Grand Daddyish build

TNThomas

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Where did you get that crimper from? How much? Can you do other things like a/c hoses?
I bought it on Amazon. I would think you could. If you get one, just make sure they have a wide variety of sizes for the dies that come with them. Mine is in some metric unit, but has very small, about 1/8" dies up to about a half inch. The silver head swivels 360 degrees which was nice when I was installing the stainless steel cables on a deck build a few years ago. They all seem to be Chinese made. I think mine was about $60, but there are cheaper ones that look to be the exact same. Metal qualiry is a little so-so on the dies, but nothing has broken or failed. If yuu have a mill you could make your own dies if you needed a very specific shape/size.

I just store it in the off/non engaged hydraulic position. You basically insert your dies (that are just under the O.D. of fitting. Then turn the dial to the ON position which seals/engages the hydraulucs, then you just pump away at the lever. The last few pumps get a little difficult, but there is a very obvious release once you hit the the full amount of force (10 tons), so you have a nice obvious point where you know you have applied enough force, a sort of sudden click / release of pressure in the Hydraulics. This one looks to be the same as mine just yellow. The case/dies are all the same shape too: https://www.amazon.com/dp/B0BP998RS...d2lkZ2V0TmFtZT1zcF9waG9uZV9kZXRhaWwp13NParams
 

TNThomas

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A few recent updates:
-I think I am going to do duel calipers. I am going to run a second set of the MCP calipers on my single 10" dia rotor. I am going to run seperate hydraulic lines, one to he pedal, one to a hand brake/parking lever. That way I have a backup should one of the lines break/burst. I am also considering mounting the hand brake/parking lever on the outside/left of the driver seat, actuated sing the left arm. More practical for accessing when not in the vehicle for braking while loading/unloading from a truck bed/trailer.

-I helped a buddy dig out a stump a few days ago and he gave me a Hi-Lift jack as a thank you. I think I'll rig up a mount for it on the buggy.

-Current priority is still the throttle cable mounting/tuning.
 

Denny

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Trust me, you never ever no matter what happens want to use the brakes when on ramps. I used to sell and service golfkarts I’ve had ramps fall off, one ramp fall off or break. It would not flip a kart if you floored it. But if you tried to hit the brakes you ended up on your side every time! It sucks!
 

TNThomas

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Trust me, you never ever no matter what happens want to use the brakes when on ramps. I used to sell and service golfkarts I’ve had ramps fall off, one ramp fall off or break. It would not flip a kart if you floored it. But if you tried to hit the brakes you ended up on your side every time! It sucks!
Good point, I forgot I can just sit in the seat and drive her up! I am only accustomed to putting dirt bikes in the back of trucks by myself, and I am tall enough to grab on the brakes if it gets dicey. But you are definitely correct. I was thinking alot about it last night, and between the seat mount for the hydraulic handbrake makes the most sense. I'll do a separate totally seperate hydraulic line from the main brake master cylinder on the pedal, so I'll have two separate hydraulic systems. That way if one fails I am not totally screwed. More money, lots more peace of mind, and more braking power. I am just going to duplicate and do the same caliper from MCP as it spacially matches up nice. I also found an in-line hydraulic cutoff that basically allows you to keep hydraulic pressure in your lines essentially acting like a parking brake.
 

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Like the old Mico locks on tow trucks!
How do those work? They look pretty cool. Here is the version I got, fairly simple. Install in-line. Apply brake pressure, push button down, telease brake pressure. Device basically keeps the downstream pressure applied. To release you apply the same or more brake pressure than yhe first time and then I think you just pull the button up. Im going to put it in a semi hidden location so it will act as a theft deterrant when parked in public locations.20231030_172510.jpg
 

TNThomas

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Man, the Chinese off-brand CNC quality is pretty good! Name brand of this hydraulic hand brake (with master cylinder) is about $300. Chinese clone is $75. Can't complain, looks cool! I am not going to paint any of the Aluminum stuff, or the SS steeringvwhile, so the final 2-tone paint job shouls look cool.20231030_172345.jpg20231030_172338.jpg
 

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With the Mico all you did was push down hard on the brake, pull the lever up. To release all you did was flip the lever back down. But you did not leave it applied for days or weeks at a time because of the possibility of seals weeping with time.
 

TNThomas

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With the Mico all you did was push down hard on the brake, pull the lever up. To release all you did was flip the lever back down. But you did not leave it applied for days or weeks at a time because of the possibility of seals weeping with time.
Cool! Yea, mine will only be for short term (a few hours max) for the hydraulic lock. Can you think of any downsides to running dual calipers on a single disc for my brakes? The disc is pretty big, 10" dia and thicker than most, it does have vent cuts as well. One master cylinder per caliper, so pressure/force shouldn't be an issue. It would just be nice to not get another disc, and keep the other side free for future garbage to bolt/weld on. I'll be running duel MCP double piston calipers.20231031_161607.jpg
 

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The only reason is heat, but I doubt that will be an issue. If you start warping rotors then you may have to separate them, but I say try it.
 

TNThomas

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The only reason is heat, but I doubt that will be an issue. If you start warping rotors then you may have to separate them, but I say try it.
My thinking too, i'll go for it, easy enough to put another rotor on if needed.
 

