Building a go kart size Aerial Atom

Status
Not open for further replies.

Tpdingo

Member
Messages
903
Reaction score
0
Location
Bellmore, NY
Lets bend some pipe :thumbsup:

I think we can incorporate the seatback/rollbar in with the bottom of the motor box.
(see drawing below) :cheers2:
Started with a 10" piece of pipe.
Marked at 20", 60" & then, at 100"
Bent it at the 20" mark to ~75* angle & also at the 100" mark to ~75*
(being sure to keep 'em in alignment)
Then, turned 'er ~90* & bent 'er to the max right in the middle at the 60* mark.

A ratchet strap easily draws 'em together to ~12" apart. :2guns:

I used my flexy straws and now my own Ariel Atom is done. I made sure to use my Harbor Freight hydraulic flexy straw bender.

It runs off coin cells and can haul two fat ants around.

:roflol:

I don't have any flexy straws :(
Nice work though! In its current state...it makes a nice coat hook! I'm sure the people at Ariel must love having their car being used as a coat hook :lolgoku:
 

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Rear Suspension

Well, that's a beginning, but what's next? :idea2:

I guess we'll start @ the back & work our way forward. :thumbsup:

An actual Ariel Atom has an independent rear suspension with a transaxle & individual axles going to each wheel.

Were not doin that. (at least not on this one) too complicated & expensive :ack2:

I think a swing arm that travels in between the bottom motor box rails might work pretty good in this situation..

So, next is to make a swing arm.

On this one, I'll just mount the motor & axle to the swing arm & then mount the batteries elsewhere.

First, we need to make a motor mount plate. (3/16" x 4" x 6" steel)

Measured, marked & drilled (8) 3/8" holes, (2) for each slot.

I used a Dremel to cut out the remainder of material & then, filed 'em 'till the bolts slid easily, in the slots.

* I am using 3/8" round headed bolts so, I don't need to use a wrench from the bottom side, when mounting the motor. :2guns:
 

Attachments

  • untitled.png
    untitled.png
    237.8 KB · Views: 5
  • SAM_2837.jpg
    SAM_2837.jpg
    256.3 KB · Views: 1
  • SAM_2904.jpg
    SAM_2904.jpg
    263 KB · Views: 3
  • SAM_2905.jpg
    SAM_2905.jpg
    243.1 KB · Views: 3
  • SAM_2907.jpg
    SAM_2907.jpg
    246.2 KB · Views: 4

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Swing Arm

For the swing arm I'll use 1" square tube, because it's easier to "square up" & the flat sides help the "rub rails" slide smoothly. :thumbsup:

First, I lined the (2) main rails up & drilled the "hinge holes".

Next, I squared a main rail up with a cross rail & tacked 'em together.

Then, squared & tacked the other (3) corners, double checked everything & welded 'er up good.

* I left ~2" in front for the "hinge" bolts & made the rear nice-n-flush. :2guns:
 

Attachments

  • SAM_2919.jpg
    SAM_2919.jpg
    495.2 KB · Views: 5
  • SAM_2917.jpg
    SAM_2917.jpg
    440 KB · Views: 1
  • SAM_2915.jpg
    SAM_2915.jpg
    315.9 KB · Views: 2
  • SAM_2913.jpg
    SAM_2913.jpg
    433.4 KB · Views: 1
  • SAM_2911.jpg
    SAM_2911.jpg
    416.1 KB · Views: 2

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Before mounting the motor plate we need to mount the axle, sprocket & bearings so, we can line everything up.
I sat the motor in place, too (didn't get any pics) & made sure everything was in alignment & cleared nicely.

Then, welded the mount plate on good. :2guns:

* Notice the way the motor mount plate got bowed a bit from welding.
 

Attachments

  • SAM_2923.jpg
    SAM_2923.jpg
    275.1 KB · Views: 3
  • SAM_2924.jpg
    SAM_2924.jpg
    242.2 KB · Views: 3
  • SAM_2936.jpg
    SAM_2936.jpg
    406.8 KB · Views: 3
  • SAM_2937.jpg
    SAM_2937.jpg
    425.7 KB · Views: 3
  • SAM_2940.jpg
    SAM_2940.jpg
    461 KB · Views: 4

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Now that we have a swing arm we can get back to the rear of the frame.

