Keyser

All that was done to mount the die onto my tube bending machine

 

 

like so

 

 

 

back to the mill to round it up

 

 

we added a roller and we ended up with this lot

 

 

added a metal holder

 

 

 

 

fits together like so ...........

 

 

metal goes fits

 

 

On to testing 

 

first attempt

 

 

 

Pretty darn good don't ya think?

 

Yer so did I but @Beb Has CDO - it's like OCD but the letters are alphabetical as they should be

 

When you bend Box the side walls expand at the side, the ridge on the die forces the middle to pus in to prevent it kinking out and the outside stretches

 

 

 

 

Hard to see in the pics but it does, Now I spent a lot of time researching tube / box bending,  what is happening is to be expected, one of the reasons that the frame we are copying has less distortion in the side walls is because they are using 1.2mm side wall we are using 3mm side wall - more metal more bulge, all that metal has to go somewhere!!

 

The newer Go Quads have a thicker side wall no doubt as everyone increases the engine size etc they need more strength, you will notice in the newer (and faster green) ones they suffer distortion

 

 

 

 

You notice the front corner has distortion - But Beb wants flat and I love a challenge so stay tuned for the Version 2 bender followed by the version 2 die and more ........................

 

 

Keyser Maxiumum Effort

 

 

 

 

OK so now we have a die we need to mount it -

 

Mounting plate with a bit of tube to hold it -

 

 

cut

 

 

weld together

 

 

mount in lathe

 

 

 

it's a tight fit!

 

 

pilot drill

 

 

drill

 

 

bigger drill

 

 

bore to 30mm

 

 

Beb in action on the lathe - I'm training him up as a replacement to my old tool  @buster

 

 

remove tube

 

 

move to milling machine

 

 

 

we end up with -

 

 

 

A lot of time consuming effort is going into this

 

More coming

 

 

 

 

 

Now for something more fun??? -  Adults should not read on - this is for (big) kids only.

 

This all started when @Beb invited me along for an evenings entertainment "Go Quading" along with some motorised scooters thrown in, these guys are insane, they have what is basically a kids scooter with an engine on the back, there are a few with electrical power including Beb's scary fast long board, brakes are an optional extra which most did not have

 

They do 20 + MPH - I know your thinking that's not that fast - It is when you are sitting on an old style school chair on a go-kart track

 

It is epic fun - so what does a Go Quad look like? -

 

 

 

Great aren't they

 

Now Beb has an idea to modify one and convert it to electrical power - I don't think it's because he is eco friendly I think it's more to do with how fast electric vehicles can go think Tesla S

 

To that end he wanted me to copy the frame so we can start from scratch (yes I'm building one for me as well) and add battery packs and a motor.

 

So I took a few measurements and went about building a die to bend box section 

 

no round bar big enough so take three bits of plate 

 

 

drill and bolt

 

 

 

Attach to the lathe and machine -

 

 

 

weld together

 

 

machine some more

 

 

 

I need a 30mm bore but dont have anything big enough to drill it or hold it so metal tube

 

 

clean it up

 

 

 

weld it to the die

 

 

and bore to 30mm

 

 

 

more in a mo ............................

 

 

 

 

 

7 minutes ago, veeg33 said:

The oil drum needs a refurb --> another side project ??

That's no ordinary oil drum that's an incinerator

 

 

Next job on the list was to tidy the spare metal, starting with a few lengths cut into pretty shapes ..........

 

 

 

Bit of setting out

 

 

Bit of welding

 

 

 

Bit more metal

 

 

cleaned and cut up

 

 

 

Some gussets welded in for strength

 

 

Then do it all again for the second rack

 

 

 

Nice weld

 

Bit of primer and installed for immediate use

 

 

 

And that's not all we we've been up to, something more "fun" next

 

 

 

Keyser Maximum Effort

 

 

 

 

 

O I added new earth points for the welder as well

 

Had to stop for breakfast though, courtesy of my 2 daughters as they took me out for fathers day

 

 

 

Upon my return from a great day out and far to much yummy food I welded up a few holes in the top

 

 

and where the vice was attached

 

 

 

The top was then oiled to slow down the rust.

 

I then took 2 castor wheels I had

 

 

made an anti flip over bar

 

 

stuck those under one end and my pallet truck under the other

 

 

One man job to drag it through into the machine shop and to its permanent* home

 

 

 

* Did I say permanent home? - Well sort of but I have decided to give the Zed Shed II a make over, scheduled to  start next week. I have run out of space   So a bit of a reorganisation is required, I'll keep you posted.

 

More soon ....................

 

 

Keyser Maximum Effort

Bit more tinkerings going on, Radical engine is with Big CC Racing (again) to have a look at the gearbox and assess the damage - not looking forwards to that report  

Meanwhile back at the Zed Shed II I finished the welding table that I just happened to end up with, if you keep up with this thread you will remember that it had a small sag in the middle,

 

So I found a small piece of steel

 

 

 

wedged it in place

 

added a hook (read old broken spanner)

 

 

 

then used my winch and the tables weight to help pull out the sag

 

 

 

had to work my way down the table welding the support bar underneath as i went

 

 

Got most of it out so flipped the table over and finished the welding

 

 

 

used my adjustable "table" to lift it

 

 

then wire-brushed the hole thing down added some end panels and I still had some of that lovely brown hammerite paint left (hey it's free)

 

 

 

Now to move it ......................................

