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Zed Shed Antics - Something will happen!


Keyser

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  • 3 weeks later...

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"! :thumbs: 

 

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 :lol:

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 :scare:

 

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

 

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

 

IMG_3759.JPG.1eba2be5000f0523ddba2484a76996e7.JPG

 

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 :(

 

IMG_3760.JPG.600cb7dae167a5841f3046f2dff7e8c6.JPG

 

IMG_3761.JPG.f67f32e1c02d7b199888db40e6329a57.JPG

 

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

 

IMG_3762.JPG.24e556a7b7d1ce53d45dce881ee58d8a.JPG

 

IMG_3763.JPG.3dcbe327b9a38a74c2bb780f697f23ff.JPG

 

More soon (I promise)

 

Keyser Maximum Effort :thumbs:

 

 

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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 :scare: 

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

 

  IMG_3602.jpg.871b737075cca0fd09494d98f0889921.jpg

 

wedged it in place IMG_3603.jpg.c0a2ab30b8c82d146ff853c634ef31af.jpg

 

added a hook (read old broken spanner)

 

IMG_3606.jpg.e85b15257e7466a2a583e3ed3fbad312.jpg

 

 

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

 

IMG_3607.jpg.cb5d20089e4b122e26442c4aa455321b.jpgIMG_3607.jpg.cb5d20089e4b122e26442c4aa455321b.jpg

 

 

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

 

IMG_3609.jpg.47e7d0142cfd90fde4345862b229fc12.jpg

 

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

 

IMG_3612.jpg.46418dc0668d9f449749080c66ef894a.jpg

 

 

used my adjustable "table" to lift it

 

IMG_3615.jpg.ac401f6c293c856838c11678e58ee994.jpg

 

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)

 

IMG_3616.jpg.2cf09c2731ece441c3da087f18ccc740.jpg

 

 

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

 

IMG_3604.jpg

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O I added new earth points for the welder as well :thumbs:

 

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

 

IMG_3620.jpg.ce660c7bd7f25a0cab13d248ac965455.jpg

 

 

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

 

IMG_3625.jpg.2a73bde22d7bd1b5d21b8965ceabafba.jpg

 

and where the vice was attached

 

 

IMG_3626.jpg.6aa72a82a95b7166ad2975ed5f6b4a90.jpg

 

The top was then oiled to slow down the rust.

 

I then took 2 castor wheels I had

 

IMG_3627.jpg.390eb36f4d38ac8c0de0f7761376a18b.jpg

 

made an anti flip over bar

 

IMG_3628.jpg.bc5327a6e0e944d09f9a0dd93f497852.jpg

 

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

 

IMG_3629.jpg.ad1a503eda0c2ba89fce39afa30883c6.jpg

 

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

 

IMG_3631.jpg.fb00856b6189b799de252ac8cabaf1f3.jpg

 

 

* 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 :lol:  So a bit of a reorganisation is required, I'll keep you posted.

 

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

 

 

Keyser Maximum Effort :thumbs:

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

 

IMG_3636.JPG.7f463521c7df1728ce9f529461c936f1.JPG

 

IMG_3637.JPG.b7a59eee06381f60228af6c87d2427b2.JPG

 

Bit of setting out

 

IMG_3638.JPG.9a250e20497bf90aaa9bd9900a52e12d.JPG

 

Bit of welding

 

IMG_3639.JPG.9a88940e168305ed9cb756c247b43ca5.JPG

 

IMG_3640.JPG.1713db666c29990d0fa5f26580756a1c.JPG

 

Bit more metal IMG_3641.JPG.56e483f824e28837a5a33c67247ac893.JPG

 

 

cleaned and cut up

 

 

IMG_3642.JPG.6ed8819ea236167925e4b6cfb7775d47.JPG

 

Some gussets welded in for strength

 

IMG_3643.JPG.767ee35d6c5769bf2d17e72e73f556f7.JPG

 

Then do it all again for the second rack

 

IMG_3644.JPG.e3da4f3d19075b9bf3fad35becdc3e64.JPG

 

IMG_3645.JPG.1b11ae1de442fb5ee6dc02ed6af8340b.JPG

 

Nice weld :thumbs:

 

Bit of primer and installed for immediate use :)

 

IMG_3712.JPG.c6ebd7ad2abac80ef07292e664361d4f.JPG

 

 

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

 

 

 

Keyser Maximum Effort :thumbs:

 

 

 

 

 

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2 hours ago, Keyser said:

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

 

 

 

I miss my old oil drum incinerator. Once you got it going it was so hot inside you could burn anything in there. Awesome things.

 

Great welding, and great job with the storage rack! :thumbs:

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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 :lol:

 

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 :lol:

 

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

 

 

quad.JPG.7cbd23d09e5c96b085bbb8b1d5562821.JPG

 

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 :lol:

 

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 

 

IMG_3664.JPG.44179be8d52e0e8888da6fef46e6c20d.JPG

 

drill and bolt

 

IMG_3663.JPG.0d8640847e77b6862b49f1bc08795edd.JPG

 

 

Attach to the lathe and machine -

 

IMG_3665.JPG.92a6481810b3816365d61f80e2314352.JPG

 

IMG_3666.JPG.a787300c438d1c640b1f3a06f03a172b.JPG

 

weld together

 

IMG_3667.JPG.d9994229b90aa3fcc6231e642105d6f9.JPG

 

machine some more

 

IMG_3668.JPG.48302d843008d874ee9afc6873b10f5e.JPG

 

IMG_3669.JPG.202653d40b710ee32d8f8d14dc829606.JPG

 

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

 