Went to set it in between the frame rails, but they seemed kinda tweaked. :ack2:

I know the swing arm is square so...

Checked with a "big" square & yup, the one on the right os off just a bit, but the one on the left is off quite a bit.

Guess we are gonna have ta do some "body work" :thumbsup:

Clamped 'er down on the back of my truck (a 10,000 lb. winch will do the trick) using a couple of 2 x 4's to spread out the pressure.

Then, slid a piece of scrap 1 1/2" pipe (for leverage) over each side & tweaked 'em back to being square.
(90* with the seatback)
 

Attachments

  • SAM_2969.jpg
    SAM_2969.jpg
    439.1 KB · Views: 2
  • SAM_2967.jpg
    SAM_2967.jpg
    414.2 KB · Views: 3
  • SAM_2966.jpg
    SAM_2966.jpg
    419.7 KB · Views: 2
  • SAM_2968.jpg
    SAM_2968.jpg
    499.1 KB · Views: 2
  • SAM_2962.jpg
    SAM_2962.jpg
    344 KB · Views: 2
  • SAM_2974.jpg
    SAM_2974.jpg
    340.8 KB · Views: 1
  • SAM_2973.jpg
    SAM_2973.jpg
    408.8 KB · Views: 1

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Next, I added a couple of "outer" rub rails. (in side of the motor box)

This way the swing arm doesn't bump, catch or clash with the lower motor box tubes

Also added a couple of wear pads (in between the hinge rails) to avoid metal to metal scraping. :thumbsup:

Will probably add a couple further back. (for power sliding) :2guns:

Once we knew what the dimensions needed to be I made up a couple of "cross bars" & welded 'em in to "lock 'er together" :cheers2:
 

Attachments

  • SAM_2986.jpg
    SAM_2986.jpg
    485.2 KB · Views: 4
  • SAM_2987.jpg
    SAM_2987.jpg
    372.9 KB · Views: 4
  • SAM_2989.jpg
    SAM_2989.jpg
    320.7 KB · Views: 5
  • SAM_2990.jpg
    SAM_2990.jpg
    248.4 KB · Views: 9

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Motor Box

Now that the bottom of the motor box, with swing arm, is done lets "build 'er up" (work on the sides & top) :thumbsup:

First, had to do some "mock up" work to get the measurements.

According to the pics, the bottom of the motor box should be just below the axle & the top should be just above the top of the rim, but not the tire.

The bottom of the motor box was supposed to be ~12" wide (between the wheels)
...but, ended up a little wider. (~14")

So, where the top should have been ~16" previously, (we had to adjust it accordingly)
…it now needs to be ~18" wide

Then, another quick "mock up" using those figures & factoring in the angles, it looks like we would need to make the upright "pillars" ~5 3/8".

This should put the top of the motor box just about where we need it to be. :cheers2:

I finally get to use a bunch of scrap pipe that I've has in a bucket for years. :wai:

2 - 18" pieces for upper cross bars
2 - 12" pieces for the rear ends of the lower "rib rails"
4 - 5 3/8" pieces for the upright pillars.

Cleaned 'em up, squared 'em up & welded 'em up. :2guns:
 

Attachments

  • SAM_3023.jpg
    SAM_3023.jpg
    309.3 KB · Views: 5
  • SAM_3022.jpg
    SAM_3022.jpg
    258.2 KB · Views: 6
  • SAM_3019.jpg
    SAM_3019.jpg
    286.6 KB · Views: 6
  • SAM_3016.jpg
    SAM_3016.jpg
    296.9 KB · Views: 6
  • SAM_3017.jpg
    SAM_3017.jpg
    231.8 KB · Views: 9
  • SAM_3030.jpg
    SAM_3030.jpg
    511.5 KB · Views: 7
  • SAM_3029.jpg
    SAM_3029.jpg
    520.4 KB · Views: 7
  • SAM_3028.jpg
    SAM_3028.jpg
    555 KB · Views: 6
  • SAM_3025.jpg
    SAM_3025.jpg
    531.5 KB · Views: 6
  • SAM_3024.jpg
    SAM_3024.jpg
    275.4 KB · Views: 5

