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Post by vmrod on May 22, 2009 18:53:13 GMT -3
I went ahead and added the shock bracket and that tension pulley bracket. A nice coat of paint was next. The end plates will get added during final installation, to ensure that the wheel is aligned properly. Since I have moved the jackshaft rearwards by an inch, I added an additional plate inside the shock bracket. That way, the shock gets mounted in the exact position as before. (Otherwise it would have made the shock be extended an extra inch.) In the above pic, you can see how i modified the shock bracket to accommodate the airbag. Again, I needed to make up for an inch.
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Post by vmrod on May 25, 2009 21:33:59 GMT -3
OK. I know I said that I'd take a break before resuming construction, but I couldn't help myself. It started out innocently enough, cutting the RA-structural parts, then grinding the ends of the ones that will mate to the tubing. Next, I used a flat (and thick) barstock, and clamped the tubing to the barstock. The adjacent rectangular tube was then clamped to the barstock. (Actually another clamp was also used which holds these 2 parts together.) Anyway, they came out perfect. I marked exactly where the bracing would go, then clamped the parts down to a thick piece of plate, then welded the structural parts together. This was done a little at a time, and measurements taken often, to ensure everything stayed nice and even. Eventually the side plates were clamped in place and the last structural parts were added. The bottom part is tack welded on (like the TA skin). The funny top-part has been cut-out (upper spring perch), but I need to beat it into the proper shape before welding. I also need to cut-out the spring mounting plate and shape it too. I have to re-cut one of the side plates, then I can drill mounting holes and install them. The plates were good, but I then decided to redesign things in order to fit a snowmobile CVT in there. (for possible future testing) I should be able to get the RA completed pretty soon. Before mounting, I'll install the airtank in the area where the motor would normally go. It will look sweet. ***** It should be noted that I did not assemble the RA like in the manual. In the manual, the plates were already water-jet-cut with the holes for the motor. Care was needed to ensure that the motor shaft was lined as straight as possible, using the bushing carriers as reference points. My plates do not have these holes yet. So I can construct a little free-er. However, when I go to drill the holes for the motor, I will make a jig, and carefully locate these holes. For me, it works better this way. For those that payed attention during the TA phase, you may remember that the mounting holes for the RA were NOT drilled yet. Why you ask? Well, chances are someone like me will still have a little innacuracy when building the RA. Once the RA has been completed, I can place it up against the TA, mark & drill holes, then perfect fit! I know this, cuz the TA and the FA gave me some issues, and I ended up enlarging 1 mounting hole a little to get it to mate correctly. Don't rush into drilling mounting holes everywhere. It's best to drill them, right when you need to. !!! Pics will get posted next time of what the RA looks like right now, and then a pic of whatever got added.
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Post by vmrod on May 27, 2009 21:26:52 GMT -3
OK, I forgot to take a pic of the RA with all of the clamps on it, but you can use your imagination for that. Here it is without the bat-wing piece on top. (It still needs to get bent, then of course welded in place) Also notice the dual plates on the side facing you. The intent is that I would install another set of structural steel in between the 2 plates, so that the outside plate would be 1.5" farther away. This would allow for the installation of the Warp 9 motor. (The motor will go up front, however this mod was kept for possible future alterations/testing.) I threw the air tank in there, so you can see what it looks like. Remember, it will get steel welded onto it, so it will become a structure that gets inserted in place of an e-motor. The RA MIGHT get installed on the chassis this weekend. (edit) Here's a CAD pic, showing the designed air tank structure. I'll start on this, only once the RA is done.
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Post by vmrod on May 29, 2009 8:30:22 GMT -3
Although the plans call for .125" T6061 aluminum, I used .120" steel, since that is what the RA is made from. (except for the side plates)
Unless you have the right tools, bending this part was tough. Armed with my largest ball-pein hammer, I beat the crap out of this part until it was formed to my will. After the sides were bent, I ground the lower edges to prepare for welding, but was pretty much out of steam to do anything else.
Friday, I'll see about adding some wrapping straps around the bushing carriers like I did on the TA. (for extra strength) Once those are installed, I'll weld RA-SM-11 in place. The spring and shock mount will get installed last.
stay tuned for more...
