Diamonite Electrathon America Racer

[Functional Artist]

little slow here....
The $1.99 class covers blindfolded welding in detail!
you were just too cheap!

Hey T,

I wasa wonderin' about where you been??

I'ma finally puttin' these black plastic wheels (& your kool custom hubs) ta use

I mocked-up the front wheels ta get a looksie

Front angle view

Profile

Rear angle view

 

[Functional Artist]

Evening retreat after a long day
...& kool pic

 

[Functional Artist]

Mockin' up the front axle

The spindle brackets will mount about like this
...maybe include a lower "brace" (additional support)

Also, thinkin' about incorporating an upper brace too (additional support)

Checkin' steering clearance (left turn)

Checkin' steering clearance (left right)

 

[Functional Artist]

Now, for them side brackets

Added some bolt holes (just pilot holes...for now)

...& squarin' 'em up on the monocoque

Front view

Probably hide the welds in/behind here

Marked for bendin'

 

[Master Hack]

Hey T,

I wasa wonderin' about where you been??

I'ma finally puttin' these black plastic wheels (& your kool custom hubs) ta use

I mocked-up the front wheels ta get a looksie

Been a lot going on here at MTL and none of it involved working on the buggy.
Looks like i might be able to get get back on it now.
I see the wheels and they actually work as advertized?

 

[Functional Artist]

Been a lot going on here at MTL and none of it involved working on the buggy.
Looks like i might be able to get get back on it now.
I see the wheels and they actually work as advertized?

Hey T,

Good! we been lookin' forward to a project update

Wheels: haven't got that far...yet

 

[Functional Artist]

Time for some side bracket bendin'

Set 'er up in a vise w/a piece of pipe (like a round die)
...& used my adjustable, manual, metal, extra leverage, bendin' aparatus (Crescent Wrench)
...ta "grip" on & bend 'er

Used a manual, impact, persuader (hammer) ta "finish 'er off"

Looks pretty good
...so, lets give 'er a try

Hmmm...just a bit too much (tight)

A closer view

We want the sides to "hug" the sides
...& the top (actually bottom) ta "hug" the top (actually bottom) a bit better

I can "fix" it
...back ta the bender

 

[ezcome-ezgo]

The foam compresses, the bolt assembly will loosen. But a spring will maintain the tension that the compression of the foam will deny.

 

[Functional Artist]

The foam compresses, the bolt assembly will loosen. But a spring will maintain the tension that the compression of the foam will deny.

View attachment 162448

Hey EZ,

Nice illustration & explanation

I thought you were talkin' about "spring loading" the fasteners
...that connect the "saddles" to the monocoque

As for attaching/installing the "pad" I wasa just gonna affix it to the suspension mounting bracket (not yet made)
...that will affix to the swing arm via the ride height adjustment bolts

As for an apparatus to "hold" the upper part of the swing arm
...& the back of the monocoque together
...but, will still "give" during suspension movement
...I wasa thinkin' ta just use a piece of nylon strap & a spring loaded latch/clasp (also, not yet made)

This way for maintenance, motor work & tire changes
...just lift the rear of the racer
...release the strap
...& the entire swing arm can/will "swing" straight down
...for super easy access

 

[Functional Artist]

Yup, that's much better

A view from the back side

Looks good-n-tight ta me

The other side too

So, the front axle is/will be mounted to
...& supported by (3) separate brackets
...that attach/connect to (4) different "planes"
...on the front of the "tub"

* Hi Ducky

 

[ezcome-ezgo]

There's an elephant in the room

 

[Functional Artist]

Now, let's do a front axle assembly mock-up

Upper spindle bracket brace/support

Upper spindle brace/support/w spindle bracket

Another view

 

[Functional Artist]

Full mock-up

Full dis-assembly (for clean up)

Close up of clean up

Makin sure the spindle brackets are square with each other
...& don't forget to slide them side brackets on (or you'll regret it)

Close up of spindle bracket
...with upper & lower braces "in place"

Makin' sure everything looks good-n-square, from up/top

The other side too

 

[Functional Artist]

Got 'er all welded up

Let's see how it looks on the "tub"

Frontal view

Angled view

Side view (profile)

* I love it when a plan comes together
...& Ducky seem pretty happy about it too

 

[ezcome-ezgo]

Going to add a little caster to them things?

 

[Denny]

No Regurts! That’s the name of the game man.

 

[Functional Artist]

Going to add a little caster to them things?

Hey Ez,

Of course we is

A kool feature of this design is that the spindle brackets, can be welded to the axle, nice-n-square
...then, the axle assembly can be mounted to the "tub" via the "saddle"
...& then, the Castor angle can be easily adjusted & set
...by these "dual purpose" Axle mounting/Castor angle, setter Straps

Like this

The EA guide book (page 19.) has lots of info on Steering Geometry like information about Tie Rod Ends, Toe in/Toe out, Camber, Castor & even explains the Ackermann Angle concept

I'm not incorporating any Camber
...as the Spindles & wheels (& King Pins) are set (welded) at, the standard ~90*

Since this racer will be (should be) kinda light (hopefully ~300 lbs. total)
...I'm only going to incorporate ~5* of Negative Castor (top of spindle & bracket tilted towards the rear)

 

[Functional Artist]

Castor Angle setting procedure:

First make sure the work bench/table the racer is setting on is nice-n-level

Yup, nice-n-level

Check level-ness of the spindle bracket

Same here

Checkin' the back side

Yup, just about 90*

Give the spindle a little "twist" (top toward the rear)
...& give 'er a check

Close up view

Pretty darn close

Checkin' the bracket on the other side/end of the axle

Looks pretty good
...so, let's "lock 'er in"

Drilled a hole via the "dual purpose" Axle mounting/Castor angle, setter Straps
...Castor setter hole

Then, installed a "dual purpose" Axle mounting/Castor angle, setter Strap
...set screw

 

[Functional Artist]

Why do we want the Spindles angled back a bit?

What does it help &/or accomplish?

Well...a spindle is basically a "fancy" hinge

Think of the hinges on your average household door

If the door is mounted "level"
...it doesn't "do anything"...unless moved by someone
But,
If it is mounted on an angle (or the door frame is "crooked")
the door can/will "move" (due to gravity)
Well...
If a Spindle (& bracket aka door frame) is mounted on a/an (negative) angle
...the wheel via spindle can "self correct"

Which means when the wheel(s) are turned (via the steering wheel)
...& then, released (stop the turning action) the wheels (& by extension the steering wheel)
...will automatically go back toward it's "neutral position"
...aka "self-correct-ing"

* Hope that made sense

 

[Functional Artist]

Looks like this, with the Spindles mounted

Looks like this, with the wheel on

Another view

Notice the Castor angle?

Left turn clearance...check

Right turn clearance...check