Giant Half-Scale Build

[doug banner]

maybe u could put some leverage on it with a bell crank or some kind of cable set up something like mooman did on his steering
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' doug good luck

 

[KustomKB]

Thanks Doug, I'll give it a try. And yes, those are impact universals, we'll see how they hold up.



Here are some frame parts and threaded bushings, to be welded into the swing arms;

 

[KustomKB]

I added a bushing to the bottom cap as Allan suggested. There wasn't enough meat to put one in, so I added a retainer. All 3 diameters are a press fit and the screws give me something to put a wrench on to tighten the bottom caps;







I also had 4 springs made up, just need to machine the spigots to keep them centred;






I started on the swing arms by setting my angle"O"meter to the template;








Then mark the template with my bend gauge;






Then mark the tube;





Then bend it to the angle;






Here I am setting a vise in the tool post of the lathe to the correct height;





Set the tube level, and put a roughing end mill in the chuck;







Bring the tube to the cutter;







And here it is fish-mouthed;







Mark to trim the excess;






Rinse and repeat;





Have fun out there! -Kevin

 

[KustomKB]

A few more misc. parts;

A new servo arm, its hard to see, but I used the gear to broach the arm a couple times. Any way, the arm is splinned pretty good plus a few set-screws to hold it;







And a whole whack, of rod end, type stuff;

 

[voo2doo]

This is GREAT! beautiful engineering.:w00t::w00t::w00t:
J

 

[KustomKB]

Thanks a lot J!


I hacked off the ends of the donor quad's rear axle and turned them down to fit my bearings and milled a square to be driven by the impact universal.

Note the difference in surface finish. I guess when you are cranking out thousands of these things, every second counts.





I thought they would be to pretty tough to drill, so I sleeved the existing hole to take up the slack for the retaining screw, but I ended up drilling right through, so I could have drilled clean holes from the start...

Here is the set-up to transfer the holes to the rear axle and have no end play;






And the assembled parts;






Happy bashing!

KB

 

[allanach]

Awesome, you got some time on your hands

 

[doug banner]

good job the rig is so cool.keep it up



doug

 

[KustomKB]

Thanks a lot Allan and Doug.

you got some time on your hands

After the kids go to bed I figure it's better than watching TV


I found the same engine on-line and added it to my computer model;













I bet the software I am using (Solidworks) could figure out the centre of gravity and help me place the engine...


-KB

 

[vassilisG]

Very impressive work mate.

This period I have an interest about Solidworks and start thinking to try with it. Maybe its not easy for old dogs but I like it.:w00t:


I have a little 'objection' to your suspension geometry.
The two arms are parallel and have the same lenght. I think that will make a ++ caber angle at the cornering, not the best for the holding.

Vass

 

[KustomKB]

Thank you Vass.

I was strictly pen and paper too, until a couple years ago. Once you get the hang of it, it really helps speed up the design process.

I am very limited in my steering/ suspension knowledge and appreciate your advice. I do not know what ++ camber means. What adjustments do you think I should make?

The rear swing arms are parallel and equal length. The front swing arms are parallel but unequal length. There has been a few adjustments since this picture was made but it is all I can post right now;




I have not yet welded any swing arm components, so I still have time to make some modifications.


I have always gone with what feels and looks about right, like this trike I designed and built about 10 years ago. But now that I have computer modelling ability, it is great to try things in the computer first and seek advice from the community.

Thanks a lot for everyone's advice and encouragement!

 

[vassilisG]

A few suspansion's fundaments:

1. no parallel arms.
2.upper is about the 3/4 of down- arm's lenght.
3. the line between hub's joints, not vertical to the ground.

....and few pics to help more.


Uploaded with ImageShack.com



An example :

Two possitions, before cornering and during the cornering.
The -2 camber ungle ( first pic ), with this geometry gives a vertical wheel on the road, that means great holding.

Uploaded with ImageShack.com

Uploaded with ImageShack.com

Hope that helps.

Vass

 

[KustomKB]

Thank you very much for the tips.

Here my pivot points are off-set like yours;




And I will increase the difference, of the lengths of the swing arms.

Thanks again!

-Kevin

 

[mooman007uk]

you might also want to allow the top arm to slide back and forth on it's pin for castor adjustment as well, with grub screws or similar to lock it in the desired position

 

[KustomKB]

Thanks Mooman, I was thinking how I could add adjustment. But gave up on it. That is so simple!

Instead of the grub screws I could leave clearance on the ends of the tube and put in different thickness spacers.
That way, the pin can remain stationary and the tube still pivots on its bushings.

Cheers!

 

[KustomKB]

Here the top swing arm is shortened;




Cheers!

 

[KustomKB]

More chassis parts and pivot pins;

 

[KustomKB]

So, after hanging about 40 sheets of drywall and re-wiring about 90% of my house I was able to squeeze in a little shop time.

Here are some lugs for the shocks' bottom rod ends;





The top end of the shocks were bored larger rubber and brass bushes were fitted to add a little "give". Any advice on bleeder valves?






Steering linkage;







The top differential mounting plate was chopped up and an aluminum doubler was added because I had doubts that I could get it out after everything was welded up; It's pretty hard to see, but the top steel plate is in three pieces.







Our youngest son turns one tomorrow, they and our home keep me pretty busy so stay tuned.....


Cheers, KB

 

[atom3624]

Looking NICE !!
How big is that going to be?
What's going to power it?
Al.

 

[doug banner]

how bout some brake bleeders out of a couple of old brake calipers or for something smaller idle mixturer screws out of and old holley 2 or 4 barrel carb your build is looking good dude keep it up and good luck
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doug