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Now we need the pillars to hold 'er up. :thumbsup:

Used the "rough" grinder to "notch" the ends of the (4) "pillars" (5 3/8" pieces of pipe)

I sat the rear frame section (lower motor box) on the bench, sat the upper motor box on a coffee can & used a couple of boards til' the pillars would just fit in. :cheers2:

Then, used a square & tape measure to get 'er centered & squared :2guns:
 

Attachments

  • SAM_3032.jpg
    SAM_3032.jpg
    500.3 KB · Views: 6
  • SAM_3034.jpg
    SAM_3034.jpg
    309.5 KB · Views: 6
  • SAM_3036.jpg
    SAM_3036.jpg
    224.3 KB · Views: 6
  • SAM_3037.jpg
    SAM_3037.jpg
    530.5 KB · Views: 6
  • SAM_3038.jpg
    SAM_3038.jpg
    571.1 KB · Views: 6
  • SAM_3046.jpg
    SAM_3046.jpg
    483.8 KB · Views: 7
  • SAM_3042.jpg
    SAM_3042.jpg
    477 KB · Views: 7
  • SAM_3040.jpg
    SAM_3040.jpg
    512.1 KB · Views: 7

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
I used the magnetic square to help keep the pillars ~90* (from front to back) & ~45* (from side to side)

Tack welded 'er all the way around (top & bottom of all (4) pillars)

Double checked everything (distances, angles & "the look")

Then, welded 'er on good. :thumbsup:

Looks like somethin' is startin' to take shape :2guns:
 

Attachments

  • SAM_3053.jpg
    SAM_3053.jpg
    407.8 KB · Views: 8
  • SAM_3051.jpg
    SAM_3051.jpg
    468.8 KB · Views: 8
  • SAM_3050.jpg
    SAM_3050.jpg
    387.1 KB · Views: 6
  • SAM_3048.jpg
    SAM_3048.jpg
    426.7 KB · Views: 6
  • SAM_3047.jpg
    SAM_3047.jpg
    477.2 KB · Views: 7

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
It is starting to take shape quite nicely. Thanks for all the pics. Even though I don't comment too often, I find myself living vicariously through your builds :D :thumbsup:

Thank you very much. :thumbsup:

I kinda try to do my "build threads" like they did in the old Hot Rod magazines. :cool:

Step by step with lots of pics & details. :2guns:

…& hopefully we have something kool in the end :cheers2:

* If ya think about it, Go karts are mini Hot Rods :auto:
 

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Instead of making (2) separate "lower rib rails", I figured I'd try to make (1) big "U" for the "nose"
...& then see If I could add the "bows" to it :thumbsup:

First, I measured & marked another 10' piece of pipe in the middle (@60")
...& then 6" each way (@ 54" & 66") for the "nose" bends

I also measured & marked it @ 6", 12", 16", 20", 24" & 30" (from each end) for the "bows"

It took ~40 pumps @ the 54" & the 66" marks to establish the "nose"

To help "widen" the bend, I adjusted the rollers "out" a couple of notches
(It's adjustable for bending larger diameter pipes)

Then, I did 5 pumps @ the 12", 16", 20", 24" & 30" marks (on each side)
...which "bowed it in" to meet up with the upper motor box rails pretty nicely. :2guns:
 

Attachments

  • SAM_3111.jpg
    SAM_3111.jpg
    246.3 KB · Views: 7
  • SAM_3100.jpg
    SAM_3100.jpg
    263.5 KB · Views: 4
  • SAM_3099.jpg
    SAM_3099.jpg
    430.3 KB · Views: 4
  • SAM_3105.jpg
    SAM_3105.jpg
    262.9 KB · Views: 6
  • SAM_3106.jpg
    SAM_3106.jpg
    264.7 KB · Views: 6
  • SAM_3108.jpg
    SAM_3108.jpg
    264.4 KB · Views: 6
  • SAM_3110.jpg
    SAM_3110.jpg
    260.3 KB · Views: 6

