Lunar Rover (prototype)

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
TOP SECRET (so don't tell anyone) :cool:

NASA Space Program

Mission:
Design & build a Lunar Rover (prototype)

Requirements:
Lightweight (gotta be shipped to the moon or ...)
Electric/battery powered (can't go around pollutin' other atmospheres)
Multi-terrain capable (gotta be able to climb into & then back out of craters)
Durable/reliable (can't be breakin' down 1,000,000,000 of miles away)

* NOT REALLY :rolleyes:
...but, a kool "backstory" for a build :roflol:
 

JTSpeedDemon

2019 Build Off Winner!
Messages
4,026
Reaction score
142
Location
Texas
Now, since you are Functional Artist, you also have to build an electric rocket for NASA so they can ship it there!:lolgoku:

I'll be watching!:popcorn:
 

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
A "real" Lunar Rover (Moon Buggy) would IMO probably be constructed out of Aluminum, Titanium (or some other exotic metal), maybe even some type of composite material.

I'm thinkin' this "prototype" will be constructed mostly out of 1/8" steel
...1/2" schedule 40 "water" pipe (7/8" od. x 5/8" id. x 1/8" wall)
...& some 1/8" flat steel :cheers2:

Why?

Cause it's strong, affordable & easily workable with most standard tools. :thumbsup:

So, after extensive research, thought & a little planning) :rolleyes: I started drawin' on some 1/8" x 3" steel

Can ya tell where the inspiration for this/these :)oops: spoiler alert) came from?

* No, it's NOT gonna be a Bat'leth :lolgoku:
...if ya don't know, Google it :roflol:
 

Attachments

  • SAM_1593.JPG
    SAM_1593.JPG
    309.5 KB · Views: 2
  • SAM_1596.JPG
    SAM_1596.JPG
    316.5 KB · Views: 5
  • SAM_1597.JPG
    SAM_1597.JPG
    317.3 KB · Views: 3

itsid

Moderator
Staff member
Messages
11,564
Reaction score
107
Location
Ruhrpott [Germany]
Mission:
Design & build a Lunar Rover (prototype)

Requirements:
Lightweight (gotta be shipped it to the moon or ...)
Electric/battery powered (can't go around pollutin' other atmospheres)

*cough* lunar atmosphere ??
You need electric power on the moon because there is no combustible oxygen in moons nearly non existing atmosphere
(frankly even nasa considers the moon to surrounded by a vacuum for almost all considerations)
the few molecules of helium and radon are really not noteworthy.

so yeah... correct decision, wrong reason :D

side note:
the real lunar rover (LRV) was rather hefty with 200+ kgs (it's essentially a two seater go kart)
but it mustn't jump out into lunar orbit just because it hit a rock ;)

'sid

PS pleaaaase make it a six wheeler :D
 

JTSpeedDemon

2019 Build Off Winner!
Messages
4,026
Reaction score
142
Location
Texas
Kevin, are those panels modeled after a 1933 Bugatti Type 59, per chance?
Look at the chassis rails. :cool:
This picture is the mild street version, the swiss cheese was more evident on the racers.
 

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Rc car or are you building this thing to drive?

RC=boring :smiley_omg:
..I'ma gonna drive/ride 'er

---------- Post added at 02:44 PM ---------- Previous post was at 02:42 PM ----------

Now, since you are Functional Artist, you also have to build an electric rocket for NASA so they can ship it there!:lolgoku:

I'll be watching!:popcorn:

I'ma buildin' it :thumbsup:
...they can worry about shippin' it :cool:

---------- Post added at 02:48 PM ---------- Previous post was at 02:44 PM ----------

*cough* lunar atmosphere ??
You need electric power on the moon because there is no combustible oxygen in moons nearly non existing atmosphere
(frankly even nasa considers the moon to surrounded by a vacuum for almost all considerations)
the few molecules of helium and radon are really not noteworthy.

so yeah... correct decision, wrong reason :D

side note:
the real lunar rover (LRV) was rather hefty with 200+ kgs (it's essentially a two seater go kart)
but it mustn't jump out into lunar orbit just because it hit a rock ;)

'sid

PS pleaaaase make it a six wheeler :D

Ya, I know
...just usin' the opportunity to "crack" on gassers :lolgoku:

Six wheeler hummmm :idea2:
...maybe next time, not the "look" I'ma goin' for ATM :thumbsup:

---------- Post added at 02:54 PM ---------- Previous post was at 02:48 PM ----------

Kevin, are those panels modeled after a 1933 Bugatti Type 59, per chance?
Look at the chassis rails. :cool:
This picture is the mild street version, the swiss cheese was more evident on the racers.

