Diamonite Electrathon America Racer

[Functional Artist]

Up next was installing the front & rear wheel sub-assemblies

The Tie Rod "hole" lines up nicely, with the Pitman Arm

But, durin' steering "turning tests" I found that the Tie Rods "hit" the edge of the access holes
...&/so, had ta do some modifyin'

The hole needed ta be "moved" upwards & backwards...just a bit
...so, I used a "temporary pilot hole" ta "get 'er done

Only removed "this much"
...& a nice-n-clean cut

Yes! That's mucho bettero

Yup, the other side "clears" nicely, in both directions, too

 

[Functional Artist]

Up next was ta get the Roll Bars installed

I "lined" the holes on the monocoque ta "pad" 'em a bit, as the bars "slide in"

Well...huh? I didn't take any pics of 'em installed
...I'll do better...next time

 

[Functional Artist]

The EA rules require a 4" red triangle under/around the Main Power Cut-Off switch
...so, I got some Permanent Red Vinyl
...& drew up a 4" x 4" x 4" triangle

Then, made up a template (outta some packaging plastic)

Checked (test fit) how it would look on the dashboard

Then, me & Ducky went ta workin' with the Vinyl

We gots us a 4" x 4" x 4" red triangle
...with nice-n-curved corners

Even though it is brand new paint
...I still gave 'er a wipin' off (just some Alcohol)
...ta make sure the sticker "sticks" goodly

Installed & workin' on the "cut-out" for the Circuit Breaker

Punched a couple a holes

Ju-alla

 

[Functional Artist]

In this pic, they show what, at first, I thought was a Shunt
...but, it's "in" the Positive (+) side of the circuit?
&
That can't be right
...because a Shunt "goes in" the Negative (-) side of the circuit

What they are showing is a Cut-Off switch (Isolation Switch) & a Fuse
Like these

I'm using this Circuit Breaker, as both components (an Isolation Switch & a "re-settable" Fuse)

The rules even specifically approve of, using a CB for this purpose

The rules also specify that this Isolation Switch must be easily accessible by the driver (without having to reach outside of the cockpit)
...& by race officials (without having to reach inside, of the cockpit)

* Yup, I think we have this "covered"

Yup, we are using "wire protection"

Nope, we are NOT using the vehicle frame, as a conductor
...as/for a Ground/Negative (-)

 

[Functional Artist]

I got my notes out, ta wire-up the PZEM-051 (AKA Power Meter) correctly

Yup, White, Green, Black & then Red

PZEM-051 installed

On/Off switch (AKA Power Lock) installed

A view of the dashboard from the cockpit

 

[ezcome-ezgo]

This is tremendous

 

[Functional Artist]

This is tremendous

Hey Ez,

This has been a glorious journey
...I'm glad you'all shared it with me
&
Thank you sir!

Ready for the next chapter?
...testing

 

[Functional Artist]

Up next, Hand Controls

9 Brakes and Axles (page 8.)

The rules require brakes, on at least (2) wheels (yup/check)

We have a Brake handle/lever, on the steering wheel
...& Rotors & Calipers, on the (2) front wheels (yup/check)

Now, we need brake cables, to connect 'em together
...& make 'em actua-table, by the driver

But/also, I "ran" into a couple of "issues"
1.) How do we connect (2) separate Calipers to (1) Brake lever?
2.) I seem to have made the brackets so that the Calipers mount, upside down

Well...for #1, I found a single pull, dual cable, brake cable (seem ta be for Adult Tricycles) (~$18.00) on Amazon

(1) "leg" of this cable looks ta be ~4' (48") with a ~5' (60") inner cable
...& the other "leg" looks ta be ~5' (60") with a ~6' (72") inner cable

As for #2, I'ma thinkin' I can just connect the cable(s) to the Calipers "backwards"

By "switching" around the cable housing mounting "eye" (or bracket)
...&/with the inner cable "clamping" mechanism/bolt

I can then, "run" the cable(s) to the Caliper properly (from the top side)

Like this

 

[Whitetrashrocker]

My .02.

Is the sheath gonna be strong enough to handle the work load of working the caliper?

Seems trivial, but your changing the workload distribution from pulling the steel cable to pushing the wrapped sheath.

 

[Denny]

Can’t you just flip the calipers over and swap them side to side?