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Post by vmrod on May 30, 2009 20:11:33 GMT -3
Slow going, but going. RA-SM-11 has been welded in place, and the spring bracket as well. I'll need to go back and re-weld a couple places, but I'm out of rods right now. Funny, some days things weld perfectly, other days (today), not so good. The welds are plenty strong as-is, but I like to have a solid weld all-around the pieces. At any rate, this is one heck of a sturdy piece. I managed to make and install those extra support strips that go around the bushing carriers (then overlap onto the adjacent rectangular tubing). I feel much better about those things now. VERY sturdy. To complete the RA, I need to fab the upper shock mount. (2 small pieces) and drill the hole out for the shock a little bigger than it is. Then the paint. The holes for the side plates will get drilled out at some point. (I also have 1 bolt to replace.)
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Post by vmrod on Jun 2, 2009 21:21:40 GMT -3
Since I did not have the holes already drilled, it took a little time to mount the RA in place. I'm pleased with the results so far. There is one issue that I must resolve though. Either the TA is 1/8" wider than anticipated, or the RA is 1/8" narrower, or maybe a bit of both. The prob is that a pair of the rubber bushings will not fit, due to the lack of space between the TA and RA. I plan on grinding the inside area of the 4 bushing carriers, so that it can accomodate the bushings. I won't have to grind much at all, as the bushings can be forced into position once it gets close enough. I'll also shave down the metal cylinders that go inside the rubber bushings the same amount. Sorry that there's not a more pleasant background for the pic... In this one, you can see the air tank inside. Still no structure yet. But it will come and be cool as heck too. I plan on ordering the pivot tube carriers, the pivot tube parts, the rear hub boss, and the rear axle tube with parts within the next couple days. I would really like to have 3 wheels on the ground by the end of the month. (June 27th marks a year since I received the plans.) ;D
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Post by vmrod on Jun 11, 2009 9:23:52 GMT -3
Had some time yesterday to MIG weld a few places on the RA. The shock mount was my main concern, since I had blown through a section with the stick welder. I succesfully filled it up yesterday and ground it back down.
The side plates have been removed and the RA structure got painted black. It was test fitted (to the TA) with rubber bushings installed and it fit good.
I've got to modify a mounting nut for TA-mounting. The hole is very close to another structure, so I'll grind the nut down as needed so it will fit. Looks like only 1 is a problem.
Next steps, shorten the steel tubes (that go inside the bushings) by 1/16", drill out some (or all) the holes in the side plates, then mount the RA to the TA!!
If I don't get to this stuff on the 11th, I should be able to get it all done Friday (12th).
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Post by vmrod on Jun 14, 2009 12:13:22 GMT -3
Done. Finally. (At least the RA) It took a little effort to shave that nut to get it to fit, but it's done. It was also a trick for the bolts to go back in, once the nuts all got welded, but that too has been done. The RA has been completed (paint and all), and it's bolted to the TA securely. The holes in the side plates are done too. (Some better than others, but still OK.) I was going to take a pic, but ya know, it looks just like the previous pics, but with holes in the side plates. The non-needed metal on the air tank has been cut off and ground smooth. On Monday, the metal will be ordered to complete the structure around the air tank, so it can get installed inside the RA as a rigid structure. Also on Monday, I'll ask Marzee for a quote on the axle tube support flanges. I figure that if I get the rear hub boss from them, I might see about getting the last few pieces from them too, if the price is right. The RA-TA tubing holders will likely get machine out of a solid block of aluminum. It will cost about $250 each! Yeah, I know, but all I will need to do is press the bearings in and bolt them into place. So, besides the air tank, the next step is attaching the swingarm to the RA.
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Post by vmrod on Jun 16, 2009 8:18:57 GMT -3
The rear hub boss and (5) RA-TA-11's were ordered yesterday. I could have fabbed the (5) RA-TA-11's, but the low price of $6.75 each was too good to pass up. I was suppose to check my metal supply before placing my next order (today), but totally forgot yesterday. So, this will get pushed back another day. The next metal order will consist of the metal for the air tank, and the rest of the metal needed to mount the swingarm and the rear axle. This will put 3 wheels on the ground! yay! Following the above will be the steering and the shifting mechanisms, but I'll just concentrate on what I need next. If things get slow in the next couple days, I'll take some more pics, so it looks like I'm bust.
