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  #41  
Old 01-27-2020, 06:55 AM
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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, 07:37 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, 07:44 AM
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this thing is sick im following along
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  #44  
Old 02-10-2020, 03:13 PM
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Should be fun, any pics with cooler on it?
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  #45  
Old 02-10-2020, 10:51 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, 02:31 PM
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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, 02:55 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, 04:58 PM
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I total missed page 2
Love the build
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  #49  
Old 02-14-2020, 06:40 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.

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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, 07:28 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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  #51  
Old 02-20-2020, 07:27 AM
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Unfortunately, I was sick all last weekend so no real progress to report.

I did received my custom laser-cut stainless steel badge yesterday though, and it looks fantastic. It came in a sturdy box, shrink-wrapped to a piece of card stock.

I'll definitely be ordering from these guys again.








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22_badge_01.jpg   23_badge_02.jpg  

24_badge_03.jpg  
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  #52  
Old 02-20-2020, 08:02 AM
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Daaaaaang! I need to order one of those!!

Where'd ya order it??
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  #53  
Old 02-22-2020, 05:16 AM
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Quote:
Originally Posted by JTSpeedDemon View Post
Daaaaaang! I need to order one of those!!

Where'd ya order it??
Google sendcutsend
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  #54  
Old 03-02-2020, 02:32 PM
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Update!

I got started on the brake cable last Saturday afternoon only discover cables are like plumbing fittings...no matter what which size you need, you don't have it.

I recently ditched the thumb throttle idea in favor of the classic twist throttle because I found an entire setup (grips, cables, etc) on Amazon for less than $30. I figured I may have to shorten the cables, but otherwise it would be plug-n-play...well, not so much. The supplied brake cable ended up being about 12" too short, not too long, which forced me to modify my plan, but I was determined to get it hooked up. I ended up with a cable that pulls a 1/8" steel rod to actuate the drum brake. While I was at it, I incorporated a return spring into the linkage, which I think will work well.

Sunday I worked on the throttle cable. Since the cable supplied with the twist grip was also way too short, I spliced in another cable I had ordered for the old thumb throttle to make it work.

At this point, I *think* I'm ready for primer and paint.

Stay tuned...
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  #55  
Old 03-02-2020, 03:42 PM
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having a rod actuating the brake is actually better than 'just cable'
it mostly provides a much more consistent angle of attack and thus gives a better response.

Anyways, you got that nice LED bar..
IDK if you like the idea,
but I think it'd look great if you embedd that into the cooler's lid
(if it fits that is)
maybe a bit sunken in even.

just an idea

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  #56  
Old 03-13-2020, 01:47 PM
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Life has kind of been in the way with this project, but I finally got a little done this week.

I decided I wanted a way to hang parts for painting. Initially I wanted a rolling-type rack, but decided I've got more than enough stuff that's on the floor in the way already. I settled on a shower rod type approach that would be a place to hang parts when needed, but be out of the way the rest of the time.

I used a 10' section of 1-1/2" EMT, some chain, and eye bolts for the construction. I bolted the eye bolts to the overhead trusses of my shop and to the EMT, suspending the EMT with chain. The rod is about 7 feet high, so I don't have to worry about hitting my head on it when not in use.

I used the left over chain along with some S-hooks to suspend the kart's frame from the new overhead support rod, and it was finally ready for paint. It's just primed for now as I ran out of time, but I'll keep moving and hopefully get it all assembled soon.

Pics:





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25_primer_01.jpg   26_primer_02.jpg  

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  #57  
Old 03-14-2020, 10:20 PM
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Wow @akalarry , thats some shop !!

How did you get up in them rafters to hang the chains for your kart paint pole ?

I am nearly finished with my shop and I planned ahead with thicker concrete piers and rebar for a lift similar to that Atlas, (one day...) Do you live in a cool climate where you have to swap to snow tires ? Lift is handy for that for sure.

Also nice work on your cooler kart !

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  #58  
Old 03-16-2020, 08:40 AM
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Quote:
Originally Posted by gegcorp2012 View Post
Wow @akalarry , thats some shop !!

How did you get up in them rafters to hang the chains for your kart paint pole ?

I am nearly finished with my shop and I planned ahead with thicker concrete piers and rebar for a lift similar to that Atlas, (one day...) Do you live in a cool climate where you have to swap to snow tires ? Lift is handy for that for sure.

Also nice work on your cooler kart !

Sent from my SM-J700T using Tapatalk
Thank you!

I just used a ladder to access the roof trusses to hang the paint rack.

Here in NC, we get more hot that cold, so I've never seen a car with snow tires here. I use the lift to do maintenance on my own cars, bu mostly to do work on our 24 Hours of Lemons race car ('93 Acura Integra).
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  #59  
Old 03-16-2020, 08:43 AM
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With the pollen in full force here, and waiting for my paint to arrive from UPS, I didn't have much to work on this weekend.

I do plan to color match the wheels to the frame, so I began the unenviable task of removing the wheels from the tires. If you remember, I had one **** of a time getting the tires on the wheels, so I was not looking forward to the reverse. I decided it would be worth it, so I pressed on...literally.

I stated by removing the schrader valve, then attempted to use a pair of C-clamps and some scrap wood to break the bead. I tell you, for a tire that doesn't use the bead for the seal, these SOBs are on there TIGHT!

Since the clamp method clearly failed, I decided the tires would need to be pressed off the wheels, kind of like they were pressed on, but in a different way. The wooden jig I used for installation, pressed the wheel in the tire, but could not be used to press the wheel back out. Instead, a needed a jig to press tire off the wheel.

Using my plasma cutter, I cut a donut out of some old 1/8" plate I had laying around. I used some scrap 1" square tube, and some 1-1/2" angle to build this:






Once the jig was in place, it worked like a champ to get the wheels free as seen here:





Next I need to scuff the wheels, and get them ready for paint. Hopefully I'll be able to press them back in the tires w/o damaging the new paint.

Stay tuned...
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27_wheel_01.jpg   28_wheel_02.jpg  

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  #60  
Old 03-24-2020, 08:33 AM
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Update.

This past Friday after work, the weather final cooperated enough for me to get started on the color coat. The color is called "Still Night Pearl", which is a 2019 Honda color code. Here's where it stands now:






Hopefully with the pollen going away, and warmer temps this weekend, I will get the color coat finished and clear coat done.
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