Diamonite Electrathon America Racer

[Functional Artist]

Hey T,
Yup, them pics are pretty much self explanatory
...& the "thingy" looks like the "thingy" in the drawin'

Yup, probably be best ta just send ya a wheel

Also, while your playin' with that sprag/freewheel unit (if ya could) take a look at the bearings
1.) it seemed like there ain't enough of 'em in there (please explain)
&
2.) seemed kinda "dry" in there (also...please explain)
...just wanted your observation/opinion/commentary

 

[Functional Artist]

We've had some ~60* days
...still too cold ta do fiberglass work
But,
I can do some other stuff

Lookie what I made

Liked it so much that I went a made a bunch of 'em

Then, Jaulla asks "how'd ya get them "corners "knocked off" evenly
...& all of the holes "straight" (or to line up) so "nicely"?

Good question Jualla

Well, first I measured, marked & drilled "marker holes" (shallow "indents" to help center the drill bit when using the drill press)
...& also, measured, marked & cut the corners off of (1) of 'em

Then, just "stacked" 'em up
...to cut the rest of the corners "to match"
...& also, drill the holes, all together (or at once)

So, they all will match "pretty closely"

 

[Denny]

There’s that dog gone Julia again.

 

[Functional Artist]

There’s that dog gone Julia again.

Hey Denny,

Well, I guess Jualla is my "imaginary" Electrathon America vehicle build/class "student"

She (yup, she is a she) asks questions
...so, I can elaborate on stuff...without...seemin' like...I'ma talkin' to myself (* yea, I've been warned about that)

So, why are some shorter than others
...& what ya gonna do with 'em...she asks

Well...(4) are for the tops (longer ones)
...& (4) are for the bottoms (shorter ones)

First, I'ma gonna put 'em in the bender
...do some bendin'

Left one was a "test" (turned out OK)
...so, I went ahead & bent the other (3)

Next "test" was to try-n-bend (1) around a ~3/4" dia. piece of pipe

Here is a bent view

Then, clamped 'er to the edge of the workbench

...& tried ta bend 'er around the piece of pipe some more

 

[Functional Artist]

The "top pieces" (longer pieces) turned out lookin' like this

...& this

Then, I went ahead & bent the lower pieces (shorter ones)
...@ about a 90* angle

Then, just "stacked" a "top piece" on top of a "bottom piece"
...like this

Another view

Yup, I made up (5) of 'em
...just in case I totally messed (1) of 'em up while fabricatin'
...or if (1) of 'em just turned out kinda "wonky"
...or even as a "spare" custom part

 

[Denny]

Now if we only knew what they were for.

 

[Whitetrashrocker]

Now if we only knew what they were for.

As my dad would say.
"To make you ask questions "

Nice work FA. Making one is easy, making repeats is hard.

 

[Functional Artist]

Now if we only knew what they were for.

Hey Denny,

Ya can't tell?

They are an "idea" for some lightweight A-frame Bushing holder/mounting brackets

This is kinda what I have in mind

But, notice how the brackets would only be mounted to the side of the monocoque

So, my thinkin' was that it would be better (stronger) ta have 'em mounted on (2) "planes" or different surfaces

 

[Functional Artist]

Here is some info...for reference

This is a (bottom view) pic of the front suspension on my mini-Areial Atom kart

The A-frames are made outta some 1" square tube
...& some 1/2" Schedule 40 water pipe

The A-frame mounting brackets are automotive (7/8") Sway Bar Bushings

It's kind of a heavy kart
...so, yup, they work very well
...but, for a "lightweight racer" they seemed ta be WAY too HD or "beefy"

 

[Functional Artist]

So, I've been thinkin' & lookin' at some different materials
A few different sizes of steel tube, with different wall thicknesses, pipes & even some solid rods

Yup, I even contemplated possibly just using some electrical conduit tube
...with a couple of "C" style mounting brackets
...& a "stock" type spindle mounting bracket
...but, it would look stupid

...& the "metal" conduit is made of is just WAY too soft

* Quick demo: clamped a set of vise grips on
...pushed down
...& it just/easily tore out"

 

[Functional Artist]

Another "for reference" pic
This is the front suspension is on my Sequoia racer

The A-frame is made of 7/8" OD x 1/8" wall steel pipe
...1/8" thick steel mounting brackets
...& 1/8" thick steel shock bracket
...& 3/16" thick steel spindle bracket

It's good-n-strong
...but, good-n-heavy too

* Notice, the 1" x 14g steel tube, bushing holders
...& 1/8" thick steel mounting brackets

 

[Functional Artist]

Well...for this "racer" the "goal" is to create a really light weight chassis
...& using HD materials didn't align with that goal
...but, they still gotta be strong (in design & materials)

