The Poboy Way

[Poboy kartman]

I just decided to sart another thread so I can chronicle the thug build without polluting another thread. There's really so much more involved than that and I want a place to feel free to ramble and people can take it or leave it. I intend to show what I am doing in great detail and imput personal perspectives that really need their own space.

I was kinda walking a tightrope on the "Gokart Alley the series' thread so that will be the " Cliff Notes " version and this will be 'too much information".

The kart I'm working on is old and many of the problems are common with old karts. So partly it will be a tutorial on how to deal with them Poboy style and also some interjections on my perspective on things.......

Thanks for watching. ...

 

[OzFab]

This should be good

 

[Poboy kartman]

One of the first and most important things in any restoration is documentation. A lot of time can pass between disassembly and reassembly. And you would be surprised at the smallest, simplest things can have you scratching your head and kicking yourself in the behind for half a day. Sooooooo- pictures- and plenty of them. It's really easy to do now. Back in the olden days- we had to have a camera, buy film, shoot pictures and not even know if we got them or not, then pay to get them developed and finally (maybe) had documentation.

Next- managing parts: again- SO much better. Ziploc baggies. Bargain brands are fine. Just write what they are on the bag with a Sharpie. The more the merrier- in other words- the more bags you use and the less you put in them, the less chance of confusion during final assembly.

The big box- try to keep everything together- in one or two boxes. You'll be glad you did......Well maybe not- but speaking from experience- you may very well be extremely sorry you didn't.

Ok- So that's a little start- I'll start posting up specific techniques and such as time allows...... And this is my baby here- but by no means a dictatorship. So anyone, anytime. ....feel free to chime in with ideas or criticism- or just why you feel like kicking the dog today.

"All are welcome. .....into the light......" poultry heist -tha mobby...

 

[fowler]

Ha this is a good idea

Still done at a large industrial level

It's common practice in my game
A bulldozer has thousands of parts so when we take it apart it's put in big plastic bags or plastic tubs
Then labled by machine number and place on machine

Then if we have a smaller peice to take apart like a valve block
Everyone has phones these days
Take photos using that

 

[OzFab]

I made it common prictise when I was panel beating: Imagine you're respraying an entire car; by the time you strip out 4 doors & remove both bumpers, there's enough nuts & bolts to stock a small hardware store; bagging & clearly labelling everything makes reassembly so much easier.

This practice followed through to when I built AmEx; I knew where everything was at any given time

 

[Poboy kartman]

A quick snippet- while I'm getting my ducks in a row...... Old tires- ( or any rubber items, actually) ....lacquer thinner. Several wipe downs will remove the "dead" rubber and soon leave you with an almost new surface. Then it's time for the second step-Turtle wax F21 Super Protectant. Apply and let sit- rinse and repeat- wait- ............maybe that was my shampooo? Seriously- this stuff is good- and no- forget the rinse part. But when it comes to reviving old tires and such, I've found it works much better when thinned by 25% with water- so if you have a new bottle- detail the wife's car, and then add some water.....

As always- more to come. ...

 

[Poboy kartman]

A few photos followed by a long winded explanation:

 

[Poboy kartman]

So in the first 2 photos- you can see the amount of slop in the pedals. The third shows the wear on the pedal bolt (the problem) , then the way I planned on fixing it- cutting tubing for spacers and tacking them in place. The last one shows what I wound up using. I went to Home Depot- no spacers, and the tubing was all too large for a 5/16" bolt. Northern Tool doesn't even sell generic hardware anymore. ..... So I'm now at Lowe's - they have spacers , just what I was looking for! Errr- ummmm- not quite, they go from 1/4" to 3/8", no 5/16"....all their tubing is too large so I resort to the all-thread connector. The one in the picture is actually 1/4-20 that I had gotten from Home Depot, IDKY- I thought that was the size of the pedal bolt. But I picked up a pair of 5/16" at Lowe's.

This turned out to be pretty good, as I was able to drill out the threads for a precision fit, and the small amount of grooves left will make a nice reservoir for grease.

Time for more photos and the downside of using them. ....

BTW- I apologize for the multiple posts- but this phone is giving me fits and this is the best way for me to go about it. ....
As it turns out

 

[Poboy kartman]

I had some other pictures I wanted to post- but they have mysteriously disappeared in this evil phone!

Anyway- I made a rough sketch to show the problem. From the factory, the holes were punched, which provided somewhat of a bearing surface, but also provided strength- much like putting rolls in a pan. After opening them up with a uni-bit, I just had very large holes. I probably could have just welded in the connector and been OK- but I chose a different route. I used 1/4" fender washers one with an oversized hole that I welded to the connector. You can see I used some 5/16" all-thread and a couple of nuts to position them for welding ( and the all-thread made a handy handle to clamp to the table and also accept the ground clamp). After welding I slipped it into the frame and the other washer was precision drilled for a 5/16" bolt, which was inserted and with a nut- cinched down. A little hammer work and the washers are ready for welding.

The result is a rock solid pedal that will be that way long after I am dead and gone.......

More to come- grab some popcorn and a cold one and stay tuned!!!!

