting.






It's plenty quick for what it is, a governed 6.5HP engine with a 215 lb. rider. Via a phone's GPS, the max speed was 21 MPH, which is fast enough riding on a top heavy kart with a short and narrow wheel base. Turn too quick and you'll end up on your @ss for sure. I didn't test that, but I can and did lift the rear wheel in the turns.

The parking lights were mostly for looks/bling, and they are bright! The headlight however was designed to be functional, and works very well. The headlights and parking lights on separate switches so they can be used as needed.

Here are the finished pics:













Attached Thumbnails
38_front_qtr.jpg   43_rear_qtr.jpg  

39_side.jpg   51_front head light.jpg  

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  #64  
Old 04-08-2020, 08:23 AM
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That turned out really well!
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  #65  
Old 04-08-2020, 09:43 AM
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Whitetrashrocker Whitetrashrocker is offline
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Nice job!
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  #66  
Old 04-09-2020, 12:15 AM
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landuse landuse is online now
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Thats awesome!!! Congrats
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  #67  
Old 04-09-2020, 07:04 AM
aka Larry aka Larry is offline
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Quote:
Originally Posted by Stew View Post
That turned out really well!
Quote:
Originally Posted by Whitetrashrocker View Post
Nice job!
Quote:
Originally Posted by landuse View Post
Thats awesome!!! Congrats

Thanks for the kind words everyone, and thanks for all the help and advice I received here.

It took way more money, time, and effort than I ever thought, but I'm happy with the result.
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