So, my thinkin' went to...I've used 5/16" solid steel rod for tie-rods for "controlling" the direction of the wheels
...many, many times
...& with some pretty good success

But, 5/16" rod seemed "undersized" for this job (A-frames are usually made of ~1" steel tube)

So, I looked at potentially using some (thicker & stronger) 3/8" rod
...with some threaded-on steel, swivel rod ends
...& some simple "C" mounting brackets

But, look at ALL of the parts that would be required
...(2) 3/8" rods
...(4) rod ends
...(2) mounting brackets
...plus, some nuts & bolts

Then I thought, "if" I just use (1) longer rod (bent in the middle)
...it would eliminate the cost & weight of (2) rod ends

 

[Functional Artist]

Then, I thought that "if" I also, bent the (2) ends I could eliminate
...(2) more rod ends
...& also, the nuts & bolts required for mounting

The 3/8" rod would be bent at the line
...with a small "washer" on each side

...& maybe have each side "secured" in place
...with a small cotter pin (not shown) on the outer sides

 

[ezcome-ezgo]

Thin solid rod might introduce this vehicle to the melodious sounds of harmonic vibration. You could always sing along as you go.

 

[Functional Artist]

Thin solid rod might introduce this vehicle to the melodious sounds of harmonic vibration. You could always sing along as you go.

Hey Ez,
Maybe if I added some adjusters, it could be "tunable"?

I can tune a piano
...but, I can't tune-a-fish (REO Speedwagon)

 

[Denny]

Groucho Marx used that line way before REO Speedwagon.

 

[Functional Artist]

Nice work FA. Making one is easy, making repeats is hard.

Hey WTR,

Anymore when I'm designing a part, the actual "Fabricat-ability" of "multiple parts" is one of the main factors I always...try-n-keep in mind

Creating & maintaining consistent fabricating "habits" (using the same concepts & practices) helps to do things over & over
...plus, taking lots of notes (about what you're doing & why) helps
...& taking lots of pics "along the way" helps too

But/still, sometimes ya "go to" make a second part
...& somehow kinda...get distracted...&/or forget...important details like
..."did I bend it...on the line...just before the line...or just a bit past the line?"
...& it comes out like...WTF

* After I made the first A-frame
...I got a couple of "tow calls"

Then, a couple of hours later, when I got back
...I kinda was like
..."where the "F" was I at?"

So, when I tried to make another/matching A-frame, I somehow ended up making (3) DUDS (technical term for bad parts)

I used the "ways" that I thought I used, ta make the first one
...but...NOPE...the mounting ends were too short (top right)
...on my second try...NOPE...didn't even get to the "ends" because I made the middle bend, way too wide (mid right)
...& then, even tried a third time...NOPE...Um...way too narrow (bottom right)

OK I figured...that's enough for today
...&/so, we'll get back at it tomorrow

 

[Functional Artist]

Um...my truck kinda "freaked out" on me
...&/so, have been kinda pre-occupied

But now, I'ma justa waitin' on parts...

So, I figured that this may be a good time, for a different distraction

So, to make another
...or a couple more A-frames, I went back at the "beginning" or "back to the basics"

I cut (2) more (24") pieces of 3/8" rod
...& then, marked 'em (both the same)

Next, I put 'em in the bender (one at a time)
...lined it up "right on the line"
...& worked on the (2) center bends (bending 'em...all about the same)

* Notice, for the "end bends" I used a "stop block"
...so, all of the bends would be "in the same place"
...& all of the 'ends" would be the same length

Then, using a "straight surface" I made sure the "ends" were both "level" & "even"
Um...nope...not yet

After a bit more bendin
Yup, that looks better

Now, the original A-frame has some "pretty closely" matching "friends"

Another view

 

[Functional Artist]

First thought, for a spindle mounting bracket was an "all-n-one" unit
...with a spindle mount
...the base or brace
...& a shock mounting bracket, all "built into" one bracket

Kinda like this "mock up"

But, thinkin' it thru
...&/also, thru mockin' it up
...I noticed that the Castor Angle wouldn't be adjustable, "if" I did it as an "all-n-one" piece

So, on to Plan B

Next, I drew out the "all-n-one" idea
...but, left the "upper & lower" spindle bracket "tabs" off

Then, cut 'er out

...& just in case, I messed this one up, I "traced out" another one

Maybe something about like this

 

[Functional Artist]

Jua'lla says that piece "looks" kinda neat
...but, how strong is it gonna be?

Well...we are goin' for light & strong
...so, maybe a bit of "boxing it in" would help

Kinda like this

Another view
Yup, CAD (cardboard aided design) at "its finest"
...it's just a piece of cereal box cardboard & some scotch tape

Mocked up with the A-frame

Another view

Close up

This is about how it would look with
...the spindle bracket
...& a coil-over shock