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Ok, a few updates, or more like a short blog post:

-2nd set of Brake calipers from MCP are ordered. I'll duplicate the mount/setup, just in the opposite orientation from above.
-I have decided to reverse the hydraulic e-brake orientation. I am very tall, and I might actually have a hard time pulling the brake without my elbow jamming into my passenger/seat. As such It will be flipped so that its a push forward to brake orientation. Better spacing for my right leg as the driver as well. Also closer to passenger's hands (like small kids) in the event that they need to grab it and engage it.
-While waiting for shipment of that and a few fittings, I am going to start fitting the brakes and researching/building a mount for an alternator.
-A major obstacle currently in my way is the weather conditions for the next 4-5 months. I live in the Pacific Northwest only a few miles from the Puget Sound. We are going to be dark, cold, and rainy till spring. This is going to be an issue with me painting as I don't really want to paint in my garage. If I did that I would need to keep the doors open, and it would just get too dang cold in that case for the paint to work/dry properly. Secondly, even if I did a setup outside, its going to be really hard to keep the humidity down and temps up in order to properly spray. I could rush it and do a simple roll on paint, but I want this to be done right, and I have a vision in my head of what that looks like. I want to do metal flake, and that requires multiple coats, and good conditions, something I won't have for a few months. No roll on for metal flake either. Realistically, I won't have a ton of amazing opportunities to offroad till this thing is properly painted either. So she definitely won't be fully finished till Spring. So, I have a slight change of plans:

-I am going to focus on fixing/building everything to get this thing running and put painting till the very end, and by end that likely means springtime. But once spring comes, I am going to do it, and do it right. I'll still take it for a test drive soon here, and get things tweaked out, but I'll do it in dry weather with a coating of oil on the steel. Once everything is tip top, I'll periodically take stabs at setting up/getting tools to be ready to paint at the moments notice once weather is good. "Nightshade" from Roth Metal Flake is still the front-runner. All while wiping it down with WD-40 and oil every so often.

-While this Iron is in the fire, I am going to put more of a focus on using my building skills to make stuff with/for my kids so that we can spend more time together. Luckily I get quite a bit of time off from work (all the gov't holidays and summers), and I work from home 3/5 days of the week. This means that I get to see them a lot. I have a 5-year-old daughter, 3-year-old son, and a 5-month-old daughter, and a wife. It has been hitting me lately that I actually don't have that much time left with the kids at home. That paired with the importance of the first few foundational years of childhood for mental, physical, social, and emotional development means that I need to back away from building just the big dune buggy a little bit. That, and people generally seem to have a bleak outlook on the world right now so I am going to put a positive focus on it for my kids and wife. Here are the big plans that are starting to take priority as I finish up the buggy and wait for better painting weather:

1) Treehouse. Well, technically not a tree house, it will be more of a fort. Somehow, we have 1 measly tree from the East Coast on our lot, and multiple 100-200ft tall Western red Cedars trees at our neighbor's houses. But, we do get a little more sunlight as a result. My plans for this fort is to build some sort of 8'x8' (minimum) structure, no more than 12'12', possibly with a small deck, a few windows, a small wood stove that can double as a cooking surface, a mini water catchment. I just got a little camping porta-poty pee thing that can be put in there as well for nighttime emergencies of little ones. We already have alot of kids around us, and more on the horizon as they enter the public school system. I made a 8'x8' sandbox for my kids over the summer, and my wife has been on my case to build a cover so the neighborhood cats stop peeing/pooping in it. This struture will double as that cover. I'll build the fort directly above the sandbox. We are a little limited on space, and this will also help to keep the sand pit dry. The height of the structure will be right around 6 feet off the ground, maybe a little taller. I want a space that my kids can play in outside of the rain, but inside of a structure that is warm/dry enough to sleep in, and possibly cook their own food on. I'm a big believer in teaching kids to use tools/control their own level of safety with initial guidance from adults. We camped outside in 30-degree weather last week (only the 3 and 5 year old and I), and they loved it. My daughter said she wants to always camp and asked why we were sleeping inside the next day! Haha. My goal is to get footings poured/supports built in the next month, that way the cement is dry for building the actual fort around Christmas. I'll post photos periodically of that build as it progresses.

2) With the acceptance of a longer than desired build for my buggy has come the realization that my kids are now old enough to start learning how to ride a small go kart. I am going to begin building/planning the build of a small 2-seater go-kart. Much simpler/smaller than mine. I'll likely just buy something already made/close to being made, and just finish it off. This will be a great way to include my kids, use leftover parts from my build, and to practice painting metal flake with their (likely Chinese built) metal body as opposed to my build. Timeline is to have this running and ready to build and paint just before mine in the spring time.

3) Periodically I get overloaded with projects that don't bring me immediate satisfaction (its easy to get down when you only build and dont get to enjoy what you are building). When that happens I go target shooting. So I'll be casting, powder coating, reloading, and doing various load development the whole time. Primary calibers include 22lr (for competition), 45acp 38 special, 357 mag, .223 Win, .308 win, 6.5x55 Swedish, 7.5x55 Swiss, 8mm Mauser, and .480 Ruger.

Wish me luck! Some day I'll have a running sparkly buggy, but right now its build-plan-build-baby! 20231103_151658.jpg
 
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