Nope,
Inspired by the designers/engineers of Percival's Hellcat (early '60's)
...look @ the "stress plates" on the rear :cheers2:

http://www.diygokarts.com/vb/showthread.php?t=24416
 

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Drilling big holes in 1/8" steel

Well, after burnin' up several (plural) step bits :huh:

I did some research & found that as you "go bigger" in bit diameter (like ~3/8" & up)
...you gotta go slower (like ~500-600RPM's slow)
…& to drill holes over 1" you gotta go really slow (like 200-300 RPM's slow)

* These "really low" speeds seems to work well when using hole saws too :thumbsup:
...think like hand powered hack saw speeds :cheers2:

** addin' a little cuttin' oil helps too :2guns:
 

Kartorbust

Well-known member
Messages
3,850
Reaction score
144
Location
Utica, NE
The original rovers were built with 2219 Aluminum alloy, with four 0.25hp series wound DC motors with a range of ~22.3mi.

So any plans for adding suspension to your version?
 

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Dual 48V 1,000W powered AWD rover

:cheers2:
The original rovers were built with 2219 Aluminum alloy, with four 0.25hp series wound DC motors with a range of ~22.3mi.

So any plans for adding suspension to your version?

Kool! :thumbsup:

I'ma thinkin' AWD will be necessary for climbin' outta craters-n-such :2guns:
* to test this capability, I'm thinkin' it should be able to climb up stairs
...maybe even "walk up a wall" :smiley_omg:
So, I'ma gonna go with the (2) small but, super powerful 48V 1,000W MY-1020 motors (~1 HP ea.)
…& put 'em on live axles :cool:

During plannin', I thought about incorporating suspension
...but, probably not on this one (tryin' to keep 'er kinda simple & relatively lightweight) :cheers2:
 

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Machining the Bearing Brackets

So, after learnin'-n-figurin' the proper way (or at least a more successful way) of drillin' big holes, I got (16) holes drilled :thumbsup:
...in each piece :cheers2:

Then, trimmed off the excess material :2guns:

* Can ya tell where I messed up? :huh:
**HINT: it's visible in last the pic :mad2:
(but, IMO not bad or visible enough to necessitate a redo) :rolleyes:
 

Attachments

  • SAM_1600.JPG
    SAM_1600.JPG
    306.7 KB · Views: 3
  • SAM_1601.JPG
    SAM_1601.JPG
    308.1 KB · Views: 3
  • SAM_1604.JPG
    SAM_1604.JPG
    315 KB · Views: 3
  • SAM_1605.JPG
    SAM_1605.JPG
    312 KB · Views: 12

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
3D Bearing Brackets

Now, let's make these bearing brackets 3 dimensional :thumbsup:

My HF metal bender is only rated to bend ~16g. steel
...but, these are made outta 1/8" (~11g.) steel :cool:

So, during the planning stage, I added some relief holes to aid in bending these brackets :cheers2:

I slid the piece most of the way in to do the "outer" bend first
...then, after the first bend I simply slid it out, to the "inner" line, & bent it again. :2guns:

That seemed to come out pretty good :smiley_omg:
...so, I did the second one the exact same way but exactly opposite :rolleyes:

