Lunar Rover (prototype)

[Functional Artist]

Astro-Seat

Lets get ta workin' on the seat

I already made/cut some pieces of 1/2" plywood for the "foundation boards" of the seat

So, I used them as templates to mark the padding
...then, cut 'em out with a razor knife

 

[Karts of Kaos]

Is that stuff you are using basically a sheet of pool noodle?

 

[Functional Artist]

Is that stuff you are using basically a sheet of pool noodle?

Yup, I guess ya could call it that
...it's kinda like "closed cell" foam rubber or something

I'm using it (black) as a "stiff" layer (for extra support)
(the softer stuff is just too soft)
…& then, I'm adding a (white) "softer" layer (for extra padding)
(so the seat still feels kinda fluffy)

 

[Functional Artist]

Here's the (approved) plan for the seat

Black-n-Silver (monochrome)
...gotta go with lunar colors

The covering will be made of "space-proof" vinyl (from Wal-Mart)

It'll have a black insert
...with a silver "header" across the top
...& also down the sides

I used the wood foundation board to draw out the "pattern"

* Notice the extra 1/2" (sewing flanges) needed on each side of the black insert
...& also the silver sides

 

[Functional Artist]

Cut the material out, as per the diagram

Got the sewin' machine out
…& did some sewin'

I sewed a strip of silver vinyl, on both sides of the black piece
…& sewed a silver piece across the top

I used the foundation boards as templates to mark
...& then, added a 1/2" sewing flange before cuttin' it out

 

[Functional Artist]

Next, I cut some 3 1/2" strips of the silver vinyl
…& then, sew them around the perimeter (of both) of the seat cover top panels

 

[landuse]

Looks awesome!

 

[Functional Artist]

So now, let's get 'er put together

I sealed the back side of the seat foundation boards up with some satin black spray paint
...a couple of days ago

For assembly, the first thing is to "stuff" the white "fluffy" layer of foam rubber into the seat cover
...then, the black "stiffer" layer goes in
…& then the foundation board
(aligning each layer, within the seat cover, as you go)

Then, start by pushing down/adding a bit of pressure
…& folding the edge so, there's a ~1/2 " of double thick" material
(looks cleaner & "holds" the staples better)

Watch/monitor the "face" of the seat
...to help maintain "straight" edges
…& start stapelin'
(in the middle of each side while, workin' toward the corners)

 

[gegcorp2012]

Great looking upholstery work ! Good job.

BTW, what type of sewing machine are you using ?

I need to do some auto and boat covers this year.
Sent from my SM-J700T using Tapatalk

 

[Functional Artist]

Great looking upholstery work ! Good job.

BTW, what type of sewing machine are you using ?

I need to do some auto and boat covers this year.
Sent from my SM-J700T using Tapatalk

Thanks!

The sewing machine is a standard (household) unit from Wal-Mart made by Brother

I've done several go kart seats with it, works pretty good

 

[Functional Artist]

Here's our Astro-seat

 

[Functional Artist]

I wanted to add a quick "monogram" to the seat

To do so, I copied the USA logo I drew up
…reduced 'er by ~60%
…& then, cut 'er out

 

[Functional Artist]

I tried the stencil out on the front of a notebook first
...just one quick/steady spray
...came out pretty good

So, I used some alcohol. to clean the area
...used some masking tape. as a straight line
…& then, marked the center "spot"

Who knows how long it will last
...but, yup everyone will know that she's "Maiden the USA"

 

[Functional Artist]

I drilled more "adjustment" holes in the "steering arm" (as per Sid's suggestion)
…& got some of the other, small parts cleaned up

Then, I threw a quick coat of primer & paint on 'em

I "sprayed" everything a nice satin black
...then thought, the brake pedal arm & cable connectors would look kool chrome'd

 

[Functional Artist]

I started re-assembly
...re-attached the "tail"
...re-installed the steering cables
...& the seat too

* I'm gonna try the "inner" holes, in the steering cross-bar
...for a bit more "gear reduction"

 

[landuse]

Looking good

 

[Functional Artist]

I got the pedals re-mounted
…& reassembled the brake system

She's about "ready to roll"
...just waitin' on the motors & controllers :toetap05:

 

[landuse]

Good work FA!

 

[Functional Artist]

I finally, got the (2) 48V 1,000W ZY-1020 (brushed) motors
...& controllers, from my buddy Miguel @ Alfa Wheels
* FYI: a ZY-1020 is IMO a "high quality clone" of the MY-1020

I love it, that their SO simple
…& that they come with directions
…& in English even

The (4) "big" wires are for power in (from the batt thru red & black)
...& power out (to the motor(s) thru blue & yellow)

The "small" wires are for the signal switches (on/off, reverse etc.)

** Now, Ima gonna have ta get 'er back down
...I kinda "sent" 'er to the Moon

 

[Functional Artist]

I suspended the Rover from the "rafters"
...'cause I needed my work bench for "bendin' stuff"

So, I had ta lower 'er down a bit, to do some work on 'er
…added a "hook" for mounting the speed controller
...& drilled some holes to "run" the wiring

* The "signal" wires will "run" thru the big hole
…& the motor's "power" wires will "run" thru the smaller hole