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Functional Artist

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Building a roadster based on an old racing kart :)

"Steppin' my game up a notch" for this one :cool:

So, I got some 1" x 14g. HREW (hot rolled electric welded) steel tube
...an actual tube bender
...& did some bendin' :sneaky:

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Functional Artist

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Well, first I must say that there is a heck of a "learning curve" when switching from using pipe & a pipe bender
...& then, using steel tube & a "proper" tube bender.

The pipe bender "bends", around a die, from the middle
...& a tube bender "bends" around a die, from the side.

So, the measurin' & markin' & even bendin' is all TOTALLY different :unsure:
...& yea, I f'd up a bunch of tube, before gettin' close to what I was goin' for. :oops:
(I even practiced on some pieces of conduit that I had first)

Then, to complicate things more, on like my 7th bend, (of the steel tube) the handle broke right off, of my new bender. o_O

Chinese stupid engineering
...they have a ~16" long handle (~1 1/2" dia) that slides over a (~4" x 3/4") receiver rod
...but that receiver rod only "fits" into the main housing by ~5/8"

So, I sent the seller a message notifying them about the failure
...& they messaged me back, "please weld it & it will be fine. If you can do this we can refund $20.00"

I sent a message back "I should get, at least, a 50% refund if I have "fix" it.
...they messaged back "we have sent 50% refund" (~$60.00) :banana:
 

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Functional Artist

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They think Stupid Americans will buy anything. o_O
...we just gotta "work it" to our favor :cool:

I was gonna just send it back
...but, about the only other option is a JD Squared bender
...but, they cost hundreds of dollars & their dies are sold separately (for hundreds more)
...so, I figured "I can make it work" :sneaky:
 
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Functional Artist

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Gotta work on the swing arm next :)

I'ma gonna try, to incorporate the motor mount & bearing mount into the same bracket :sneaky:

Drilled motor mount holes
...bearing mount holes
...ventilation holes
...& bend relief holes

Trimmed some excess material off
...& added a couple of bends to give 'em a bit of a 3D structure
 

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Functional Artist

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More pics :cool: SAM_6831.JPG
 

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Functional Artist

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I used my new bender to fabricate some swing arm bars

Drilled & threaded some 3/4" rod
...& welded 'em into one end of the swing arm bars.SAM_6845.JPG
 

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Functional Artist

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Next, I did some notchin' to the top/ends of the motor/bearing mount plates
...so, the swing arm bars would "nestle in" nice-n-tight :sneaky: SAM_6899.JPG
 

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Functional Artist

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Before welding the motor/bearing plates to the swing arms
...we have to get 'em angled properly :)

Ta do that, we gotta get the front section "aligned" with the swing arm

But, before we can do that, we gotta make some brackets
...& then, get the "Torsioning Rubbers" mounted :cool:

* Simply, automotive Sway Bar Bushings for a 1" bar
...& a couple of plain 'ol hardware store U-bolts :sneaky:

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Functional Artist

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Installed the rubber bushings, with the U-bolts & brackets, onto the swing arm bars
...& clamped some brackets, to connect the front of the swing arm bars, onto the front section of the frame :)

I used a piece of angle iron to help align the "bushing brackets" (vertically, horizontally & with each other)
...& a ratchet strap to help hold the swing arm bars "in place"

Double checked the alignment of everything
...& tacked 'em in place (U-bolt brackets & the front mounting brackets too) :cool:


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EpsilonZero

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FA, what do you do with all of these kart frames you build? Do you just have a huge lot or barn full of karts at your house?
 

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We (me & my twins) ride 'em around, a lot :) I just don't do videos or post about it much, unless there's some useful data/info to share :cool:
...& I've sold a few, over the years

I keep 'em safe, in a 40' wind & water tight, shipping container :thumbsup:
 

EpsilonZero

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We (me & my twins) ride 'em around, a lot :) I just don't do videos or post about it much, unless there's some useful data/info to share :cool:
...& I've sold a few, over the years

I keep 'em safe, in a 40' wind & water tight, shipping container :thumbsup:

Your videos were part of what got me interested in spending a bunch of money on making an electric kart. I bought a camera that can do 360deg and low light videos and periodically make karting videos, but they are way less informative. The 360deg ones are good for making my wife sick in VR though. :sick:
 

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Well, I discovered a fatal flaw in the chassis I was building :(
...not in this torsion'ing chassis "itself"
...but, in the "combination" of concepts, that I brought together.

While doin' some twisting tests, (to see how much/far this chassis would flex) before deciding where to add some "cross braces" I noticed that the motor/bearing mounting "plates" flexed too :eek:

Because, the way I have it set up/designed (with the motor mounted to the outer frame rails instead of in the middle of the kart)
...it looks like, every time the frame flexes, the motor sprocket & axle sprockets can/will come "out of alignment"
...which can/will make the chain "pop" off :oops:

I could "stiffen" 'er up so, this can't happen
...but, that would prevent most flexing, on a chassis that's "supposed" to flex
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Soooo, back to the drawin' board :popcorn:
 

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Functional Artist

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I made these motor/bearing brackets out of 1/8" (~11g) steel
...then, reinforced 'em, along the top edge, with a 1" steel tube
...plus, I planned on adding at least (1) or maybe even (2) "cross braces" ;)

So, I think they would have been OK, if not for the "torsioning/twisting" action of that particular design
...also, it seems like having the "twisting" action, not "in line" with the axle, like other torsening karts (Lancer GT) intensified this "issue" :unsure:

But, I'ma thinkin' that If I invert it (flip 'er over)
...I can still put 'er to use :cool:

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Still, thinkin' :popcorn:
 

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EpsilonZero

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I made these motor/bearing brackets out of 1/8" (~11g) steel
...then, reinforced 'em, along the top edge, with a 1" steel tube
...plus, I planned on adding at least (1) or maybe even (2) "cross braces" ;)

I'm just comparing it against my little 3.75"x4" 1/4" steel plates that mount the axle bearings on my kart and the near 3/16" steel motor mount. Neither have to do double duty either. If you can work with 1/4" steel plate it might be easier than redesigning the kart if it works.
 
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