I did a quick video too :cornut:
https://www.youtube.com/watch?v=e0KVk5WM2hI
 

Attachments

  • SAM_1617.JPG
    SAM_1617.JPG
    310.2 KB · Views: 1
  • SAM_1615.JPG
    SAM_1615.JPG
    315.4 KB · Views: 1
  • SAM_1609.JPG
    SAM_1609.JPG
    310.2 KB · Views: 1
  • SAM_1608.JPG
    SAM_1608.JPG
    310.5 KB · Views: 1
  • SAM_1607.JPG
    SAM_1607.JPG
    312.2 KB · Views: 1
  • SAM_1628.JPG
    SAM_1628.JPG
    311.5 KB · Views: 3
  • SAM_1630.JPG
    SAM_1630.JPG
    314 KB · Views: 1
  • SAM_1633.JPG
    SAM_1633.JPG
    312 KB · Views: 4

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Tail Section Upper Rail

Now let's bend some pipe :wai:

Here's the plan :thumbsup:
…& here's the Upper Rail :2guns:
 

Attachments

  • SAM_1725.JPG
    SAM_1725.JPG
    316.5 KB · Views: 1
  • SAM_1637.JPG
    SAM_1637.JPG
    310.9 KB · Views: 1
  • SAM_1638.JPG
    SAM_1638.JPG
    310.5 KB · Views: 2
  • SAM_1639.JPG
    SAM_1639.JPG
    312.6 KB · Views: 2

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Assembling the Tail

Next, we gotta align/attach the bearing brackets to the Upper rail :thumbsup:

I used a 5/8" rod to help align the bearing brackets
…then, clamped 'er down good :cheers2:
…& then, tacked 'em down :2guns:
 

Attachments

  • SAM_1644.JPG
    SAM_1644.JPG
    308.9 KB · Views: 1
  • SAM_1642.JPG
    SAM_1642.JPG
    311.3 KB · Views: 1
  • SAM_1643.JPG
    SAM_1643.JPG
    310.7 KB · Views: 1
  • SAM_1651.JPG
    SAM_1651.JPG
    307.9 KB · Views: 1
  • SAM_1648.JPG
    SAM_1648.JPG
    317.1 KB · Views: 1
  • SAM_1647.JPG
    SAM_1647.JPG
    313.9 KB · Views: 1
  • SAM_1646.JPG
    SAM_1646.JPG
    316.9 KB · Views: 2
  • SAM_1645.JPG
    SAM_1645.JPG
    312.5 KB · Views: 2
  • SAM_1655.JPG
    SAM_1655.JPG
    321.4 KB · Views: 1
  • SAM_1656.JPG
    SAM_1656.JPG
    307.9 KB · Views: 3

MrC.

Member
Messages
238
Reaction score
0
Location
florida
Thanks for sharing

Thank you, for making the rest of us with grinders and a welder seem somewhat inadequate.
And I'm handy.

Merry Christmas
MrC.
 

Attachments

  • 20191224_181517.jpg
    20191224_181517.jpg
    526.7 KB · Views: 9

Functional Artist

Well-known member
Messages
3,454
Reaction score
355
Location
Toledo, Ohio
Next, I (temporarily) installed the bearings & axle to double check the symmetry & squareness
...just to be sure everything lines up properly :thumbsup:

Then started workin' on/linin' up the "goose Neck" :cool:

My lower level stress plates ended up a little longer than necessary :huh:
...but, longer is "way better" than too short :cheers2:
 

Attachments

  • SAM_1661.JPG
    SAM_1661.JPG
    315.2 KB · Views: 1
  • SAM_1659.JPG
    SAM_1659.JPG
    310.5 KB · Views: 1
  • SAM_1658.JPG
    SAM_1658.JPG
    313 KB · Views: 1
  • SAM_1657.JPG
    SAM_1657.JPG
    313.2 KB · Views: 1
  • SAM_1663.JPG
    SAM_1663.JPG
    308.5 KB · Views: 1
  • SAM_1667.JPG
    SAM_1667.JPG
    315 KB · Views: 1
  • SAM_1669.JPG
    SAM_1669.JPG
    314.3 KB · Views: 1
  • SAM_1670.JPG
    SAM_1670.JPG
    317.7 KB · Views: 2
  • SAM_1671.JPG
    SAM_1671.JPG
    310 KB · Views: 1
  • SAM_1673.JPG
    SAM_1673.JPG
    316.6 KB · Views: 1
Top