New guy building a Radio Flyer Wagon Kart

[zenking12]

Your right !! I guess that was a bonehead new guy move on my part. Guess I can grind them off and well them closer to the front or extend my frame crap. !!!

 

[OzFab]

Yep, sorry dude; always trial fit the axle fully assembled...

Now, to fix the problem, carefully gring off the bearing plates; if you need to damage something in the process, it's better to be the plates rather than the frame...

Put everything on the axle; sprocket, brake disc, bearings & wheels (you don't need keys just yet, it's only a trial fit). If you don't have bearings yet, get them & bolt the mounts to the bearing mount plate. Now you can fit the axle where it needs to be.

Line it up square & level & tack the bearing plates in place. Unbolt the bearings from the mount plates & the whole axle will fall out. Complete the welds & everything is good to go

 

[zenking12]

I need to thank you for catching that. Maybe I should just make it into a cool pull wagon then I won't have to worry about sprockets. Ha ha I guess is how you learn thanks man I really appreciate it I will start working on it in a couple days.

 

[zenking12]

fixing my screw ups

Fabroman, After thinking about this mistake I made, here is what I think I will do to fix it.
Cut the sides of the frame off. They have the hangers on them. Then cut new sides. (I didn't like the way they came out anyway. Could have lived with it but now I can weld them better.) With the old sides cut off I can use my chop saw to cut part of the hangers clean. Then grind the other sides of the hangers off. Then Re-weld the hangers the way you suggested and with axle and sprocket on ex..
Wow it will be almost like starting over but hope it will be right this time.

Dan

 

[itsid]

Wait a second...

I think it's not too much that the sprocket needs,
it just hits the frame, right?

How about a smaller sprocket and a jackshaft to compensate for the gear ratio then, no need to grind or weld the frame again.

Would you mind to measure how much of an "error" we're talking about?

'sid

 

[landuse]

I see that but, my concern is that the sprocket won't fit, it'll hit the frame because the axle is too far back.

If you lok kat the last pic in rocketkarts pocs, you'll notice the rear of the wheel is level (or there about) with the rear of the wagon, I'm guessing your wheels protrude past the frame...

I agree. You might have to grind those hangers off and reweld

 

[Jimmy_B]

Keep the pics coming. I did a wagon 12 years ago and am always interested to see what others build.

 

[OzFab]

Keep the pics coming. I did a wagon 12 years ago and am always interested to see what others build.

Ah, welcome back Jimmy. Perhaps you could add some input/insight to the current dilemma..?

How about a smaller sprocket and a jackshaft to compensate for the gear ratio then, no need to grind or weld the frame again.

Fair point but, what about the brake disc?

Would you mind to measure how much of an "error" we're talking about?

Measure from the axle to the nearest point of the frame & report result...

 

[Jimmy_B]

Ah, welcome back Jimmy. Perhaps you could add some input/insight to the current dilemma..?

Thanks, I've been around. Just been lurking to see all of the cool projects here.

Still excited to see the progress!

 

[zenking12]

So I don't want to put a lot of money into this. I got the bar stool for 50 dollars and plan to use as much as I can without spending a lot. Before I saw the posts I already started cutting and welding again. (remember I'm new at this and find it fun stuff). So I cut the sides as I have more steel than parts like sprockets and things. Re-welded the new sides on and fixed one corner that I was never happy about.
Frame is welded and I'm happy. I have not cut the hangers off the frame yet because I need to mock up the axle and sprocket, disc ex...
So now can someone tell me how to get the parts back on the axle? They wont go on without a big hammer. Can I sand the axle ?? Emery cloth or steel wool?
Then I might just weld the hangers on with the one inch part of the sides I cut off. It will bring it up one inch and I don't know if that will work .

Anyway I appreciate all the help so far and please keep suggestion's coming.
Dan

 

[zenking12]

kart

Kinda went nuts today. The fireplace repair guy was going to be here at 11:30 and didn't show up till 2:30 so I worked on the kart.
Two new sides and fixed a corner. Installed the hangers and have plenty of room for sprocket. I had to steel wool and wet sand the axle just to make it useable.
Everything works nice now. On to the next mistake.
Dan

 

[itsid]

Fair point but, what about the brake disc?

smallest around (smallest 'useful' that is) is about 130mm in diameter, that'll do

But everything's cut, so no need to buy new parts hopefully

'sid

 

[OzFab]

I know it's difficult but, you need to slow down a bit & wait for us to respond to your questions. Unless it's a bad camera angle illusion, now you're too far forward; you only need max 1" of clearance.

I can't tell from the pics whether you cut the tubing off the bearing mounts but, you should; being open at the ends makes the tube weak & susceptable to collapsing/bending.

Yes, it's ok to sand the axle, it's also a good idea to check &, if necessary, run a smooth file over the bore of the sprocket, brake & wheel hubs to remove any possible burrs that may have formed.

 

[zenking12]

I only did so much because I had time waiting for the repairman to come who was very late.
I have 1.25" of clearance and cant re-weld it again. (just don't have it in me) I thought about the tubing and decided to grind the mounts off and re-welding them. After what you said Fabroman I'm glad I did.
This is it for me for a while. Next will be the front end. Hope I can use the one from the bar stool.
Dan

 

[zenking12]

just a little work today

started welding the font end today but ran out of time.
Dan

 

[landuse]

Looking good!!

 

[Hendersonjk]

Sitting on top of the live axle will make Turning tuff. Plan on making one of these and saw another guy have that problem. Like setting too far back on a three wheeler.

 

[zenking12]

Worked on my kart a little today.
I will clean up my welds tomorrow. I have a rolling kart !!
Dano

 

[landuse]

A roller!!

 

[fattony]

Nice it feels good to have something that rolls doesn't it. Well done.