Polaris

[Denny]

Oh...yea
...& we gots us some "baby ducklings" too

Before (& still workin'-inspectin our brake components, before assembly)
View attachment 142155
After
View attachment 142156
We gots (4) 'wittle guys (or gals?)

Didn't want to disturb 'em too much
...so, I'll get better pics later

Oooh, bite sized!
Do you have a little kid to drive this? Saves weight!

 

[Functional Artist]

American ingenuity at its finest. The wheels, not the cat...

Thanks!

I got a set of rotors, to use with the 48mm adapter hubs that I have
...but somehow, I ordered 160mm rotors (instead of 180mm rotors)
...& the spindle brackets are made to work with 180mm rotors
& also,
I noticed that I bent the brackets backwards
...so, the left caliper went on the right side (but, upside down)
...& the right side went on the left (also, upside down)

So, back to the drawin' board

I bent up a couple more spindle brackets

I needed (3) lines, on the same level, on both pieces

So, I used a 3/4" wide piece of steel to mark 'em all evenly


Left side V1 / right side is V2
* Notice the difference in the position of the caliper bolt holes?

 

[Master Hack]

Still ingeuity at its finest, just backwards. I did QC at a sheetmetal shop for short time. You would be surprised at how many times experienced pressbrake operators woud bend parts backard.

 

[Functional Artist]

I re-established the Ackermann angle

Marked 'em at the 2 1/2" & 3"

...& whittled down some of the excess material off of the spindle brackets

Left side is before & right side is after some whittlin' & smoothin'

Used the whittled down bracket, as a template, ta make the other side match

Ta lighten 'em up a bit more, I added some holes, ta remove some material
...& them holes may even help provide some ventilation, to the brakes

Next I gotta install the spindle/axle(s)
Anyone have an opinion on what grade of 1/2" bolt should be used? (Grade 3 or 5 or 8?)

 

[Functional Artist]

Hey Master Hack,

How much Loctite should be used or is recommended for bearing retention?
...just a drop & let it spread around?
...a light coating, on both surfaces?
...or slather it on & just wipe off any that squeezes out?

Also, I would assume that some should be applied to both sides, of the spacer material?

So, in between the bearing & spacer
...& also, in between the spacer & hub

 

[Master Hack]

The correct answer is B, light coating a both.
Shims, bearings, hubs anything ya want to stay put. Then it takes a few hours to grab hold.

 

[Functional Artist]

I got some of both (grade 5 & grade 8)
...but, stronger is better (right?)
...so, I went with the grade 8 (1/2" x 5") bolts (& their golder)

Before attacking one of my V2 spindle brackets with the welder, I stuck a 1/2" bolt into one of the V1 spindle brackets
...& did a couple of test welds

Not too bad I guess

According to the heat marks, on the other side, it seems like we got some decent penetration

Also, had an idea

Yup, there's one for each side

 

[Functional Artist]

What the heck are those things?
...& what are they used for?

Well, Ima glad you asked

I wanted/needed to weld the spindle bolts, to the spindle brackets, on both sides ta make 'em stronger
...but, I also needed a nice flat surface for the bearing (or washer) to sit/ride against
...& I didn't want to have a clean up nightmare
...&/or mess up the spindle
...so, I made up them little guys

They go over the spindle, to give us a nice flat bearing/washer surface

* I used a piece of conduit to use as a temporary spacer
...to bolt the spindle bolt down good-n-tight
...& protect the spindle/axle from "splatter" during welding

Up close view
* Them openings, will allow me access to the bolt
...so, I can weld the bolt to the bracket
...& also, to the little spacer (making them all "as one")

Kinda like this

 

[Master Hack]

Excellent! Grade 5 would have been plenty strong, but overkill is mo bedder! Who doesnt love a grade 8 bolt?
Even stronger is a socket head cap screw (SCHS). Just for future reference.

Bolt Grades Decoded: Essential Chart for Builders!

Explore essential bolt grades with our comprehensive chart for builders, detailing US and metric strengths, and easy PDF downloads.

www.cnccookbook.com

 

[Functional Artist]

Excellent! Grade 5 would have been plenty strong, but overkill is mo bedder! Who doesnt love a grade 8 bolt?

