My Design

[Simon Thomas]

Square Flanged Cast Housing Mounted Bearings

Specifically, this is the one I mentioned earlier on.

Plan to permanently weld the inner race to its housing.

 

[landuse]

Specifically, this is the one I mentioned earlier on.

Plan to permanently weld the inner race to its housing.

I am sorry, but I wouldn't be able to tell you if it can be welded or not. I don't have that knowledge. Maybe wait for one of the more experienced welders to answer.

I can't remember if you said, but what welder would you be using to weld with?

 

[Simon Thomas]

I can't remember if you said, but what welder would you be using to weld with?

I am using arc welding.

 

[landuse]

I am using arc welding.

I just did a quick google search, and it seems like you will need a special rod made for welding cast iron. It also looks like it might be a bit tricky. Here are a few sites I found:

http://www.ehow.com/how_2164565_wel...ce=yahoo&utm_medium=ssp&utm_campaign=yssp_art
http://bbs.homeshopmachinist.net/archive/index.php/t-9899.html
http://www.smokstak.com/forum/showthread.php?t=13406
http://ths.gardenweb.com/forums/load/metal/msg0922303621319.html?23
http://www.locknstitch.com/castironwelding.htm
http://www.smokstak.com/forum/showthread.php?t=9102

It might be more trouble than it is worth, but give it a try

 

[Simon Thomas]

Welded Bearing Housing

Thanks for the links. I like the demo video.

From my reading at http://www.esabna.com/EUWeb/OXY_handbook/589oxy15_1.htm, looks like the cast iron whether it is weldable or not, depending on the composition of carbon and ion.

While puzzling whether bearing housing is weldable or not, I found something from our maintenance workshop here where I am working. Surprisingly, it is weldable! But no answer to what type of welding type used.

Again my bearing housing brand is different than the one that I found. I use the MZD brand while the welded one is FK.

Need to try this out tomorrow.

 

[karl]

You can stick weld with a high nickel content rod. You will haft to heat it then when done welding put it in a bucket of sand to cool down. But why not use the boltholes?

 

[TorqueRanger]

I would not weld cast iron to steel unless you know what you are doing and trust those weld with your life..

 

[fowler]

u can weld cast iron to cast but im not sure about cast to steel

also u have to cool the weld over a few hours with an ozy torch
u can put it in sand but that is a bit redneck style (no offence to anyone that does it)

if u are trying to make a hub u are welding to hardened steel which u cant really weld properly

 

[Simon Thomas]

Welded Cast Ion Bearing Housing

Using an arc welder, I managed to weld the cast ion bearing housing to a galvanized washer. This is the anwer to the situation I have now.

Probably my bearing housing contains more ion than carbon, thus can be welded. I do not know.

 

[Simon Thomas]

Welding Stand and Hub Making

And I used the broken threaded rod as my stand for welding works.

Luckily I managed to find a bigger galvanized washer that is bigger than the inner race. I aligned them using the broken threaded rod.

This is the process of making the hub. Now I have 2 sets. One for wheel and another one for sprocket. The same method used for the brake disc (I did not have the screw yet so I do this later).

 

[Simon Thomas]

Trimming of the bearing side

I trimmed the side so that I could change the screw later with stainless or hardened steel.

 

[Simon Thomas]

Rear Shaft

Then I moved to the rear shaft. I first drilled the hole to hold the bearings.

This has turned my car porch as mini garage .

 

[Simon Thomas]

Mount Rear Bearing and Shaft

Now time to mount the bearings and its shaft.

 

[landuse]

Looking good. You did a lot of work this weekend. I am still just a little bit worried that your sprocket and brake hubs do not have keyways, as well as your axle. I just think that under some stress, the set screws will start slipping on the axle.

Otherwise you are doing a great job there. I can't wait to see it done

 

[Simon Thomas]

Key Way vs Screw Way

I am dilemma now also whether to consider keyways or not. Keyway will incur some additional cost to my build. Currently as you know am using the allen key screw to hold the hub to the shaft.

Speaking of my first current successful buggy, I tested my threadlock adhesive (hardex brand) last week again. After 30-40km drive, the screws at the right rear wheel hub came loose. I don't remember I glued this part lat week. So I have glued it back after that and next week, if possible needs to test again.

I think it is still the best is keyways instead my current screw way. Only time could give the answer.

 

[TorqueRanger]

I am dilemma now also whether to consider keyways or not. Keyway will incur some additional cost to my build. Currently as you know am using the allen key screw to hold the hub to the shaft.

I tested my threadlock adhesive (hardex brand) last week with by first build. After 30-40km drive, the screws at the right rear wheel hub came loose. I don't remember I glued this part lat week. So I have glued it back after that and next week, if possible needs to test again.

I think it is still the best is keyways instead my current screw way. Only time could give the answer.

Check out bmi karts for a keyed axle..

 

[landuse]

Check out bmi karts for a keyed axle..

Simon is located in Malasia, so shipping might be a big expense.

 

[Simon Thomas]

TorqueRanger,

Thanks for offering an alternative to me. I just visited the website http://www.bmikarts.com/shop/?shop=1&cat=255 and the stuffs they are offering are pretty cheap.

In contrary to me, it is quite expensive. Imagine the currency exchange (1USD ~ RM3) and distance will incur even more cost to me. In the same time, I need to buy all the package offered to ensure they are fitting to each other.

Having all the existing parts in hand, ideally it is suitable for me to continue with whatever I have now.

 

[Simon Thomas]

Left and Right Front Axle

This is my own way of making my left and right front spindles. I know during the process of making them, it consumes lots of energy and time to make. However, I can re-use these stuffs again in future if I want because of conventional process of making them.

The internet coverage not so good at this moment. Will include the photos tomorrow.

 

[Simon Thomas]

Good question. It is as the media to hold the inner race (which I use as a hub) and as a base to weld the screw (used to hold the sprocket or brake disc).

Hope I answer you. It is low cost method to have a simple hub. Actually, the bearing housing cast iron here has no specific meaning. Coincidentally they are sold that way.