Diamonite Electrathon America Racer

[Functional Artist]

Sorry (not sorry) for all of the "info dumps"
...but, "if" ya think about it
...most of these "steps" are only 15 - 20 min "jobs"

So/see what a Mo Fo can do &/or get done
..."if" he or she doesn't sit around watchin' TV (for hours)
...or "stuck" to them stupid phones (just scrollin')

Moral of the story:

Step away from the TV
...&/or put the phone down
...& DO SOMETHING!

 

[Functional Artist]

Now, on to the rear inner "saddle"

Put the "blank" in the bender

Same procedure, ta produce a "curve", as before

Got all of the "hardware" outta the way

Test fit

Another view

Installed (aligned, drilled & bolted in)

 

[Functional Artist]

A view of the cockpit with the inner "saddles" installed

A view of the rear "saddle" area
...from up underneath

Installing the swing arm

* Notice how the swing arm can "swing down" straight down
...for easy access to the rear wheel, motor & chain?

Looks like this
...when "swung up" in place
...& sittin' on the suspension "pad"

 

[Functional Artist]

Whats the 7 layers come out to in thickness?

Hey WTR,

I removed the front "saddle" ta drill out the hole, for the steering shaft, in the FG

* So, I didn't affect (over drill) the size of the holes, for the steering shaft bushing, in the "saddles"

After drillin' I took some measurements...for us
...& the FG, in this 7 layer area, looks ta be ~1/4" thick

The area under most of the bolt holes, look ta be ~1/4" thick too

 

[Functional Artist]

Now, I'ma workin' on installin' the steerin' shaft

Also, "set" the seat in place
...ta double check
...some inter-cockpit-al dimensions

With a dashboard/upper steering shaft support
...maybe about something like this

 

[Functional Artist]

I'ma gonna try-n-use this Butterfly style steerin' wheel

Looks pretty kool
...& has these "nubs" stickin' up on each side
...that can be used for mounting hand controls (like a Brake lever & Thumb throttle)

Also, includes my unique, custom (should be patented) flip-up steerin' wheel mount

Uses a simple spacer
...& a pressed steel bearing, outta a HF wheel

Should "go" maybe something like this

 

[Functional Artist]

Ta double check
...& try-n-be a bit more scientifical
...I went to my Hell-raiser kart
...& took some measurements

From the floorboard up to the upper steering shaft support
...looks ta be ~14"-15"

From the center of the steering wheel to the back of the seat
...looks ta be ~23"-24"

A better view

Back at the racer:
From the floorboard up to the upper steering shaft support
...looks ta be ~14"-15" CHECK

From the center of (where) the steering wheel (will be) to the back of the seat
...looks ta be ~23"-24" CHECK

A better view

 

[Functional Artist]

Now that we know about where the steerin' wheel (& upper support bushing) need ta be
...just need a quick mark

Should look about like this, when installed

Side view

See how much (more) room there is with the steerin' wheel...flipped up

Another view

 

[Functional Artist]

Lookie what I found on the side of the road (more free materials)

* TIP: Whenever ya get something new
...don't just set the carton out to the curb

As then, folks (& thieves) now know:
...A.) you have just got a brand new (fill in the blank)
&
...B.) Now know all of the details/features & everything about it

This is some pretty "beefy" cardboard

* Hi, Ducky

I'ma gonna use it for some CAD work
...like for figurin' the dash/upper steerin' support

First thought wasa something like this (but, closer to the bearin')

Then, I got ta thinkin'
...maybe I can incorporate the dashboard, upper steerin' support & the hood
...all into (1) unit

Another clos(er) upp(er) view

 

[Grizzlymi]

Your creativity and repurposing is amazing! Top notch brotha!

 

[Functional Artist]

Your creativity and repurposing is amazing! Top notch brotha!

Hey Grizz,

Thank you, my friend!

I love it when the craftsmanship gets noticed
...& even more when it gets appreciated

Way back when
...most everything I made, was from repurposed materials
...so/now, it's just part of my MO (method of operation)

Again, thank you
...your comment really "made my day"

 

[Functional Artist]

Been workin' on a mock up of the hood, dash, steering support combo unit

Side view

Side view w/steering wheel "flipped up"

View from the cockpit

View from the cockpit w/steering wheel "flipped up"

 

[Functional Artist]

Ducky says: "lets try this again"

Mock up #2 w/steering wheel

Another view

Side view

Angled view

Frontal view

 

[Functional Artist]

The "proper way" or standard procedure ta "turn" a "piece" like this into fiberglass would ta be:
1.) get some MDF (probably 1/2")
2.) measure, mark & cut it up
3.) assemble it (then, wait for the glue to dry)
4.) shape, smooth & sand it
5.) paint it (then, wait for the paint to dry)
6.) coat it with a PVA (Poly Vinyl Alcohol) release agent (then, wait for the PVA to dry)

Then, (7th step & probably a couple of days later) ya can do a "lay up" of a couple of layers of FG
...just ta make the mold

After the FG cures ya gotta "pop" the FG mold off of the wooden mold
...clean 'er up
...fix any flaws
...coat it with PVA
...& then, do the FG lay up, for the actual part

Experiment:
I got an idea

I'ma just gonna try-n-make a FG mold off of this CAD piece (skippin' the wooden part...completely)

So, I covered the CAD hood with plastic box tape (as a PVA like "barrier")
...while Ducky napped

Looks like this...so far

Also, had some ideas for some kinda hood "embellishment"

But, figured, let's see how this turns out...first...before we B gettin' too fancy

 

[Functional Artist]

Before fiberglassin'
...it's best ta pre-cut the FG cloth
...for the mold (folded)
&
I went ahead & pre-cut the FG cloth
...for the actual piece too (on the roll)

* Used my "handy dandy cutter"

Now, we ready

Gave the piece a good pre-coating of resin

Layed on & aligned the first layer piece of CSM

Then, "rolled" a good coating of resin, on top, to "wet-ten" the cloth

* Just this first layer "took up" 16 oz. of resin

Then, did a layer of the stronger 1708 cloth

Then, another layer of the 1708
...for a total of (3) layers (same as most of the monocoque)

* Seems ta be workin' OK...so far

Now, we gotta "see" how everything "looks"
...after (if) we get the FG mold off of the CAD form

 

[Denny]

Why not just coat the cardboard with resin and fiberglass cloth and leave the cardboard in it as a strengthening device. I’ve done that with race car parts and it works good. And ends up being lighter weight and stronger.