2015 - "Alumaflyer"

[slidewayz]

DirtyDamage, thanks for the very nice words.
Joe, thanks for noticing the roadster. No this is not the original. We are calling the roadster a tribute build, as it won't have a flathead or buggy spring rear end. But aesthetically should be pretty close to the version that won the America's Most Beautiful Roadster award in 1955. Thanks for asking, and cool info about the magazines.

 

[slidewayz]

PS, Ray is our uncle.

 

[slidewayz]

Well, first mounting of the rear axle is done. The plate that becomes there rear bumper was too narrow. I forgot to allow for the widening of the frame because of its taper, so I have to draw up and route a new piece for that. My engine plate didnt come out half bad, but it needs a bit of tweaking as well, but nothing too major. Brake mounted up just as I had hoped, and the lever is nicely tucked inside the frame rail.


Snagged the 212 off my Rupp for a test fit. Dropped right into place.




The big goals for this weekend are to finish the seat back and support. Bolt in the seat sides and bend up the center bulkhead in prep for my steering columns arrival. I also need to finalize the part that will become the support for the front of the engine swing mount.

 

[Desertduler]

Looking Fantastic!

 

[chancer]

Nice!

 

[DirtyDamage]

very nice build so far, can't wait to see the finished project.

 

[slidewayz]

Well I got about 80% of what I wanted to do done. But I did order a bunch of new button head allen hardware and nylocks for all the fastening of the chassis and axles. Right now I am just buttoning things together with whatever I can find on the shelf. The center bulkhead was a bit more work than I anticipated (go figure) and I also had to make accommodations for the throttle cable and brake rod in it and also in the seat back that I nearly forgot about. And wow did adding that one single piece to the chassis stiffen it up big time...very happy about that. Also notched and formed the rear seat support and started installing it. It is currently just tacked in place with some self drillers, but I will be putting that together with rivets at final assembly.

Here are the pics...




Finish this area up and next items will be the front axle and spindles.

Thanks for looking in guys and the very generous compliments.

 

[chancer]

ok... so..... do want to sell it????
Just kidding. but... Man that is nice. being a former sheet metal guy. It is so cool to me. I want one.

 

[landuse]

This really is an awesome build, and your skill shows

 

[Desertduler]

Slide, That thing is flat cool!

 

[slidewayz]

Thank you guys very much....very very humbling indeed, especially in the company here...some very talented folks on this site!

So far I am really happy with the concept, and design of this lil guy. The tweeking of my design file continues, and with every part I modify and install, I make notations of the adjustments as I go. I still have plans to build one of these out of .063" and the hope is that with that one the parts will be refined enough that all I will have to do is drill some 3/16" holes for the button allens here and there, and weld up the front and rear bumpers and the chassis will somewhat fall together after its been bent up. I see little things here and there as far as the look that I want to change. I think the seat back looks too bulky so I will be changing that a bit, and I am reshaping the seat gussets just a tad so they fit better and hopefully look better. I also had a bit of a snafu, as the steering column upright would not fit into my brake after 3 of the 4 required bends. So on this one I had to do the final bend over an anvil. So I have redrawn that part so it will better suit my equipment. I am also in the process of drawing my design for the pedals. If it all works out there will be 6" of adjustment in the pedals....

Thanks again fellas!!!

 

[Desertduler]

The thing that I have found also is the next time you build another kart you will have a better idea on how to do some things easier and better, little refinements here and there keeps ones mind occupied with thoughts and different ideas, your next one will be even better and so on, that is what is so much fun to me and challenging,I would love to see one of your aluminium karts with a little two stroke on it just like in the 60's, when I was a kid I worked as a mechanic at a lawnmower / small engine shop and I let many of those old two strokes slip out of my hands and into the garbage bin, I wish that I would had kept all those engines but when you are a kid you don't always look ahead into the future!

 

[chancer]

I agree. The second time around is easier and comes out way better. I just built matching karts converted electric for my two kids. The second was way better and is adjustable and better thought out. But I still really like your original here.
O and been there done that... I hate when your piece will not go back in the brake after 3 of 4 bends. At least for you, your not at work and if you had listened to your boss and did the bends in the order he said it would have worked. and now he is standing there looking at your anvil\pliers\ugly bend, going I told you so. I am glad I dont work there anymore, but I do miss the sheet metal Fab. It was just HVAC.

 

[OzFab]

ok... so..... do want to sell it????
Just kidding. but... Man that is nice. being a former sheet metal guy. It is so cool to me. I want one.

Slide, That thing is flat cool!

Thank you guys very much....very very humbling indeed

...& you were worried?

 

[slidewayz]

Thank you guys for all the great comments, input and even the bit of ribbing. The attention my lil Alumaflyer is getting here is awesome, and very encouraging. I really feel its just enough of a departure from the norm, and yet its very traditional too. I actually cant wait for the opportunity to build a few more.

Not a whole lot to report, other than a few more bits and pieces showed up on the door step today. All the components for the steering column, a new 72T sprocket, and throttle cable. So I nearly have all the bits to make it a roller. Which leads me to tonights progress. I started making a little jig to build the front axle on. Hopefully this will aid in setting the spindles, and the angle brackets that will be welded to the axle so it can be bolted to the chassis. Here is what I have so far....


Hopefully by the end of the weekend I will have a rolling chassis.....fingers and toes crossed.

Thanks again guys!

 

[landuse]

Nice. Could you explain how that jig is going to work. I am scratching my head here

 

[slidewayz]

Nice. Could you explain how that jig is going to work. I am scratching my head here

Best I can explain right now is, it will have fixtures for the angle iron brackets to drop in so they will be in the correct place. Then I will have a few stops welded in place to hold the 1" round tubing axle perfectly in place, square and plumb. Then I think there will be some 5/8" rod with welded washers that will hold the spindle brackets exactly where I want them. I am leaning towards 12-15 degrees of castor, and the 5/8" rod will dictate that as well. I hope to weld it all together in place on the jig, then be able to lift the entire assembly out of the jig, and install the axle into the chassis.

Well thats the initial plan anyhow.....Clear as Mud....

 

[chancer]

I think I understand now. It would be cool if you shared that process as it goes. But I know how it is when you get in the zone of fabbing stuff. It is hard to stop take pics and explain.

 

[crazykart]

Step a: set up video camera.
step b: do the jig work while talking yourself through it.
step c: post it up here for all to view.
step d: grab a beer lol

 

[Joe-405]

Or e ........... Take a few pics while its in the jig right before welding it. Bet half of us could get it from there.