2013 - AusEx (AmEx Replica)

[landuse]

Is that a #35 clutch?

 

[OzFab]

Wow. I thought we had it rough!

Nah, you guys have it easy... Think about it, I have to build a frame coz I can't buy one anywhere in the country

Is that a #35 clutch?

Yes it is; 12t #35 clutch to be matched with a #35 70t axle sprocket.

Yes, I know, that's less than 6:1 (5.83333333333333:1 to be exact) but, not enough to matter...

 

[souperman000]

Yes, I know, that's less than 6:1 (5.83333333333333:1 to be exact) but, not enough to matter...

Do you know what the factory gearing was on these things?

Any luck with the bending company?

 

[OzFab]

Do you know what the factory gearing was on these things?

No idea...

Any luck with the bending company?

I haven't had a chance to update on that...

I measured the distance a few times just to make sure, went all the way out there (an hours drive) & showed the sales lady (the guy I'd been dealing with was off sick). She called in the guy who bent it who slapped a tape measure on it & it measured perfect

So, after much discussion on what to do, I decided to "adjust" the angles myself to achieve the correct height. The downside is, because they docked the ends (after I asked them to leave some excess), the overall length is now 4" short so I'll have to make some extensions; man, what a waste of time

*Twin post*

I finally got my lathe onto it's new home & managed to turn up one of many spring retainers (so far)

... & bent the "C" brackets. Front end should be assembled in a few days

 

[Doc Sprocket]

Excellent!

Guy probably had a Chinese tape measure...

 

[OzFab]

I have absolutely no idea what happened but, it was like being hit with a baseball bat; you know, that moment when you realise you have absolutely no comeback...

I have a piece of thickwall pipe I can turn down to use as plugs for the extensions

 

[Doc Sprocket]

Yeah- going to war with a knife and finding out the other side's got guns...

I had a supervisor that I very much respected, had a saying, "There are no problems, only solutions". Okay- so it's a bit Karate Kid, but it gets the point across. You can work through it, just put your mind to it.

 

[OzFab]

Front Axle Done

Well, I've had some fun over the last few days spinning up the spring retainers for the front suspension.

Along with that, I bent some 30mm x 6mm flat bar to create the C brackets for the front spindles. Once I fitted the whole assembly together (C bracket, spindle, spring & retainers) it was time to weld them to the front axle.

Once I calculated the correct height, I used a length of RHS to establish a base line, then used a length of 65mm RHS as a spacer from the base line to the bottom of the stub axle (65mm being the desired height). A strategically positioned piece of 2mm scrap gave me exactly 2° negative camber.

Tack the C bracket to the axle, repeat on the other side & the front axle is complete.

I then put the wheels on the stubs & took a measurement; it's 4" wider than the rear axle... that won't do

So, I took it all apart, cut 60mm off each end of the axle, then put it all back together using the same process...

 

[DaiSan76]

Looking good. How did you bend those spindle brackets?

 

[landuse]

Coming along nicely! Things never go smoothy when you want them to though

 

[OzFab]

Looking good. How did you bend those spindle brackets?

Have a look at this post, it should answer your question

Coming along nicely! Things never go smoothy when you want them to though

Murphy's law my friend

 

[OzFab]

More progress on the front axle. I finished welding the C brackets to the axle beam which turned out quite well considering I was welding 6mm flat bar to 1.6mm wall tube...

I also sourced a pair of grade 8 bolts for the kingpins, some finishing touches on the bench grinder & the front end is done... well, apart from tie rods, mounting the axle to the frame, steering column... I think that'll be next.

 

[landuse]

Great work!! Where did you get the springs from?

 

[OzFab]

Believe it or not, they're used valve springs, the lightest ones I could find. I called an engine reconditioning shop & the guy said "come & have a look". when I'd found what I wanted, I asked him how much & he said "see you later"...

 

[landuse]

Believe it or not, they're used valve springs, the lightest ones I could find. I called an engine reconditioning shop & the guy said "come & have a look". when I'g found what I wanted, I asked him how much & he said "see you later"...

Nice! They look like they are going to be perfect for the job.

 

[OzFab]

I hope so. I have a feeling they may be a bit heavy but, we'll see...

 

[freqster]

Looking great so far Fabroman. So do the springs on the spindles act as sort of a mini suspension/shock absorber? I haven't made mine yet and I may just copy what you did.

 

[Doc Sprocket]

Ahhh- Valvesprings. If I had a nickel for every time I told somebody to use them for exactly that style of suspension...

Either way- you're looking good!

 

[OzFab]

So do the springs on the spindles act as sort of a mini suspension/shock absorber? I haven't made mine yet and I may just copy what you did.

well, that's the plan...

 

[Orange Krate]

This is pretty awesome! It's like watching 70% of my go-karts being manufactured...(I got a lot of Manco frames)

Showoff! I should have taken pictures of the boy drilling out his minibike brake rotor bolt hole circle on the mill w/rotary table. I was too busy making sure he kept all his fingers LOL