American Ethos (2025) Electrathon America Racer

[Functional Artist]

The first tab welded on "normally" nice-n-straight

...but, the second tab somehow "tacked" down kinda crooked (technical term)

So, I got out my "patented" adjustable tab adjustor
...& did some adjustin'
...before weldin' 'er on good-n-solid

Yup, they seem ta be lined up, pretty nicely

My "patented" adjustable tab adjustor
...also, works for adjustin' seat mounting brackets too

Left side, rear seat back mount installed

Another view w/both brackets

 

[Functional Artist]

Trays & Pans

When workin' on a project
...I always try-n-use trays (or pans)
...to hold all of the parts
...for THAT project

Like while doin' all of the assembly, dis-assemble & reassembly of the Nacelles
...so, nothin' gets lost &/or mis-placed

I also, re-use my wife's old bakin' pans
...when she gets "fresh/new" pans
...& de-commissions the old ones

I like to use the steel pans on my drill presses
...to help "catch" the steel shavings
...& debris from drillin'

* I found that ya gotta "mark" em'
or
One day your wife will come out
...& "see" her pan
...& you WILL get "the look"
&
Then, you WILL be questioned
...about using "her pan"
...to collect steel shavings
&
Even when you try-n-explain to her
...that...that is one of her old pans
...she IS still skeptical
SO,
Now, I "mark" 'em
...with spray paint
...just a "spot" will do

 

[Functional Artist]

Ducky says "Whatsa ya got goin' on today?"

What's this thing?

He...he...he...do you wanna use it?

Well...Ducky...that is a 5-n-1 scraper tool
...& it's great for removing welding debris
...especially, when building "tube" chassis

They are great for general scraping
...on flat surfaces
...like coil-over shock bracket mounts

The curved area is great for scraping round surfaces

That "pointed" area is great for gettin' in them little nooks-n-crannies (technical term)

* Here, I'ma makin' sure that the area where the Nacelle's rubber bushings "go"
...is "nice-n-clean" before re-assembly

 

[Functional Artist]

Now, I gotta do another re-assembly
...to make sure everything still works together
...& everything "clears" everything else
...&/also, "plays together nicely"
...with the seat installed

After cleaning the area of weldin' debris ('cause them little metal "balls" could/would damage the rubber bushings)
...I re-installed the Nacelle bushings

Then, re-installed the Nacelles
Profile
On angle view
Yup, I'ma happy to report that everything "seems" ta be co-operatin'

Another view
More weldin' (rear Castor Wheel mount)

* I left the seat & Nacelles mounted for this weldin' procedure
...but, used an old weldin' apron
...to protect these components

Especially the plastic seat
...as it was the closest to the weldin' area

 

[Functional Artist]

Rear wheel/Castor...installed

View from the rear

Profile

Yup, it can swivel a complete 360* (if necessary)
...& clears everything...pretty well

The rear bumper will help keep 'er protected
...& functional (technical term)
...if ever impacted from the rear (during a race)

Now/next, maybe we can "tuck" a front wheel up under here

Probably somethin' more like this

* I'ma thinkin' the front wheel could just be stationary (not swivel-able)
&
Maybe have it "suspended" ~1/2" (hangin' up in the air...not w/suspension)

So, it doesn't add extra "rolling resistance" (or drag)
...during acceleration
...or while crusin'
...&/or affect maneuverability (when steerin')

* This front wheel should only "come into play"
...or be used to "catch" the momentum (mass) of the vehicle
...which would make the front of the racer "dive" (go downward)
...when/while braking

 

[Denny]

Ducky says "Whatsa ya got goin' on today?"
View attachment 154894
What's this thing?
View attachment 154895
He...he...he...do you wanna use it?
View attachment 154896
Well...Ducky...that is a 5-n-1 scraper tool
...& it's great for removing welding debris
...especially, when building "tube" chassis
View attachment 154897
They are great for general scraping
...on flat surfaces
...like coil-over shock bracket mounts
View attachment 154898
The curved area is great for scraping round surfaces
View attachment 154900
That "pointed" area is great for gettin' in them little nooks-n-crannies (technical term)

* Here, I'ma makin' sure that the area where the Nacelle's rubber bushings "go"
...is "nice-n-clean" before re-assembly
View attachment 154899

But that’s only 3 uses what are the other 2?
That front wheel is awefully close to the “Crown Jewels” ain’t it?

 

[Functional Artist]

But that’s only 3 uses what are the other 2?
That front wheel is awefully close to the “Crown Jewels” ain’t it?

Hey Denny,

I "nailed (3) of 'em
...so/maybe that there...my friend...is (1...or 2) of the mysteries of life

It seems like when a driver is seated (in the drivin' position)
...the wheel would be up under the "arch" of the driver's knees (in that unused little pocket)
&
That front wheel, would also have a fender (steel or fiberglass) over it
...as part of the floorboard
&/also
This way we maintain a nice foot-well
...in the front area

* The floorboard will be ~3" lower than the "lower chassis rails"
...just under the bottom of the seat

 

[ezcome-ezgo]

My $0.02 is make the front wheel swivel also. The front end of a vehicle can dive for a number of different reasons, if you are in the process of trying to negotiate a turn and a stationary front wheel strikes the ground, you'll probably be looking at the event upside down.

 

[Functional Artist]

My $0.02 is make the front wheel swivel also. The front end of a vehicle can dive for a number of different reasons, if you are in the process of trying to negotiate a turn and a stationary front wheel strikes the ground, you'll probably be looking at the event upside down.