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Our lower rib rail looks pretty good :thumbsup:
...but (sorry to say) it's a little bit too wide. :ack2:

So, I measured 1" each way from the center mark & cut a 2" piece out of the middle. :cheers2:

I'll use a 3" piece of 5/8" rod to "pin" 'em back together & then, weld 'er up good. :2guns:

The "nose" was ~14" wide, now it's ~12", much better. :cornut:
 

Attachments

  • SAM_3118.jpg
    SAM_3118.jpg
    309.7 KB · Views: 3
  • SAM_3117.jpg
    SAM_3117.jpg
    286.1 KB · Views: 3
  • SAM_3114.jpg
    SAM_3114.jpg
    326.4 KB · Views: 3
  • SAM_3113.jpg
    SAM_3113.jpg
    336.3 KB · Views: 3
  • SAM_3112.jpg
    SAM_3112.jpg
    363.6 KB · Views: 3
  • SAM_3120.jpg
    SAM_3120.jpg
    233.4 KB · Views: 3
  • SAM_3119.jpg
    SAM_3119.jpg
    265.8 KB · Views: 3

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Lets see if we can "get 'er together" :thumbsup:

Marked, trimmed & cleaned the ends up a bit.
:cheers2: How's that for "triangulation"? :smiley_omg:
Propped 'er up on the "right" angle & clamped 'er down

Tacked 'er on (both sides) double checked everything (height, width, length & the angle)
...& welded the lower rib rail to the motor box. :2guns:
 

Attachments

  • SAM_3121.jpg
    SAM_3121.jpg
    181.3 KB · Views: 2
  • SAM_3123.jpg
    SAM_3123.jpg
    211.7 KB · Views: 2
  • SAM_3125.jpg
    SAM_3125.jpg
    200 KB · Views: 2
  • SAM_3132.jpg
    SAM_3132.jpg
    415.5 KB · Views: 2
  • SAM_3136.jpg
    SAM_3136.jpg
    427.5 KB · Views: 2
  • SAM_3135.jpg
    SAM_3135.jpg
    273.1 KB · Views: 2
  • SAM_3134.jpg
    SAM_3134.jpg
    229.8 KB · Views: 2

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Not perfect :worried2:
...but, looks pretty good! :thumbsup:
 

Attachments

  • SAM_3141.jpg
    SAM_3141.jpg
    504.7 KB · Views: 3
  • SAM_3140.jpg
    SAM_3140.jpg
    367.3 KB · Views: 3
  • SAM_3138.jpg
    SAM_3138.jpg
    378.7 KB · Views: 2
  • SAM_3137.jpg
    SAM_3137.jpg
    387.5 KB · Views: 2
  • SAM_3139.jpg
    SAM_3139.jpg
    397.1 KB · Views: 2

Functional Artist

Well-known member
Messages
2,899
Reaction score
96
Location
Toledo, Ohio
Lets catch up a little paperwork :cheers2:

I made some adjustments to the measurements, again (for like the 56th time) :thumbsup:
Now, it looks like we'll have ~48" wheelbase & ~60" overall. :smiley_omg:
So far, we have made
1.) seatback/lower motor box combination
2.) the rest of the motor box
3.) & the lower rib rail
 

Attachments

  • SAM_3156.jpg
    SAM_3156.jpg
    231.9 KB · Views: 3
  • SAM_3158.jpg
    SAM_3158.jpg
    155.3 KB · Views: 3
  • SAM_3157.jpg
    SAM_3157.jpg
    192.6 KB · Views: 3
  • SAM_3160.jpg
    SAM_3160.jpg
    164.7 KB · Views: 3
  • SAM_3159.jpg
    SAM_3159.jpg
    196.2 KB · Views: 4
  • SAM_3162.jpg
    SAM_3162.jpg
    167.1 KB · Views: 4
  • SAM_3161.jpg
    SAM_3161.jpg
    203.7 KB · Views: 4
Status
Not open for further replies.
Top