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Post by vmrod on Jun 23, 2009 13:13:50 GMT -3
Just wanted to give a status, since it has been some time. The channel for the air tank structure should come in today. I'll start measuring and possibly cutting it this evening. The round, flat, end plates will get measured and cut as well this week. Perhaps on Friday, I can weld it all together. Marzee will be delivering the rear boss soon too. I'll need to hunt down a local machine shop and get it milled on one section. This is the stuff that slows me down. I forgot to order the 2 tubes needed for the jackshaft and the rear axle carrier. I MIGHT be able to order than straight from a machine shop already complete, but I'll have to check on that later tonight. Most likely, I'll have to order the tubes, then go to a local machine shop for the machining. (Yea, then I can weld it together) Be patient, cuz this is the slow part of the build. After this, it should pick up a bit.
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Post by vmrod on Jul 13, 2009 14:23:30 GMT -3
3 days ago (friday afternoon), I talked the air tank structure.
6 pieces of 1" channel were welded equally around the airtank. I still need to printout the patterns for the round ends, then weld that to the channel pieces. At any rate, it's going.
The rear boss and other marzee parts look very good. If you are considering getting parts waterjet cut, then these folks do a great job. Despite only ordering 6 pieces, the turn-around time was fast.
I will try and mill the rear boss myself with a router. It may or may not work. I figured it's aluminum and might be do-able.
I've been feeling pretty lazy lately, so progress is slow. Must be the hot weather...
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Post by vmrod on Jul 20, 2009 9:17:55 GMT -3
I used my normal wood router with a normal wood bit, and slowly started to mill the rear boss myself. After about 25% progress the shaft of the bit snapped. I was getting satisfactory results though, and will likely try to continue with this method. ************************* Call me lazy, but I still have not completed the air tank structure. Maybe this week....
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Post by hondacrzy on Jul 31, 2009 1:05:16 GMT -3
Sorry, but any more progress? reading this is pushing me to get started. Just need to finish cleaning out the garage and buying a few more needed tools
Cheers Chris
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Post by vmrod on Jul 31, 2009 8:39:58 GMT -3
Not really. I was last milling the rear boss hub (no pics) and the bit on my router broke. I may be able to keep using it. (the shaft broke, but it broke in a place that I can maybe shove the broken shaft into the router and re-use it.) I usually do my metal grinding and such outside. The last time I did aluminum fab work outside, the aluminum shavings just stayed on the ground. It took a long time for them to get 'absorbed' into the ground. (mild steel will rust and break down pretty quickly) The aluminum milling I had done in my shop to avoid the metal in my yard). Little shards of aluminum went everywhere! They aren't really thick, and don't seem to pose a pricking hazard, but there was a lot. My armouring projects are kinda scattered on the floor or nearby shelves, so shavings got sent all into my armour as well. I figured that my best bet will be to spread a tarp out on the yard, then set my table ontop that, then do my milling outside. The tarp should catch most of the shavings. Unfortunately, rain was in the forecast everyday this week, so I didn't even plan on any outside work. This weekend, I'm going to see a the Genghis Khan and the Terra Cotta Warriors exhibits in Houston. So I MIGHT have time Sunday evening. Sorry for the no progress. It's been bumming me out too, especially since I am so close to starting on the drive-train.
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Post by vmrod on Aug 3, 2009 21:59:20 GMT -3
Good news! After removing that broken router bit shaft from the router (using an easy-out), I put the bit back in. There was enough of the shaft left to get a good grip, and I was able to finish the job. Since you've been patient with my lack of progress. Here's a tip: *** Before milling the rear boss, get the rear brake caliper and see exactly how much you need to mill. I was going to mill much more, until I realized just how small the mounting surface of the brake caliper was. (notice the sharpie line on the boss) The plans showed that you need to mill it up to the hub circle. Here's a pic of the rear boss: When I first started working, I had set the bit 1/8" too deep, so I cut a piece of steel out to use as a shim plate. It fits perfectly in there. I've got the brake caliper with me, so I can hopefully get the needed bolts for it either tomorrow or Friday. ****** Next is to finish up the air-tank structure, and get back on the RA-TA tube carrier and axle carrier.
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