 

along

Nice to see a bot more progress mate

 

I've been busy breaking my toys so I'll be back in the Shed rebuilding them soon

 

Keep it coming

Nice work mate

 

Amazing how all the little bits add up though, not saying you overspent, hopefully you will have a fun and reliable run about for a while, it just makes me wonder how much I've spent on my fleet of toys

2 hours ago, Andy_Muxlow said:

Chris, Sarah and I hope to be able to come down to this event also, but with everything going on here we will have to make the decision nearer to the time if that's ok my good friend?

 

No worries mate - Hope you can make it though

Congrats mate

Just read this

 

Been there done that (the stresses of moving house that is)  - I heard of a very similar thing I can vouch for the validity of the tail, They actually went into the lender to tell them, This was 1 week before completion, the lender said it would require the offer being re-assessed, delays etc etc so the lenders rep gave them some "off the record" advice - If you don't tell us we won't know - Completion came and went the wife started a new job 2 weeks later, never missed a payment lender earned huge amounts of money from setup fees and interest, they moved into their new house and life went on and no one got hurt.

 

Not saying it's right but it happens

 

@nowhereboy Hope you get it all sorted mate

 

 

I've been so busy I haven't updated you lot for ages, Loads going on.

 

The Pop is pretty much on the back burner until the winter again now, The Radical was out for another run on track and OMG it was awesome!!!!!

I took some ballast to balance out the car in the form of @Beb He hasn't been out in the Radical since 2017 when it was Pre-Turbo and summed it up perfectly for me when we came in from a session and the comment was "F**k Me that's fast"!  

 

Now the last time I was out with Beb we had a small rain shower and I took the opportunity to demonstrate how little grip slicks give in wet conditions and spun us off on Camp corner, it was a very sedate spin ending up with us in the infield covered in grass

So taking things to the next level this time out. The paddle / Power shift system developed a fault and gear selection became difficult and approaching Camp corner at a little over the 100mph mark gear selection suddenly became impossible.

I pulled for a down shift - Stayed in 5th

I pulled for a down shift again - Stayed in 5th

I eased off and turned in for the apex a little late due to the gear selection issue

One more attempt at a downshift and we got neutral !!**?????

Gave up on the gears and in my head I was going to coast round the corner and get off the track

just on the apex the gearbox gave us 2nd - about 80mph give or take!!!

Rear wheels locked and this was a proper tank slapper, Caught the slide - went the other way, caught it again (hand slipped off steering wheel) went the other way, frantically grabbed the wheel and we stopped about 18" away from the Pit wall

 

Limped back to pit lane and was offered a loo roll by the marshals it was hysterical - I did shout back that clean underwear was also in order  

 

So the Radical is in and the engine out - apparently we only have 6th gear now - oppsee - so new gearbox needed, possibly a race box if funds stretch that far.

 

Also cracked the manifold which is due to vibration and weight

 

 

That will be welded and we are looking into Turbo mounts and possible turbo  relocation due to heat (our big enemy in this car)

 

Then taking the "sprocket" off the modified nut broke

 

 

 

So a special tool had to be made and welded to the last bit of nut to remove it -

 

 

 

More soon (I promise)

 

Keyser Maximum Effort

 

 

On 27/06/2019 at 17:23, Foo56 said:

What year is it? I’m after interior plastics (low centre console section/door & vent trim pieces) for my Hr.

 

Its a 54 so probably to early for you?

 

Door cards are here and some interior trim.

On 24/06/2019 at 14:58, Mike D said:

Hi do you have the OSF air duct its the plastic part fitted to the radiator core support?

Thanks

Mike

Sorry missed this - I will look but don't think it is there.

On 25/06/2019 at 09:59, coldel said:

What time do you fire up the bbq Chris?

 

We are very laid back people usually start showing up around 12 midday and we go from there

You gonna insulate the roof Ian?

 

I would them metal ones condensate and drip ..... just a thought

EDIT: Although that may not be metal is it that fibre stuff??

 

Looking good though

 

Can I park on the end of you lot?

If not I'll just be Billy no mates (as usual)

Check your engine earths - especially the one on the top front above the power steering pump - its the end earth point for the coil loom.

It's only a 10mm bolt into the front cover but the ally corrodes take it out check the wire for damage give it a clean and put it back on.

There is also any earth to chassis on that side make sure it's good.

May not be it but won't do an harm

 

Good luck

 

 

Hi all,

 

The annual BBQ and celebration of my eldest daughters birthday is set for Saturday the 3rd August, so clear your calenders load up the camping chairs and head on over

Resident BBQ Chef @Beb will be cooking all kinds of strange things as usual

 

BYOB drivers are expected not to drink!!!

 

Place limited(ish)

 

Get ya name down if you fancy coming along.

 

1. Keyser

A DC motor will run backwards if the polarity is reversed so the polarity must be reversed, I would guess you put the caps on backwards but I have never actually stripped and refurb'd the fan motors so I don't know that for sure, just seems the only simple thing to reverse the polarity.

10 hours ago, rabbitstew said:

Dread to think how much that weighs!

A Lot

Quick update -

 

The table is in the garage

 

 

 

First job was to get the other table top or steel plate off, not sure why they loaded it with a fork lift, all you need is an @Beb to lift it off

 

 

(Sorry Beb I forgot to Photoshop the cable out

 

At this point Beb had to leave so I ended up at this point with the table -

 

 

The rest was far to dangerous (stupid) to take pics but the end result was ........

 

 

 

started to strip it down starting with the draws

 

 

 

Don't think they have been opened in a while

 

 

 

But it did have a CD

 

 

 

 

took the old wooden side off

 

 

 

and the vice

 

 

Next thing to do is see if I can sort the slight sag in the top

 

longways

 

 

front to back

 

 

More on that soon but this is evening work so only a couple of hours a night.

 

Keyser Maximum Effort

 

 

 

Very cool