Lunar Rover (prototype)

[Functional Artist]

The connections, on the front steering cross-bar, are currently ~3 1/2" from the center
...but, I can easily add holes & adjust the connections to the 2 1/2" or 1 1/2" marks


Moving on, I cut a piece of steel for an upper seatback mounting bracket
...added seat mounting holes
...bending relief holes
...& also, a couple of bigger holes to look kool & reduce weight a bit
...then, bent 'er into shape

 

[Functional Artist]

Next, I cut a custom base/foundation for our seat back & bottom, outta some 1/2" plywood

Shaped 'em to kinda match the frame

I made sure the seat base, mounting bar, sat nice-n-flush
…& the steering cables clear nicely as well

 

[Functional Artist]

Gotta round up some upholstery
...to give 'er a protective cover & some paddin'

Until then...

I cut, bent up & installed a couple of bars
...these will act as protective barriers between the astro-drivers feet & the front wheels
...…& also, to "tie together" & strengthen the (2) tiers (upper & lower) of the front end

 

[Functional Artist]

I'ma thinkin' we'll work on the front "drive unit" next
...set up, test etc.

She'll basically be a front wheel drive kart
...but, just for a minute

I thought about settin' the front up with "dual compatibility"
...so, either a live axle or a diff could be installed.
...but, ran into some issues

The sprocket on a live axle can be adjusted almost infinitely, not so much on a diff

I have a peerless differential, out of a riding mower, that I used for measurement purposes.
...but, with the diff centered, in the frame & the sprockets aligned, the back of the motor would intrude into the operators foot area a bit. (~1 1/2")

So, live axle "it is"
...maybe we'll put a diff on the "tail" to aid steering/maneuverability

 

[Functional Artist]

Front Motor Mount

I cut a piece of 10g. steel to use as a motor mount (it's a bit thicker than 1/8" steel which is ~12g.)
…added (4) adjustment slots
…& then, clamped 'er to the upright bars, right behind the axle/sprocket

* Used a straight edge to align the sprockets

First, I tried a 60T sprocket
…there was ~2" of clearance from the front bumper/bars

Then, tried a 72T sprocket
…& there was ~1 1/4" of clearance

** The 60T sprocket will make 'er faster
...but, the 72T sprocket will give 'er more torque

Ima gonna go with more torque, for now (better for climbin' outta craters-n-such)
...but, can always switch 'em later (like for racin' with/against alien rovers/karts)

 

[Functional Artist]

Floor Boards

I tac welded the motor mount plate in place
…& then re-installed/assembled the axle, sprocket, motor & chain
(just to be sure it's where it needs to be before weldin' 'er down good-n- permanent)

Yup, looks good

Next, I moved on to the floor boards
...which I'm also gonna try to incorporate the axle/chain guard into as well

So, I measured, marked, cut & bent a piece of expanded steel
...but, when I tried a "test fit", it just seems like too much (kinda overbuilt)

Now, I'm workin' on something a bit smaller
...more to come

 

[Functional Artist]

Floor boards 2.0

I came up with some smaller floorboards
...but, the actual floor/foot space did not decrease

They go across/under the foot area
...then, rise's up @ ~45*
…then, level out
…& finally tucks up under the front bearing bracket stress plates

Gives a nice-n-clean look
...& also, isolates the rotating shaft from the foot/pedal area

 

[Functional Artist]

Before I can make/install the left floor board, we gotta work on the braking system

First, we have to establish
...what type of brake system
...how it's gonna function
…& where & how it's gonna be mounted

Then, make a brake pedal
...& figure where it needs to be mounted


Well, it looks like it would be simplest to just mount a drum brake
...right in front of where the brake pedal, will be
…& have it actuated directly, by the pedal, via a short metal bar

* It would put a whole new meaning to "Stompin' on the Brakes"

So, to mount the "pivot side" of the brake band to the frame, I used a 3/8" "long nut" on the frame side, of the brake drum
…& made up a bracket to support the "inner" side

Made sure everything was square, with the axle & then, tacked 'em on

Now, I am gonna make up a brake pedal
…& a "connecting rod"
…& then, do some testin' (to see if/how well it functions/works)

 

[Functional Artist]

Brake Pedal

I rounded up some steel that seemed like it would make for a good pedal
…& then, made up a simple U-bracket, for mounting it to the kart

Looks pretty good, paired with the throttle pedal

 

[Functional Artist]

Brake Pedal Connecting Rod

I measured, marked, cut, & drilled a piece of 1/8" x 1" steel to use for the brake connecting rod
(it's pretty simple so, I forgot to take pics)

But then, when I connected everything together & gave 'er a try
...the brake band kept floppin' around
…& also, droppin' down/out of alignment with the brake drum

So, it looked like, maybe, a set of "sliding brake band retainers" may help

These retainers don't need to be so Heavy Duty so, I'll just make 'em out of some 1/16" steel

I'll make them both simultaneously, right next to each other

Started off by measuring, marking, drilling, cutting, slotting & some filing too

Not bad so far

 

[Functional Artist]

Next I had to cut 'em apart
…& then, clean 'em up

 

[Functional Artist]

Brake Band Assembly with Sliding Retainers

Pics of the sliding retainers, mounted onto the brake band
...with the connecting rod

 

[Functional Artist]

Brake Assembly Testing

I installed the brake band assy. around the axle
...& mounted onto the kart

Clamped the pedal down directly across from
...& "in line" with the throttle pedal

Connected 'em together with the connecting rod

Then, gave 'er a try

I tried (3) different connecting points on the pedal
...the middle one seemed to work the best

Well, it works/functions
...but, still needs some adjustin'

So far, I'm likin' it
...short sweet & to the point

 

[Functional Artist]

The first government issued brake band bracket (part # 100007062.79627-2.01) has been recalled
...it just didn't meet specs for an "other world explorer"

So, I've been workin' on installing the new "approved"
...& "improved" brake band bracket (part # 60279LR201.63B) on the Rover

This "updated" version is a lot lighter
...& looks like it's more/better engineered too

 

[Functional Artist]

Left floor board

The left floorboard has to work with/around the brake assembly, which makes it a bit more complicated

So, I made a template out of a piece of cardboard first, to help work out the fine 'er details

Then, re-assembled the pedal assembly, to make sure everything "clears" & still functions properly

Looks good to me

 

[Functional Artist]

Making the floorboard, out of expanded steel, was pretty simple using the template

Cut 'er out, lined 'er up, clamped 'er down & welded 'er on

Pretty & sturdy

 

[Functional Artist]

These floor boards will provide some protection
…& won't pick up any "moon rocks"
Got a couple more pics

 

[Functional Artist]

I think were gonna need something a bit "meaner" than turf savers, for climbin' outta craters-n-such

Like some really "grippy" tires
...really really grippy
…even super grippy

Yup, I think these Carlisle X-Trac (15 x 5.00 - 6) should work
Picked 'em up from Surplus Center for ~$50.00 per pair
...can't beat (4) brand new rims & tires for ~$100.00

Um, I mean "Government Issued"
...yea, yea, their from the "Government" Surplus Center

 

[Functional Artist]

Here's how these X-Trac's look on the front of the kart

Um...Corona wheels

 

[Functional Artist]

After lots & lots of clean up, I re-mounted the axle & brake assemblies
…aligned & tested the brake system
...covered & protected everything
…& then, got the brake pedal mounting bracket welded on