Yup mo bedder
...& they are gold

Dry fit 'em (again)

Another (closer) view
* Notice the nice-n-clean spindle/axle

Looks pretty good ta me
...so, after some clean up, I hung 'em up & wiped 'em down

Then, sealed 'em up with some Satin Black spray paint

Back side

 

[Functional Artist]

I finally received my order for a bottle of Loc-Tite 680 (green) High Strength Retaining Compound

Assembled a tray of parts

First, I cleaned up the hub (inside & out)
...& inside of the adapter hub too

Applied a small bead around the perimeter of the hub (& spread it around)

...& a light coating inside (on the threads) of the brake rotor adapter too

Then, put 'em together with the green hub rings
...& some Stainless Steel hardware (bolts, washers & Loc-Nuts)

The brake rotor (adapter) is now firmly attached (mechanically & adhesively)

I also, put some of the retaining compound on the threads of the bolts (under the Loc-Nuts) for added durability

 

[Functional Artist]

I did about the same procedure ta "glue" the bearings into the hubs

Looks like this

...& this

Just to be sure the bearings were setting "true" I ran a 1/2" bolt thru each wheel & then, let 'em set for a day

The next day
...& were ready ta roll

 

[Master Hack]

Looks great! With the shim material in there, the bearings fit the hub nicely.

 

[Functional Artist]

Looks great! With the shim material in there, the bearings fit the hub nicely.

Thanks!

Yup, it's almost like a machined fit, thanks to your expert advise

I also, used some of the Loc-Tite ta "glue" some Chineseum bearings, into the Boss Tubes, that I got off of some old scooter wheels

These should help 'er ta turn a bit smoother than just havin' a 1/2" bolt run thru a couple of 1/2" holes

Bottom side

Let them sit for a day
...& then, dry fit the spindles, again

Another view

...& then, the wheels, again

...& calipers, again

Top view

 

[ezcome-ezgo]

ooh man this is coming together. Looking forward to the next installment.

 

[Functional Artist]

Steering Stops
I didn't incorporate any steering stops on to the spindles
...&/so, it seems like they turn too far

I used a stock go kart spindle for a turning range comparison

* The turning range seems ta be ~45* (each way)

** Notice the arm of the stock spindle "bumps" against the mounting bracket, creating a "stop"

So, (1) side provides a "stop" when turning in (1) direction
...& the other side provides the "stop" when turning the other direction

So, here is starting off at pretty much going straight (90*)

...& we want them to go to about here (45*)

Clamped a piece of steel "stop" on the Boss Tube
...& compared it to the stock spindle again

Looks pretty close ta me
...but, I'ma gonna just tac them in for now (just ta make sure)

 

[Functional Artist]

The morning dew has been initiating an unwanted patina on the chassis
...so, after lots & lots & lots of clean up (basically "four hours later")
...& "boy 'O boy" do my hands & arms ache

Then, I sealed 'er up, ta stop all of that patina BS "in it's tracks"
...& make 'er look purty too

* Set 'er up on an angle, ta be able ta paint up under
...& in all of the nooks & crannies, first


Another view

Then, set 'er down nice-n-level
...& went at 'er again

Another view

...& even another view

* Notice, I didn't seal up the Boss Tubes (&/or their attachment areas)

They are just tac'ed in place
...& I want to do some testing, ta make sure of steering functionality, before weldin' them on good-n-solid
...& then, sealin' them up

 

[Functional Artist]

I'd like ta point out the 5-Point seat belt harness mounting brackets (as required in the rule book)

This pic shows the (2) side seat belt mounting points (top & bottom)
...& the mount for the crotch belt too (over on the right side)

Close up view of (1) of the side mounts
...should be good-n-strong

The upper holes, in these dual-purpose brackets, are where the shoulder straps will mount
...& the lower holes are for mounting the seat

 

[Functional Artist]

I'd also, like to point out the control cable mounts

In this pic (on the left side) is the dual brake cable mount.
(the rule book requires an independent brake cable, going to each front brake calipers)
...& on the right is the front cable mount, for the throttle

Here is the rear cable mount, for the throttle
...& the throttle itself, mounts on this little "pearch"

 

[Denny]

Where is the gas tank?