Diamonite Electrathon America Racer

[Master Hack]

It might be a good idea to chase those threads. That 5052 aluminum is purdy soft and my antique taps are getting dull.

 

[Functional Artist]

A bit of progress
Gots a "new" idea
...for a "laminated" fiberglass Swing arm
&/so
Ta "work" on it
...I went ahead & assembled the rear wheel

We gonna be "running" a 13 x 5.00 x 6 ribbed tire

Here is the sprag/freewheel unit & 48T x #35 sprocket

 

[Denny]

Is that tire ribbed for her pleasure?

 

[Functional Artist]

Is that tire ribbed for her pleasure?

Of course

I had some issues mounting the tires on these rims

These tires are labeled "tubeless"
...so, they are designed to fit "tightly"
...but, WTF??

Doin' research, some say to use talcum powder ta help the rim, slide into the tire
...but, a whole ~1/8"...yea right!

After "fighting" with 'em for a while
...I "trimmed" a little bit off

* Not sure if you're supposed to do that
...but, I did

Tried ta keep the "trimming" nice-n-even, all of the way around

Yup, they fit on there...now

 

[Functional Artist]

I wasa/been thinkin' about the monocoque mold, that I built last winter, for Diamonite

Now, that I'ma learnin' a bit more
...it seems the mold, that I made is...just awful

In a few different ways

I ain't gonna even gonna try-n-explain

So, "for my next trick"

Ta da

 

[Denny]

NAPA Ruglyde for rubber. Use it on tires all the time.

 

[Functional Artist]

Back to the "drawin' board"

I gots some new ideas
...& some more boards...too

Went-n-cut 'em up

Pile 'o wood

After some assembly

Used a plate ta mark/round the upper corners

 

[Functional Artist]

Roughly assembled into some "ribs"
...on a "kabob"

* Notice the "skewer"?

The "skewer" helps with "rib" alignment
...& will make the whole (upper 1/2) "mold" turntable
...like on a rotisserie

Assembled 'er on the "base"
...ta make sure "everything" lines up

FYI: the "base" is upside down

Um...I made a "covered wagon"??

 

[Functional Artist]

3D
Small (in front)
...big (in the middle)
...& small (in the rear)

Covered the sides with strips of 1/8" MDF

Used spray foam to "fill in" the gaps
...& help "stiffen up" the wood strip/sides (ta make 'em all "as one")

* Now, it looks like a boat

 

[Functional Artist]

Base
...upside down
...ta "work on" the "outward facing side"

The perimeter is the same, as the bottom edge of the "body" plug
...but, the top (actually the bottom) is a ~1/8" smaller
...so, I could make the sides "taper" inwards a bit

The actual top (still the bottom) is ~1/2" smaller
...so, I could really round them edges goodly

This is the front (work still in progress)

This view shows the round-ness
...& taper, that I'm "goin' for"...pretty well

 

[Functional Artist]

Glue is dry
...& the foam has cured

Body work begins
First, I did some "rough" smoothin' & shapin of the wood
...then, "trimmed" out some of the excess foam

Applied some body filler

Primed/sealed up that 1/2

 

[Functional Artist]

Just like when I made up the FG hoods for American Ethos racer, I'm researchin' experimentin'/tryin' different materials

I have an almost full can of White Rustoleum Oil based paint

* From my experience, a couple of coats of this stuff creates a really durable surface/finish
...much thicker & stronger than standard spray paint

So, I wanted to "see" how well it would work on a FG plug/mold

But, I wasn't sure if
1.) Oil based paint could just be applied over new/bare wood
2.) What kinda primer would work with wood & oil based paint

So, I did some researchin'
...& come across/found this stuff called Gesso

Gesso (Italian pronunciation: [ˈdʒɛsso]; 'chalk', from the Latin: gypsum, from Greek: γύψος), also known as "glue gesso" or "Italian gesso",[1] is a white paint mixture used to coat rigid surfaces such as wooden painting panels or masonite as a permanent absorbent primer substrate for painting. It consists of a binder mixed with chalk, gypsum, pigment, or any combination of these.[2]

Gesso is used in painting as a preparation for any number of substrates such as wood panels, canvas and sculpture as a base for paint and other materials that are applied over it.

So, ta seal up this wooden "bottom" &/or "floor plug/mold" I got & tried some

Yup, it gave 'er a smooth but, kinda chaulky surface (perfect for paint)

Then, after a couple of hours
...I gave 'er a coat of the White Rustoleum Oil based paint

 

[Functional Artist]

Body workin' the other side

...& more rounding

Worked on evening out the (2) sides
...so, they kinda match
Front

Back
I'ma gonna try this Gesso stuff, on the body plug/mold too

 

[Whitetrashrocker]

Don't you have a day job? You're the busiest guy I know.

 

[Functional Artist]

Don't you have a day job? You're the busiest guy I know.

Hey WTR,

Yup, I'm self-employed/drive a tow truck (a little over 30 yrs...now)
...& am almost always "on call"
But
Whilst I'ma waitin' for the phone to ring
...instead of just sittin' around
...or watchin' TV
...I do stuff
&
While I'm out driving around (towing cars) I think about
..."what I'ma doin' next" on my projects
or
Pick up any needed supplies
...while I'ma...already out

 

[Whitetrashrocker]

I knew that.
Sarcasm doesn't translate well. Lol.
Self-employed, good man.

 

[Functional Artist]

OMG
The more I worked on this "thing"
...the more I dis-liked it

On the "bright side"
...I'ma learnin' stuff

Like I found that, using 1/8" MDF strips wasn't a good idea
...as they don' hold their shape very well between the upright supports (wavy)
...& they "flex" a lot, when tryin' ta do body work (smoothin') too

So, I tried to re-enforce or "back 'em" with some spray foam
...but, found that "spray foam "keeps on tryin' to expand, for several days after application
...& this continual "pressure" actually made the wavy-ness, of the strips worse(r)
&
I just didn't like the overall shape either

So, I went back to the "drawin' board"

I'ma gonna try-n-use some different materials for the "strips" (1/2" MDF)

...& a bit of a different construction method too

This monocoque/body/mold will have a bit more 3D "roundness" to the sides
...& the "top"

Both "up & down"
...& from "front to back" too

 

[Functional Artist]

Been makin' some progress

Another view

Closer up(per) view

Top(per) view (of the "nose")

More progress...
Front "bumper"

With "grille"

Another view

 

[Denny]

But the big question is will you be able to fit in it?

 

[Functional Artist]

But the big question is will you be able to fit in it?

Hey Denny,

The "nose" is ~36" wide
...the "tail" is ~14" wide
...& the sides are ~20" tall (in the middle)

So, yup
...everything but the drivers head

Also, all (3) of the wheels will be inside of the body too

* The front wheels require/need ~8" (on each side)
...so, with a 36" (nose) - 16" (8" wheel wells x 2) = 20" (of leg room)