 

[OzFab]

I consider myself lucky, if I need a spacer like that, I simply knock one out on my lathe but, for those who don't have that luxury, this is a fantastic idea; nice one Douggie

 

[Orange Krate]

Man your all over the place. I didn't even see this thread. I wish I had sent Bandit with you. Your attention to detail is outstanding

 

[DMCdesign]

Poboy, keep giving us the advice to build on the cheap, And I might as well become a redneck

EDIT: by redneck, I mean myself, no offense

 

[Poboy kartman]

Me a redneck? Uh huck- now that there's funny, I don't keer who ya are....

I have the frame in the kitchen now so I can sand on it out of the cold and near the cold ones. Now I ask you- what could be redneck about that? I have possums for pets. But I'm a classy redneck- my truck actually has more wheels than my house.

If I was worried about getting offended I wouldn't be here. And if we couldn't rib each other in good fun- this site just wouldn't be what it is.

Anyway- I've been doing a bunch of cosmetic druggery work on the frame: sanding, bondo, and smoothing welds so nothing earthshattering to post up right now. I will be in a few days though. ....

 

[DMCdesign]

Me a redneck? Uh huck- now that there's funny, I don't keer who ya are....

I have the frame in the kitchen now so I can sand on it out of the cold and near the cold ones. Now I ask you- what could be redneck about that? I have possums for pets. But I'm a classy redneck- my truck actually has more wheels than my house.

If I was worried about getting offended I wouldn't be here. And if we couldn't rib each other in good fun- this site just wouldn't be what it is.

Anyway- I've been doing a bunch of cosmetic druggery work on the frame: sanding, bondo, and smoothing welds so nothing earthshattering to post up right now. I will be in a few days though. ....

got that. you have possums, I had guinea pigs (had is the keyword)

 

[Poboy kartman]

Hah- Rednecks, possums and guinea pigs. Gotta love it!

Anyway- got me to thinking. There was a feller got lost on the backroads around here and he stopped at a farm to ask for directions. As he was talking to the farmer he noticed a pig with a wooden leg and started laughing.

"What's so dadgum funny? " -asked the farmer. "A three legged pig!" was the reply. " Now just hold on there sonny" the farmer continued-" You don't know the story behind that pig.....that pig is special. Let me tell you about that pig: I was plowing the back forty when it was 110° and the dadblamed tractor turned over on me and pinned my leg. I mighta died if that pig hadn't came along and rooted me out."

" Is that what happened to his leg?" asked the traveler. The farmer continued:"No, but let me tell you what else that pig done.. I was sleeping real good one night when that pig got to rootin at the door and woke me up. The barn was on fire. He had even rooted out a hole for the chickens to get out before I got there. If it hadn't been for him the whole place may have burnt down." "Oh-so did he lose his leg in the fire?" asked the traveler. "Nope" replied the farmer.

"Well how the heck did he lose his leg?" the traveler wanted to know. The farmer looked at him and said:" Listen sonny- when you got a pig that special.......you don't eat him all at once."

 

[DMCdesign]

Observation- He was hungry and obsessive of his pig at the same time.......
Result- The person was most probably saving the pig for thanksgiving, But changed his mind......

 

[Poboy kartman]

About the possums- they live under my sheds. Whenever some food goes bad, I put it out to feed them. I've had them for years. Back when I was married we had a little family of three (possums) .....hmmmmm....... come to think of it- (me, wife,+ daughter=3, also), and we saw them pretty frequently. We named them Andy, Oppie, and aunt Bea. Opie got killed crossing a side street before he got half grown. But the population of possums has been around ever since.

So one time I caught a baby. My wife said the same thing she always said when I caught something: "we're not keeping it! "

Anyway- after the divorce I caught another one. I put it in a rabbit cage in the living room. Fed it cat food and took it out and put it on my lap and petted it every night. It didn't work out. Mean little bessurd. I wound up catching 3 other babies over time and trying to make pets out of them. I kept trying to get a female to see if they had a different disposition. I would think I had one and month later it would develop a sack.I finally did get a female and raised her from a little baby to full grown.

So when you first get one they twist and hiss and bite and poop all over you. ....After time I had this one sitting in my lap- no biting- no pooping, pretty calm.I had a little litter box in her cage she was pretty good about using. I had varying degrees of success with the others and kept every one over a month at least.

But the thing was that they just didn't make good pets. They have a programmed fear in them that they just can't overcome. They became tame but could never enjoy human interaction because of it. But most likely some of those guys running around out back spent some of their childhood on my lap. I usually only catch a glimpse of them now and then as they scurry for cover- but I still like them.

 

[DMCdesign]

since pets are hijacking the thread, I am starting another one.

 

[Poboy kartman]

since pets are hijacking the thread, I am starting another one.

That's one of the reasons I started this thread- so I could ramble on guilt free.

Here's another quick "Poboy Way" snippet. This has saved me a lot of time and money over the years:

 

[Poboy kartman]

I really love the Plano type boxes. I started putting everything that would fit in them into them and labeling them. It's almost like having my own hardware store. It's really in the time savings and gas cost that makes this so worth the time to set up. I built a little shelving unit to house them ( details on request) and went through several labeling methods. Now I use a Brother P-Touch label machine and I love it. The labels are easy to read and I put one on a plastic tumbler and it's survived more dishwasher cycles than I can count. I also cut up old mini-blinds and use them for plant markers in the garden and use those labels. They stick and stay legible.

Anything that doesn't fit in those goes into plastic shoeboxes from the dollar store and bigger than that- totes.