My large not so scale project

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superchip

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Before I start I'd like to say that I can't find a more suitable section to post this in so I'll post it here, the moderators are welcome to move it if need be.

My project is something of a year in the making and I actually nearly finished the first incarnation before I decided to tear it apart and start again ha!

You will not see any polished spanking new parts in this thread and you won't see any snazzy bits and bobs that have been turned on a lathe or any fancy welds either primarily because I can't weld lol. What you WILL see is my continuing attempt to build a large scalish buggy of sorts that I can have a laugh with which is what this hobby is partly all about right?

Now because I can't weld, everything will be bolted together at first until I have a final working design that I'm happy with, after which I'll get a friend to weld up for me.

So what are we talking about here? A piece of wood with four wheels, one in each corner with an engine bolted to it? Well no but the principle is almost the same so anyone who is interested in good old back yard engineering they are most welcome to comment and give advice.
More to come soon ;).
 
I was going to reuse these wheels but decided not as they're too heavy20150708_171645.webp

Instead I opted to use a set of pushchair wheels as they're lighter and easier to modify20150708_171542.webp

These wheels didn't have bearings so I modded the two front wheels20150708_171529.webp

Wishbones, in a fashion lol20150708_171723.webp

Chain driven diff in the making20150708_171629.webp
 
The engine was taken off a petrol scooter20150708_171706.webp

That's all the pics I have for now but more will come. I'm sure Kustomkb and nitrocat will be pleased that I've made a start lol.

Also I have an idea for suspension, I'm thinking of making a kind of pull spring arrangement using trampoline springs and gas struts for dampening but we'll see haha.
 
That's right Jonah, I'm planning to trim all unnecessary plastic off in time but they can stay on for now. I think I'm going to paint the wheels once finished too just to get rid of that garish silver lol.

Good to see you found my post nitrocat ;) I hope you're well.

I actually have a pic of my project before I ripped it apart. Very roughly put together just for proof of concept as it was my very first attempt20140930_153934.webp

Sorry for the quality, the buggy was so large I couldn't get any closer plus I wanted to see how it supported it's own weight.
 
Maybe I should explain what I did with the front wheels lol.


20150708_171529.webp.

Originally they simply locked onto a spindle and that was it, The hole to accommodate the spindle was uniform so in order to make a bearing fit I carved out a larger hole just big enough to press fit a bearing into. That metal lump at the side of the wheel is actually the the turn buckle/wheel hub I'm going to be using on the buggy. I have only fitted one bearing to the back of each front wheel, the rest of the wheel hub is touching the the spindle of the turn buckle but I've greased it to stop the plastic from melting which I think might happen in time if left dry.
 
Small update, I started the chassis. Skid plate underneath and I fixed the first of two lower cross members for the wish bones. Sorry but no pic of that at the moment as my phone was dead lol but I'll upload one tomorrow :D.
 
Right, I've been a little busy today and finished front lower cross members for the wish bones 20150711_175707.webp
I also braced them at the top as the tubing I'm using for the chassis rails is rather weak but it's solid now.

This is a pic of what I did yesterday when I put some of the chassis together. It will be longer than this but not by much20150711_132544.webp when the chassis is finished it will be welded hopefully, I can't weld the skid plate as it's made of aluminium. All non structural stuff will be riveted to save weight.

Made the upper front wish bones, they're longer than the bottom ones and I hope it doesn't have a detrimental affect on the suspension.20150711_175757.webpI made them longer because it will be easier to make the upper fixture plus I don't want to add more weight, in fact I hope this will lessen any chassis twist when the suspension is working.

This is how the lower front wish bones will eventually fit to the cross members20150711_175739.webp I'm hoping to make some kind of bushings for these.

I'm hoping to work a little to the rear of the chassis tomorrow to get a final length plus I want to plan what to do with the rear suspension. I might go for a similar kind of arrangement as the rear of a VW beetle (just the way in which the camber changes when the suspension is working), not exactly the best option but will save weight and it will allow me to just use one universal joint per side.

Hopefully more to come tomorrow :).
 
Thanks jammer, I don't consider myself a master craftsman and I'm a little worried how the wish bones will hold up but it's starting to come together and so long as I brace the weak tubing it seems pretty strong, we'll just have to wait and see how it performs on its maiden run.

I decided to work on the diff today, sorry there's no pictures because I didn't actually get anywhere with it lol. My problem is the bevel gears have a 17mm bore whereas the universal joints I've ordered only have a 10mm bore. I knew this beforehand but I thought I'd sort some kind of reducer shaft but I haven't managed it yet.

I've also figured out some kind of layout for the engine and electronics which was easy as I only had one real choice. Electronics as far up front as I can and engine as far back as possible to try and prevent any interference from the suppressor and coil. The battery will be behind the electronics in a box of some sort and the fuel tank will go between the engine and electronics box. Fairly standard layout really.

Hopefully in a couple of days I should have the diff together and some sort of arrangement for the rear suspension.
 
Yeah your right on both counts nitrocat, I was also thinking about neatness too and ease of changing out components without having to take half the car apart lol.

I've been thinking about the diff and I've decided if I can't figure out a way to make two output shafts then I will be getting two sets of angle grinder gears because I've seen some on eBay that have a 10mm bore and just remake the diff cage.
 
That's exactly what I've tried to do, but all the tubing I have doesn't fit into each other properly. I might have two sizes that reduce from 17 mm to maybe 14mm but it's not a tight fit. I might as well get some angle grinder gears that have a 10 mm bore to begin with then at least it'll be a clean and secure fixture. It's a pity the gears I have won't work, they're out of a mobility scooter diff so they would've easily held up.

I'm looking into using brass bushings for the wish bones but I'm not sure yet. There's so much to think about it's not even funny lol.
 
I had a look on eBay at shim stock, a little out of my price range considering my project consists of mostly old, used, modified and recovered components. In fact the most money I've spent on it so far is about £30 for two motor controllers to drive the windscreen wiper motors. I just feel that if I get something ready made that will do the job for less money then all the better. Although there still might come a time when I may need some shim stock, at this present time though I think I can manage without it :).
 
Did a bit more today, not much but I thought it needed addressing. I realised a potential flaw in my wish bones so I pot riveted bracing to the inside and lengthened the bolt holding the rod end in place20150713_174241.webp.I also added a bit more strength to the pivot points because I thought they looked a bit thin.

It's not pretty but it's added considerable strength 20150713_174249.webp, I've only managed to get the two large wish bones done today but I'll be doing the same to the smaller ones tomorrow. Once this is done I'm going to attempt to mount the wish bones to the chassis.

I know I said I was going to work on the rear end but my plans have changed in that area so until some bits and bobs get delivered I'm going to leave it for now. I decided to bite the bullet and purchase two sets of angle grinder gears for the diff. I've seen them used for this purpose before and they stand up to abuse very well.

I'm actually getting a little excited because once the wish bones are attached I can work on the steering system and mount the (once elusive) homemade steering servo, or at least figure out the final placing.
 
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