VW panel van replica kart build

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itsid

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A question inrelation to the motor /controler. Can I slow the trottle down by adding a resister inline with it. Also if I am going to add a sensor to cut the power when too close to something should I add relay/sensor inline with the trottle to cut it off or inline with the motor cable?

Also I have lights and indicator buttons on the handle bars from the origianl scooter. I checked last night and they output 24 volts. As the lights and indicators I'm going to use are 12 volt whats my best option here.
1.Replace bulbs with 24 volt not sure if there are available?
2. or buy a 24 volt to 12 volt convertor to run lights etc.
3. use 24 volt relays and put in 1 extra battery to run 12 volt lights etc. problem here is how to I charge the 12 volt battery assuming I was going to fit 24 volt charger for the main batterys. fit 2 chargers.?
I had intended having the charger onboard as I have lots of space then just plug in a flex and turn a switch to start charging.

Thanks For your help.

I don't know what kind of throttle you have, so it's hard to tell if you can simply add a resistor to it,
the more important thing would be: what kind of controller do you have, some come with a throttle limiter some are programmable etc.

And the sensor should tell the controller to stop, not cut of the motor itself;
mainly because the sensors are all low voltage low current (just as the controller inputs) the motor is not ;)
It can be inline with the throttle via a relay;
but again, maybe the controller is the better alternative if it comes with a kill switch connector.

if you cannot find 24V bulbs (which I think is by far the best option you have)
you might get away with just a resistor set up
that is if you have LED lights and indicators...
(it'll draw some power, yes but it works and is relatively cheap)

The next best option is the 24V to 12V step down converter, but find one that's up for the task (some do not provide enough watts to run lights)
The last I'd do is get a second 12V battery.. that'll end up being more expensive than a converter with all the extra cables, mounts, chargers etc.;)


'sid
 

fattony

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It looks like my trottle is a pot of some sort so resisters should slow it down I think. testing will prove I suppose.

I have found 24 volt bulbs that I think will work out ok. I will check my sensor collection. I think I do have some serious relay type jobbies that could even handle the motor power but might be safer to cut the trottle trough a relay.

The rear window might have to get a bit bigger to make it look right.
I started to make up the gutters and tack them on also.

Thats it for now.
 

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fattony

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I finished up the gutters and made a start on the roof skin.
I have also made a start on the rear number plate.
I'm making the rook in sections trying to get the shape right.
Of course I ran out of welding gas before finishing up the rear section.
I have made the sun roof/ enter hole in the roof bigger too as It was as bit tight for my 8 year old nephew and I want the kids to get a few years out of it.
 

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Volksdad

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I've been dreaming about this for the better part of a year... Did a search last night and found this thread. Beautiful work Tony. I can't wait to see your finished product.

Here in the USA they sell a fiberglass body for a bus. It's pretty pricey IIRC, but is not nearly as nice as your creation.

It is truly beautiful Tony, your kids must think you can do anything! You've set the bar high, my friend! Lol
 

fattony

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Thanks very much VolksDad. I too was thinking about doing this for a very long time. I had planned on buying a fiberglass body but it was getting very expensive between the shell and the shipping. This little bus will end up costing a little over half what the shipping was going to be.


Now back to the plan.
The rear roof section is almost complete.
 

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fattony

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No idea what it weighs now:oops: I may have to reconsider alot of the original plan as it is only one wheel drive and one wheel brake at the moment with zero suspension . I don’t mind really once the body is done the sky is the limit as far as running gear. Just turn it upside down to fit what ever is needed. I have resigned myself not to be finished by Christmas now so no great hurry.
I have a small plastic seat I was going to fit but the more I think about it the more I think I should fit 3 pint belts and a roll bar of sorts. I was speaking to a guy over the weekend that does upholstery and I’m think leatherette Eddie rockets style for the seat and inside panels. So watch this space.
 

itsid

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I'm not.. I wasn't actually taking any real world size into consideration.
...
On a more serious note..
the roof looks a little too flat.
The curves should be 'tighter' close to the lip not much, but noticeable.
I think it'd be quite a task to get it right.

But, I know you can, you made an incredible job so far.

Don't get me wrong, if you'd live closer, I'd still snitch it (since you refuse to sell),
but it's not quite right as it is right now :D

'sid
 

fattony

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Again sid you are right. I think the problem is the gutters are too high. They are almost the same as the original. so when I finish dressing the welds I might cut a few mm off the gutters.

When I have the metal complete I am going to spend sometime prepping it and making what ever mods I have to to have it look as close as I can to right.

As I am not going to finish it for Christmas now I haven't bothered to do any metal work in the last few days. I did take the wiring to bits last night. I found the motor cut off to the controller. I though it was for the brake lights:oops:. I am going to make up a new system. Some of the shinny pics have arrived too. Lights indictors battery gauge:cheers2: I cant wait to get to the fun bit of putting them all together.
 

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Its been a lazy week on the little bus. I had started to fab the front panel and it is already wrecking my head. I have decided to make the seam where the front panel and doors meet an the A frame first. Then I will make the front panel with out the V to get the shape half right after which I intend to make the V shape and weld it on. First seam made and tacked on. Its all about the front, if it doesn't look half right the whole look is doomed so the pressure is on.
 

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fattony

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little update

Little update. The front panel is been done in 2 parts. First part complete, second to come. As you can see the V shape is cut out just need to shape it and tack it all together. it was too cold out in the shed so had a look at the wiring instead. I have got my head around the wiring now just need to find some nice connector boxes and tidy it all up.
 

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machinist@large

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Little update. The front panel is been done in 2 parts. First part complete, second to come. As you can see the V shape is cut out just need to shape it and tack it all together. it was too cold out in the shed so had a look at the wiring instead. I have got my head around the wiring now just need to find some nice connector boxes and tidy it all up.

Looking good!!! Though, I have to admit, you're somewhere in that zone where it seems like you'll never get there (I really don't want to think about just how much time I've spent there along the way......:surrender::surrender:)

You will make it; you've more than proven that you can do it.

I, for one, am rooting for you.

Pat :thumbsup: :cheers2: :popcorn:
 

fattony

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Thanks Pat, it does feel like i'll never finish but I have been distracted by other projects at the moment. I'm going to make an effort to get back into it this week finish up the body at least.
 

Volksdad

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Tony:

more than just one of us are pulling for you! You've inspired me to drag that kart from behind the shed and start looking at it. Mine is gasoline powered, well if it still runs that is!

Glen
 
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