Diamonite Electrathon America Racer

[Functional Artist]

I spent WAY too much time wondering what ASU could stand for. Yes, I saw what day it was. Yes, I read the patriotic messages. Way... Too... Long...

Now whats 052?

Hey ES,
Looks like "we" just determined this racer's # Ohio 52

 

[Functional Artist]

Making a hot tub?
you'll try anything! AND make it look easy.

Hey T,

Just showin' you'all (my friends) what a MOFO can do in his backyard

 

[Functional Artist]

Peelin' the PVA (barrier) off the FG part

Comin' off in (1) big piece

Jualla

There are a few (a bunch) of imperfections

...& some air bubbles & "casting/mold" marks ta "deal with"

...but, "we" definitely have "something" to "work with" now

POOF!!
...made somethin'...outta nuthin'

 

[Functional Artist]

Some re-cap stuff

I used ~2 gallons of resin
...~20 ft of FG cloth
...(3) roller "heads"
...(3) pans (paint tray liners)
...& (3) plastic cups, for this (3) layer, lay-up of FG

The Appliance Epoxy paint seems ta stick really well...ta everything

Creates & maintains a really hard surface

Even held up to all of the pickin' & proddin"
...that I did during de-molding

Inside corner of the "nose"

Along the perimeter flange

 

[Functional Artist]

This FG piece came outta the mold
...with some pretty rough/dangerous edges

So, before doin' anything else
...let's do some trimmin'
...& clean up

First, I put/set 'er back on, the mold base (holds the piece good-n-firm & nice-n-snug)

Then, got out some PPG (gloves & glasses)
...my preferred (for this task) weapons of destruction
...& the shop vac

* These oscillating tools "run" slower
...& don't seem to create the toxic FG "dust cloud"
...like the fast(er) spinny things do (like saws & cut off wheels)

Made pretty "quick work" of it

Popped the "nose" on
...ta help hold & help stabilize it, durin' trimmin'
...& gave me a nice trim line/guide ta work with

Yup, that's sooooo, much better

Now, just gotta do a bit of edge sandin' & smoothin'

 

[Denny]

Peelin' the PVA (barrier) off the FG part
View attachment 162146
Comin' off in (1) big piece
View attachment 162147
Jualla
View attachment 162148
There are a few (a bunch) of imperfections
View attachment 162149
...& some air bubbles & "casting/mold" marks ta "deal with"
View attachment 162150
...but, "we" definitely have "something" to "work with" now

POOF!!
...made somethin'...outta nuthin'

Those ain’t air bubbles and casting marks. Their character marks and character lines!

 

[Master Hack]

I've been wanting a boat....

 

[Functional Artist]

Yay you made a bathtub!

Seriously it looks good Kevin.

Hey Denny,
This mono-tub would actually "hold water"
...& who doesn't want a tub that looks like a racecar?

I've been wanting a boat....

Hey T,
This mono-boat would actually float
...& who doesn't want a boat that looks like a racecar?

 

[Functional Artist]

Let's see what this "guy" weighs

Stood 'er up

...on the scale

Looks ta be ~30 lbs.

Seems ta be pretty good/about right
...for ~2 gallons of resin
...& ~20 ft. of FG cloth

 

[Functional Artist]

A quick re-cap

At the beginning of last winter, I made a 1/2 scale CAD (Cardboard Aided Design) model

Then, made a full-size wooden model
...mainly working around the driver accommodations & the seat

Then, made another, full-size wooden model
...with a larger seat
...while also, refining some of the dimensions

Then, started workin' on makin' it inside out (for a plug mold)

Now, let's see "if" the seat actually fits

Yes!!!
...yes, it does...beautifully

Another view

 

[Functional Artist]

Mock up

Another view

Another kooler view

Now, we gotta figure out how we gonna mount the axle & wheels

I got some ideas
...but, am "open" to hearin' some suggestions??

 

[ezcome-ezgo]

I suggest you make it fancy.

 

[Denny]

I suggest you make it strong.

 

[Functional Artist]

Notes, doodles & ideas

I've been thinkin' about the strength to weight ratio of potential components
&
Then, contemplating what materials & what thickness(es) would be best
...for makin' the other components out of

So, far the strongest/beefiest parts are
...the spindle brackets, which are ~3/16" thick
...& the axle pipe/tube, which is ~1/8" thick

Also, thinkin' about
A.) makin' & incorporatin' a Saddle type structure
...for mountin' the front & rear wheel assemblies

* Saddle:
(noun) 2. A devise mounted as a support & often shaped to fit the object
(verb) 2a. To place under a burden or encumbrance

B.) Also, thinkin' about incorporatin' some side mounts too

Frontal drawin'/view

 

[Functional Artist]

A couple of important details, the A. strap type brackets need ta be
...bent at ~90*
...then, a roundy bend ~180*
...then, another ~90* bend
&
The B. mounting bracket(s) are mostly just straight
...but, need ta be welded to the axle tube

So, I went with 16g steel for the (A) bracket(s) (easier ta bend)
...& 14g. steel for the (B) bracket(s) (easier ta weld)

I got out one of my DIY metal benders

...& bent the roundy bend in the A. brackets, first

Then, clamped 'er down
...& did some "body work"

After bendin' the other side

The B. Bracket(s) just needed ta be cut out
...& then, a hole drilled in 'em

Mountin' "mock up"

 

[Functional Artist]

I ended up makin' a few of the strap brackets

Because some didn't fit as snug as I wanted 'em to

Also, workin' on the "Saddle"
The strap brackets would mount...about like this

The side brackets would mount about like this

* I'ma gonna try-n-bend that lower "tab"
...up under the bottom...for extra strength

Front axle assembly...parts

** Is this fancy & strong enough...fellas??

 

[ezcome-ezgo]

Fancy is satisfied. What will be on the other side (interior?) of the FG?

 

[Whitetrashrocker]

Fancy is satisfied. What will be on the other side (interior?) of the FG?

I agree. Needs some backing plates.