Sequoia Electrathon Racer

[Functional Artist]

Caliper bracket CAD to steel (~10g)
...which is kinda in between 1/8" & 3/16"

Making (2) at once (1 for each side) so they match

Need to cut a 1/2 circle, out of the end, of each piece
...so, I clamped 'em together
...& installed a "notch" right in the middle

Then, layed them end to end

...& clamped 'em down to a 1/4" steel, backer plate
...& then, used the (2) "notches" to drill a 1/8" pilot hole (in between the (2) caliper brackets & thru the backer plate too)

Next, I drilled the 1/8" pilot hole out to 1/4" (when ya hit wood, ya know your done/thru)

...& then, used a 1 3/4" hole saw to, cut the hole

...& a 5/8" drill bit to install the spindle hole

Here is the back side

 

[Functional Artist]

Put the Caliper Mounting Bracket & spindle, on a wheel
...& did a "rough" dry fit of the Caliper, to double check fitness

Then, added the Caliper mounting bolt holes
...& did a bit of rounding & smoothing

A more refined dry fit (lookin' pretty good)

Checking Caliper Bracket to Rotor clearance (looks good too)

Checking Caliper to Tire clearance (~1/2")

Now, I can work on "fine tuning" the dimensions, for the custom Dual Flange Hubs

 

[Master Hack]

Your CAD design/prototyping sytem works really well. I should start using it, but l prefer to make parts like that several times, using the actual material. That way l can fine tune the parts with each revision. An added bonus is, l waste a lot of valuable time and material!

Looks nice! Up to the high standards we expect from you.

 

[Functional Artist]

make parts like that several times, using the actual material.

Hey T,

I used to do it like that too
...but, found that it takes a lot more initial work (cutting steel vs, cutting cardboard)
...uses up my materials a lot quicker
...& then, I end up with a lot of "bad parts" just laying around everywhere, in my way

Looks nice! Up to the high standards we expect from you.

Thanks!

Now, Ima workin' on measurements

Spindle mount to outer edge of the tire seem to be ~8"

 

[Master Hack]

...but, found that it takes a lot more initial work (cutting steel vs, cutting cardboard)
...uses up my materials a lot quicker
...& then, I end up with a lot of "bad parts" just laying around everywhere, in my way

All benefits of doing it the hard way. I'm too stupid to change now....

 

[Functional Artist]

After gathering all of the measurements, for the custom dual flange hub, I went ahead & drew up a Mechanical drawing
...to (well...) document where them measurements went

The upper section of the drawing illustrates the ~4" overall length, of the hub
...& ~3 1/4" from outer flange "face" to outer flange "face"

Also note, the outer "face" of the rotors bolting flange, needs to be ~1/2" from the edge (of the hub)
...to position the rotor, in the proper place
...so, it will align with the caliper

The lower section shows the measurements, for the bolting flange(s)

 

[Master Hack]

Got the CAD files? Oh yeah, they are on the cardboard!

 

[Master Hack]

Yer not slackn are ya?

 

[Functional Artist]

Yer not slackn are ya?

Nope, Just took me a couple of days to get to the steel place
...& pick up my order
...but, I finally got there

* News Flash
Weather guy says winter is a commin'
...so, I got to measurin' & markin

I used a straight edge as a cutting guide
...& used a couple pairs of Vise Grips to clamp it in place

Used a standard Cut-off wheel
...& they seemed to come out pretty straight & clean cut

All cut up

Cut a couple of hub pieces, while I was at it

Then, ~1 hour later
...winter arrived

 

[Master Hack]

Nope, Just took me a couple of days to get to the steel place

OK, we ain't got no room fer slackers!

 

[ezcome-ezgo]

Winter is overrated

 

[Functional Artist]

Winter is overrated

Hey Ez,

Well, the current temp here is 0*
...so, I'ma just gonna sit here
...& think about stuff for a while

 

[Functional Artist]

Winter is still here
...but, it's warmed up a bit (~30*)

So, I had to "clear" some space
...before I could get back to doin' some more trimmin'

After doin' some measurin' & markin'
...I used a straight edge to aid in trimmin'

Then, used the "piece" as a template for trimmin' a couple more

I used a paper template to help with markin'/trimmin' the 4" (rotor flanges)
&
Jualla, we have (3) 6" wheel flanges
...& (3) 4" rotor flanges

 

[Denny]

Wait, I’m lost. Who’s Julia? Looks good.

 

[Functional Artist]

Wait, I’m lost.

Um....that's what Brandon says

Who’s Julia?

Inga's sister

Looks good.

Thanks,
...are ya still feelin' fatally ill?

 

[Denny]

...are ya still feelin' fatally ill?

You weren’t supposed to tell anyone!

 

[ezcome-ezgo]

 

[Master Hack]

Ya need to adjust yer meds? Since ya been stealin ours...

 

[Master Hack]

I like the way ya stage the photos with the grinders and clamps in the shot. Then bring out the finished laser cut parts, for the final shot!

Nice work!

 

[Master Hack]

lf ya ever want to drill a flange for one of dem brake rotors, here's the pattern.
easy fo figger out with a bolt circle calculator