Hey Ez,

Love the "feedback"
...& appreciate the concern
...keep "it a commin"

For the record, Zero (~2017) was V1 of this "powered steering" concept
...motivated by (2) 36V 350W motors
...with (2) swivel Castor wheels, in the front
...& (sucky) scooter hub brakes

Land Speeder (2023) is V2 of this "powered steering" concept
...motivated by (2) 48V 1,000W motors
...with (2) stationary wheels, in the rear
...& (hard on the tires) scrub brakes

American Ethos (2025) would be V3 of this "powered steering" concept
...also, motivated by (2) 48V 1,000W motors
...but, with (1) swivel Castor, in the rear
...with (go kart style) drum brakes
...& (hopefully) better balanced
(video(s) to come)

So, I'ma just tryin' some different ideas
...but/also, tryin' ta be safe about it

"you'll probably be looking at the event upside down."

I'ma hopein' NOT
...but, that's totally what the driver "safety cell" (double frame rails around the driver) is for
...plus, the roll cage
* Which is specifically designed, to be able, to support the entire weight of the racer, plus the driver & battery pack
...& completely protect the drivers head too
&
There will be more to the roll cage
...just haven't got that far yet

Also, gonna have a 5-way safety belt system
...ta help keep the driver "strapped" in the "safety cell"
...in the event of an incident

* TBH I have this same concern about a racer that
...should be able to go 25+ MPH
...without (an actual) steering wheel

 

[Functional Artist]

Also, for the record
I'm NOT an actual "formally educated" engineer (design, electrical &/or mechanical)
...I just "play as one"
...in my back yard
...& on the internet

FYI:
The "wheel track" (from the outside edge of (1) tire to the outside edge of the other tire)
...is ~46"
&
The overall length of the chassis is ~60"

So, more thoughts about the front wheel...set-up
...& placement

1.) What would be the difference in "tip-ability" &/or maneuverability (in general)
..."if" the front wheel was "further back"? (toward the rear) (like I have pictured...above)
...as opposed to being closer to the front? (like right behind the front bumper)

2.) What "if" the front wheel was
...horizontally "spring loaded"? (think about it)

So, "if" the front wheel was to
...touch the ground
...in a turning situation

The front wheel would "give" a little bit (if necessary)
...& couldn't "immediately" act as a "pivot point"?

 

[Denny]

Also, for the record
I'm NOT an actual "formally educated".

Oh we know buddy, we know.
Sorry, I saw my shot and had to take it.

 

[Functional Artist]

Ducky went "splat"

Workin' on mountin' the front wheel

I'ma thinkin' about like this
* Notice the front wheel is "propped up" ~1/2" higher

Another view of the "mock up"

* Notice the "alignment lines"?
...& the "areas to be cleaned" for weldin'?

Everything re-aligned
...& ready for weldin'

After tackin' & double checkin' that everything was still "in place"
...I flipped 'er over for more weldin'

* I wasa weldin' along pretty goodly
...& ran out of wire

I went & got some new wire
...but, NOW the welds are lookin' kinda crappy

There doesn't seem to be much of any slag coverin' the welds (like usual)

 

[Functional Artist]

What "if" the front wheel was
...horizontally "spring loaded"?

WTF does that even...mean?

Well...it means
...ta have a small spring
...on each side of the wheel

So, the front wheel has the ability
...ta "slide sideways" a little bit
...if it wants ta

I harvested the spring from an old Aluminum screen door

Ya know that "spring loaded catch"
...that "hangs" from the top
...to help "catch" the door when them hard wind gusts...come along

Ex.

Just had ta cut 'er in 1/2

Nice-n-even

* Notice the "cut outs" for mountin' the axle?

 

[Whitetrashrocker]

We have use those same springs on the tailwheel of the supercub.
A&PIA approved.

 

[Functional Artist]

We have use those same springs on the tailwheel of the supercub.
A&PIA approved.

Hey WTR,

Yup, I can "see" where this horizontally "spring loaded" concept
...could be beneficial, to the tailwheel of airplanes

Front "horizontally spring loaded" wheel...installed

Still...suspended (in the air)

Startin' ta "take shape"

 

[Whitetrashrocker]

They help keep the shimmy out and still allow for light turns. A heavy turn will cam over the mechanism and the wheel will free spin.

 

[Denny]

Better inflate that tire to get the proper circumference before you burn it in forever like.

 

[Functional Artist]

They help keep the shimmy out and still allow for light turns. A heavy turn will cam over the mechanism and the wheel will free spin.
View attachment 155097

Hey WTR,
That concept is a bit different, than what I got "goin' on"
...but, I like it
...& will definitely "keep it in mind"

 

[Functional Artist]

Better inflate that tire to get the proper circumference before you burn it in forever like.

Hey Denny,

"We don't need no stinkin' air"

Yup, I thought about that too

The front & rear wheels are the same (rim & tire)
...& seem to have about the same height (with or without inflation)

Inflation just seems to make 'em more "bouncy"

 

[Functional Artist]

Inspector Ducky...takin' a well-deserved nap

Oops...musta woke 'er up
...while workin on a CAD floorboard

I'ma thinkin' ta have the "fender", in the middle
...with "drop downs" on either side
...& a "foot well" in the front, in the front (where the brick is)

Takin' measurements-n-notes, from the CAD mock-up

Then, transferred the "notes" to a piece of 1/8" Hardboard

Then, used a table saw to cut some "slots" or strips