Building a go kart size Aerial Atom

[karte_m0lim]

looking good

 

[Functional Artist]

Hmmmm

Now, for them upper "rib rails"

I did some figurin'

It looks like we need (2) ~60" pieces of pipe for the "upper rib rails"
...but, they'll probably "shorten up" just a bit from bending so, we'll make 'em ~66"
...& then, cut off the excess later.

First, I marked both pieces of pipe @ 2" intervals.

We (kinda) know where to bend.
...but, how much to bend?
…& @ which mark?

We'll just have to "wing it"

 

[Functional Artist]

We got striped pipes

I had to start @ the 8" mark, the 6" mark was too close to the end.

To start off with I just did (5) pumps @ the 8", 12", 16", 20", 24", 28", 32", 36", 40" 44", 48" & 52" marks.

I put a gold X on each one to mark 'em as I bent 'em.

We got a "bow", but it needs more

I put 'er back in the bender & did (3) more pumps @ the 8", 10", 12", 16", 18", 20", 22", 24", 26", 28", 30", 32", 34" & 36" marks.

Gettin' closer.

The "arch" still wasn't big enough.

I put 'er back in the bender & did (2) more pumps @ the 10", 12", 16" & 18" marks.

Yup, that should do it.

 

[Functional Artist]

Yea, I think were makin' some progress.

 

[Functional Artist]

Now, for the final fittin' of them top "rib rails"

First, I had to cut "quite an angle" off of the rear end of both pieces.

I was kinda conservative for the first cut on the left side.

So, I had to cut it again & then, again ...til I got it close.

I was able to cut the right side in just (1) wack.

Before we can go any further we gotta make the "nose box"

It looks like we'll need (1) ~11" piece for the cross bar & (2) ~4 1/2" pieces for the "pillars"

Measured 'em, cut 'em, notched 'em , squared 'em up & then, welded 'em up good

 

[Functional Artist]

Took everything apart & reassembled it outside, for welding.

* High temp in Toledo today ~33*

But, a little bit of welding & them pipes will warm right up.

First, I weighted the bars down in the back (just to hold them in place)
...then, used a 2 x 4 as a center prop, across in front of the seatback (to keep 'em even)
...& some 2 x 4 scraps to prop the front of the bars (@ ~ the right height)

Quadruple checked everything, then started tackin'.

First, I spot welded the nose box to the lower "rib rails", brought the front of the rails, up into place & then, tacked the rear end of the upper "rib rails" to the rear end of the lower "rib rails" then, moved up to the front & tacked 'em too.

 

[Functional Artist]

Once everything was tacked, I double checked the measurements again
...& gave 'er a good visual inspection too.

I checked both sides of the front, in the middle & in the back.

yup, lookin' pretty close

 

[landuse]

It's starting to look so much like an atom!!

 

[Functional Artist]

It's starting to look so much like an atom!!

Were gettin' there

I'm tryin' to keep 'er smallish, but maintain the long sleek look

Here are some more pics

 

[Functional Artist]

A-frames

Well, lets move on to the front
...suspension.
I'ma gonna try a little different style of an A-frame design for this one.

 

[Functional Artist]

Before welding, I cleaned up the areas that needed to be welded & even beveled the edges a little bit.

Made sure the square tube was square with the pipe & gave 'em a quick tack

Double checked everything & welded 'em up good

We got A-frames, 'er P-frames
...whatever we got (2) of 'em

 

[Quinc]

 

[Functional Artist]

Rounded up a piece of ~1/8" steel that we can use the top side as a foot board & underneath as our A-frame mounting plate

It has a couple of nice flat weldin' spots then drops down, which gives us some additional foot clearance & it even has a nice ~1/2" lip in the front which adds some strength.

Marked it, following the angle of the lower "rib rail", trimmed off the excess & clamped 'er on.

 

[sikbrik]

Coming along nicely!

 

[Functional Artist]

What ya think?

Reinforcement loop/brace toward the front or back?

 

[ezcome-ezgo]

Front

 

[Functional Artist]

Hmmm...….
I was more thinkin' toward the rear would be best.

I kinda like the toward the front "look", but if positioned that way they
...may clash of the tie rods (during suspension travel)
…& (mechanically) having the brace "prop" the "axle" & providing support from the rear seems (to me) like a stronger situation.

 

[Functional Artist]

Well lets see about gettin' these A-frames mounted
...@ this point they can still go either way

I think I'ma gonna use a couple of these rubber (sway bar) bushings on each side to mount 'em

Simple mounting & should provide some impact absorption too

https://www.moog-suspension-parts.com/moog-k8791

Measured, marked, center punched & drilled the "foot board" then, used some 5/16" nuts-n-bolts

 

[Functional Artist]

Here is some more front suspension pics

 

[Functional Artist]

Winter has arrived in Toledo.

So, physical progress has slowed dramatically
...still thinkin' & doin' what I can

Workin' a bit on the steering

I cut a couple of bushing holders (~1" for the top & ~3" for the bottom)

Lined 'er up (kinda) from the dash bar (not installed yet) to the foot board (also not "actually" installed yet).

Gonna (try to) put the "pitman arm" just below the floor board
...ain't got much room down there anyways, but definitely can't be standin' on them tie-rods
Looks like it'll work, just gotta make sure everything clears