Diamonite Electrathon America Racer

[Denny]

Are you wanting to add a sprag to freewheel the motor?

 

[Functional Artist]

Are you wanting to add a sprag to freewheel the motor?

Hey Denny,

Yup,

To help visualize
...check out this video that shows Polaris with a free-wheeling, rear wheel
...& Sequoia with a direct drive rear wheel

* Rear wheels & freewheel unit shown ~4:00 into the video

 

[Denny]

As long as the sprag holds up it’s a great idea to conserve energy. Not so much for slowing down though.

 

[Master Hack]

You have the threaded thingy on the left? I don't. (Thingy 1)
l have the threaded thingy on the right.( Thingy 2)
the blue sprocket goes on the right?
so thingy 2 gets welded to the wheel flange, thingy 1 gets bolted to the sprocket.
Is thingy 2 the same material as thingy1? Please don't tell me thingy 2 is a pipe fitting.
assuming thingy 2 is steel that means a steel wheel flange (for welding)

 

[Functional Artist]

Hey T,

Left to right
1. wheel flange (not included in the box, because I wasn't sure if we should use 1/8" or 3/16" steel)
2. threaded free wheel mount (included in the box)
3. free wheel unit/sprag (included in the box)
4. 48T (blue) sprocket (included in the box)

So, #1 (a steel flange) needs to be welded to the non-threaded side of #2 (threaded free wheel mount)

 

[Master Hack]

I expected to make the wheel flange, but l didn't find thingy 1 in the box.
all l found is thingy 2. You sure thingy 1 got in da box?

 

[Denny]

No, it’s not in the box because he is unsure of how thick it needs to be. I think 3/16” because of side loading, but it’s not my call.
Hope that clearerized you.

 

[Master Hack]

No, it’s not in the box because he is unsure of how thick it needs to be. I think 3/16” because of side loading, but it’s not my call.
Hope that clearerized you.

Pay attention! That is the other thing.

 

[Functional Artist]

I expected to make the wheel flange, but l didn't find thingy 1 in the box.
all l found is thingy 2. You sure thingy 1 got in da box?

Hey T,

Hmmm...it should have been in the box
...'cause I knew you would need it

I even cleaned off my work bench today
...& double checked, just to be sure

I have another freewheel unit & mount


This is what the mount itself looks like (for reference)

 

[Master Hack]

Nope only thing l got was this thingy:



OH WAIT!......

Boy l feel purdy stupid now....

 

[Functional Artist]

Hey T,

No worries...mate!

It was hidin' in "plain sight"

Glad you found it


Still doin' research

This is about thermoforming plexiglass windscreens

 

[Denny]

I hate the way Canadians talk. Aboot for about, ut for out and others. But it was informative and his wife is hot!

 

[ezcome-ezgo]

Bad Chad is da man

 

[Functional Artist]

Hey You'all,

Stand back!
...or sit down

I gots me an idea

What if...we design & make a monocoque out of some formed polycarbonate sheet?????????
...kinda like Transparent Aluminum (IIRC from Startrek 3)

Hold on...hold on...hold on, before ya answer
...check it out, here is some info/homework

Were thinkin' "outside" of the "box" here
...so, ya gotta be "openminded"
https://plaskolite.com/docs/default-source/fab/fab015_tuf_en.pdf

 

[Master Hack]

Among all the other high tech materials that get used here at the MT top labs, poly carb is our fav.
Heating and forming the stuff is easy enough, with only one problem. It has to be heated EVENLY or disaster awaits.
While the oven in the kitchen works for most parts, large parts present a problem. The stuff is incredibly tough and there is a reason its referred to as "bullet proof glass". It's a great material and fun to mold into desired shapes. It is not cheap tho.

 

[Denny]

Hey You'all,

Stand back!
...or sit down

I gots me an idea

I thought I heard what sounded like a giant wet fart coming from out west.

 

[Functional Artist]

Among all the other high tech materials that get used here at the MT top labs, poly carb is our fav.
Heating and forming the stuff is easy enough, with only one problem. It has to be heated EVENLY or disaster awaits.
While the oven in the kitchen works for most parts, large parts present a problem. The stuff is incredibly tough and there is a reason its referred to as "bullet proof glass". It's a great material and fun to mold into desired shapes. It is not cheap tho.

Hey T,

I've never even thought about workin' with this stuff

When researching DIY windshields someone mentioned that polycarbonate was virtually indestructible
...& I was like WAIT...WHAT???
...& the "gears" (in my little head) started a spinnin'

Check this out
...then, imagine a racer body size tube

Thinkin' out loud here:

Maybe
1.) Curve/cold form a sheet of polycarbonate sheet into a semi-oval
...& use some shaped bulkheads (front, middle & rear) ta help maintain the shape

2.) Have each side (end of the curve) overlap (~2") a flat floorboard

3.) Use a couple of aluminum strips (underneath the chassis)
...& then, bolt it all together with some nuts & bolts

 

[Denny]

 

[Functional Artist]

Hey Denny,
I like it
...but, thinkin' it thru, that rounded shape introduces some extra challenges

My original plan was to make a couple of box's (top & bottom molds) to lay the fiberglass into
...& then, either bolt or bond (or both) the top 1/2 (of the body) to the bottom 1/2

The shape was where the Diamonite name "came to mind"

So, check this out

Now, I'm thinkin' that I could form a top 1/2
...& a bottom 1/2 (or "tub") from a sheet of polycarbonate
...& then, bond & bolt them together

Here is how the front suspension would/could be mounted up
...notice how the upper 1/2 & the lower 1/2 would overlap "nicely"
...which would "double" the thickness (& strength) along the entire lower 1/2 of the racer

 

[Functional Artist]

Did some drawin's while "thinkin' it thru"
...&/with some rough dimensions
...it's a "work in progress"