GT-E

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:

SAM_6887.JPG
 

Attachments

  • SAM_6559.JPG
    SAM_6559.JPG
    311.5 KB · Views: 6
  • SAM_6552.JPG
    SAM_6552.JPG
    309.5 KB · Views: 8
  • SAM_6685.JPG
    SAM_6685.JPG
    312.7 KB · Views: 7
  • SAM_6893.JPG
    SAM_6893.JPG
    308.1 KB · Views: 7

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:
 

Attachments

  • SAM_6681.JPG
    SAM_6681.JPG
    308.7 KB · Views: 1
  • SAM_6682.JPG
    SAM_6682.JPG
    313.3 KB · Views: 1
  • SAM_6684.JPG
    SAM_6684.JPG
    313.7 KB · Views: 1
  • SAM_6693.JPG
    SAM_6693.JPG
    313.8 KB · Views: 2
  • SAM_6694.JPG
    SAM_6694.JPG
    307.3 KB · Views: 2
  • SAM_6697.JPG
    SAM_6697.JPG
    313 KB · Views: 2
  • SAM_6696.JPG
    SAM_6696.JPG
    317.3 KB · Views: 1
  • SAM_6724.JPG
    SAM_6724.JPG
    318.8 KB · Views: 1
  • SAM_6738.JPG
    SAM_6738.JPG
    314.1 KB · Views: 1
  • SAM_6741.JPG
    SAM_6741.JPG
    320.8 KB · Views: 1

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:
 
Last edited:

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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
 

Attachments

  • SAM_6707.JPG
    SAM_6707.JPG
    309.9 KB · Views: 2
  • SAM_6774.JPG
    SAM_6774.JPG
    304.8 KB · Views: 2
  • SAM_6775.JPG
    SAM_6775.JPG
    306.3 KB · Views: 1
  • SAM_6776.JPG
    SAM_6776.JPG
    302.4 KB · Views: 1
  • SAM_6779.JPG
    SAM_6779.JPG
    305.2 KB · Views: 1
  • SAM_6781.JPG
    SAM_6781.JPG
    312.1 KB · Views: 1
  • SAM_6783.JPG
    SAM_6783.JPG
    314.2 KB · Views: 1
  • SAM_6794.JPG
    SAM_6794.JPG
    315.6 KB · Views: 2
  • SAM_6812.JPG
    SAM_6812.JPG
    324.4 KB · Views: 2

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
More pics :cool: SAM_6831.JPG
 

Attachments

  • SAM_6787.JPG
    SAM_6787.JPG
    314.3 KB · Views: 0
  • SAM_6791.JPG
    SAM_6791.JPG
    312.8 KB · Views: 0
  • SAM_6792.JPG
    SAM_6792.JPG
    311.7 KB · Views: 0
  • SAM_6819.JPG
    SAM_6819.JPG
    311.9 KB · Views: 0
  • SAM_6823.JPG
    SAM_6823.JPG
    309.1 KB · Views: 0
  • SAM_6827.JPG
    SAM_6827.JPG
    315.2 KB · Views: 0
  • SAM_6828.JPG
    SAM_6828.JPG
    312.8 KB · Views: 0
  • SAM_6829.JPG
    SAM_6829.JPG
    313.8 KB · Views: 0
  • SAM_6830.JPG
    SAM_6830.JPG
    314.1 KB · Views: 0

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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
 

Attachments

  • SAM_6846.JPG
    SAM_6846.JPG
    312.8 KB · Views: 1
  • SAM_6843.JPG
    SAM_6843.JPG
    309.6 KB · Views: 1
  • SAM_6848.JPG
    SAM_6848.JPG
    319.4 KB · Views: 1
  • SAM_6847.JPG
    SAM_6847.JPG
    320.1 KB · Views: 1
  • SAM_6876.JPG
    SAM_6876.JPG
    313.3 KB · Views: 2
  • SAM_6880.JPG
    SAM_6880.JPG
    318.7 KB · Views: 2
  • SAM_6881.JPG
    SAM_6881.JPG
    314.7 KB · Views: 2
  • SAM_6907.JPG
    SAM_6907.JPG
    309.8 KB · Views: 1
  • SAM_6908.JPG
    SAM_6908.JPG
    311.4 KB · Views: 1

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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
 

Attachments

  • SAM_6894.JPG
    SAM_6894.JPG
    307.2 KB · Views: 1
  • SAM_6895.JPG
    SAM_6895.JPG
    309.8 KB · Views: 2
  • SAM_6896.JPG
    SAM_6896.JPG
    308.1 KB · Views: 1
  • SAM_6897.JPG
    SAM_6897.JPG
    310.5 KB · Views: 1
  • SAM_6898.JPG
    SAM_6898.JPG
    308.5 KB · Views: 0
  • SAM_6901.JPG
    SAM_6901.JPG
    307.7 KB · Views: 2
  • SAM_6903.JPG
    SAM_6903.JPG
    316.8 KB · Views: 2

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:

SAM_6918.JPG
 

Attachments

  • SAM_6916.JPG
    SAM_6916.JPG
    312.5 KB · Views: 1
  • SAM_6917.JPG
    SAM_6917.JPG
    314.6 KB · Views: 1
  • SAM_6920.JPG
    SAM_6920.JPG
    311.9 KB · Views: 1
  • SAM_6919.JPG
    SAM_6919.JPG
    316.7 KB · Views: 1

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:


SAM_6925.JPG
 

Attachments

  • SAM_6924.JPG
    SAM_6924.JPG
    310.8 KB · Views: 0
  • SAM_6922.JPG
    SAM_6922.JPG
    314.4 KB · Views: 0
  • SAM_6926.JPG
    SAM_6926.JPG
    318.9 KB · Views: 0

EpsilonZero

...still cheaper than a boat!
Messages
395
Reaction score
182
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?
 

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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

...still cheaper than a boat!
Messages
395
Reaction score
182
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:
 

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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
SAM_7014.JPG
Soooo, back to the drawin' board :popcorn:
 

Attachments

  • SAM_7013.JPG
    SAM_7013.JPG
    312.2 KB · Views: 2
  • SAM_7018.JPG
    SAM_7018.JPG
    309.8 KB · Views: 2
  • SAM_7019.JPG
    SAM_7019.JPG
    314 KB · Views: 3
  • SAM_7020.JPG
    SAM_7020.JPG
    309.8 KB · Views: 3
  • SAM_7036.JPG
    SAM_7036.JPG
    313.5 KB · Views: 3
  • SAM_7037.JPG
    SAM_7037.JPG
    308.6 KB · Views: 2
Last edited:

EpsilonZero

...still cheaper than a boat!
Messages
395
Reaction score
182
The motor mounts look a bit thin for the work they are doing. Can't you go a bit thicker?
 

Functional Artist

Well-known member
Messages
4,371
Reaction score
1,636
Location
Toledo, Ohio
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:

SAM_7044.JPG

Still, thinkin' :popcorn:
 

Attachments

  • SAM_7042.JPG
    SAM_7042.JPG
    310.1 KB · Views: 1

EpsilonZero

...still cheaper than a boat!
Messages
395
Reaction score
182
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.
 
Top