IMG_3670.JPG.1cdf1921a6bd575bc32a8699d5a54c41.JPG

 

clean it up

 

IMG_3671.JPG.9f2cb75c50dfa7700fb44ae8167500b3.JPG

 

 

weld it to the die

 

IMG_3672.JPG.95fded06ce0cac155f4eb11e75a7eeab.JPG

 

and bore to 30mm :thumbs:

 

IMG_3676.JPG.4dbe0904f74eb4d4f32a9eae71015a70.JPG

 

 

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

 

 

 

 

 

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

 

Mounting plate with a bit of tube to hold it -

 

IMG_3677.JPG.3d36808473f33e3156ee53f155faa153.JPG

 

cut

 

IMG_3678.JPG.c78874185b7fea5306eeee6fb160d542.JPG

 

weld together

 

IMG_3679.JPG.d8f794976090c802b46ebc1196466ccd.JPG

 

mount in lathe

 

IMG_3681.JPG.c171625b043f6fcee43c7d0f49ba9d7f.JPG

 

IMG_3682.JPG.a534b4338ed4463523e555abc77f6c4a.JPG

 

it's a tight fit!

 

IMG_3680.JPG.1f1086eae939730d00ab3edec248636f.JPG

 

pilot drill

 

IMG_3683.JPG.69a81793431a83eda192c175dd95bfd4.JPG

 

drill

 

IMG_3684.JPG.4bc56b4d166d9ecf53f51078db2915f5.JPG

 

bigger drill

 

IMG_3685.JPG.6285f7e2a89113e2d7b6ea043df5bdf8.JPG

 

bore to 30mm

 

IMG_3686.JPG.cd98b2c90d3fdb699706eec49810dc0a.JPG

 

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

 

IMG_3689.JPG.c1dcc5e14ead59d2d64d31b29f8d845e.JPG

 

remove tube

 

IMG_3687.JPG.5ede6a31324db33f35acfe8c38446b0e.JPG

 

move to milling machine

 

IMG_3688.JPG.04a5f09c9b36372e49e3edcbf996f4a9.JPG

 

 

we end up with -

 

IMG_3691.JPG.b1426f8f5a79bd4055beab3d8cd7dbdb.JPG

 

 

A lot of time consuming effort is going into this :lol:

 

More coming

 

 

 

 

 

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

 

IMG_3692.JPG.1c571f9e484eafb038e7d35861dc3ae0.JPG

 

like so

 

IMG_3693.JPG.1ddd71c6e872257ed8153403919fd07d.JPG

 

 

back to the mill to round it up

 

IMG_3697.JPG.59a8c74851b01010d6f7cbbf384e6f47.JPG

 

we added a roller and we ended up with this lot

 

IMG_3698.JPG.cea16e1b29396b552123e09a2f4e7484.JPG

 

added a metal holder

 

IMG_3701.JPG.1006b824b38848b7ae735a8fbed2e010.JPG

 

IMG_3702.JPG.0bf0b5c7a13cb4be2b56675e47b569f4.JPG

 

 

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

 

IMG_3699.JPG.5193be2397975211cb94446e9bb0d31a.JPG

 

metal goes fits

 

IMG_3700.JPG.0c834d605ec1b328ac3f287ce1e30c94.JPG

 

On to testing  :thumbs:

 

first attempt

 

IMG_3703.JPG.6ba483cd906ca0e9ce98034f0c71b6eb.JPG

 

IMG_3706.JPG.5193b996bcd804671aad39abbb50c84d.JPG

 

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 :doh:

 

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

 

IMG_3707.JPG.c62aaaa8505e140de8923120d33011c1.JPG

 

IMG_3708.JPG.86bf8736241791a4de566c01e5a9e3bc.JPG

 

IMG_3709.JPG.543a2d02a9b99006231f6aef9fb5bf39.JPG

 

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

 

1483466387_greenquad.JPG.03d53842525f62f7a6a95dea759788a0.JPG

 

 

 

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 :thumbs:

 

 

 

 

Edited by Keyser
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On 12/07/2019 at 18:30, andy james said:

You guys are unbelievable! Looking forward to having a go in this.

Recaro CS chair from 370 nismo would look cool!

 

 

Oh yes :lol: 

 

Definitely an upgrade for when we build v2 of this kart

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  • 2 weeks later...

Been so busy here!!!

 

Radical engine went away for inspection, I had first and sixth gear left but could only use sixth as the primary that engages first was toast - basically I belw the entire gearbox to bits :oops:

 

So new (2nd hand) gearbox fitted, complete engine check reviled one valve stem a few thou out of true most likely from the massive over rev from a 5th to 2nd gear change at 100mph :doh: That was replaced all valves re-lapped and the engine is back in the Zed Shed II :yahoo:

 

I can't get the Radical in the Zed Shed due to a massive re-org going on, along with being mentally busy with my day job (gotta pay for all this somehow) not to mention the Beb Shed / Zed Shed Go-Ped/Go-Quad collaboration and a host of other commitments things have been MANIC!!

 

Anyway what's been going on - I know you are all desperate to find out (or not :lol: )

 

Someone came in for a bonnet change - well he is always on it like a car bonnet :lol: 

 

IMG_3784.jpg.56f871584f247a17c7b00a2de53c714c.jpg

 

 

I added some bits to the die we made for bending the Go-Ped frame

 

62327993_IMG_3798-Copy.JPG.07e8e4ca6f86f341faad64004a9f82ec.JPG

 

340201984_IMG_3795-Copy.JPG.6791d2d5826815aef2920aeb3784bdcf.JPG

 

315973800_IMG_3797-Copy.JPG.604f501587c43986bc74878278da7495.JPG

 

Made a mount for the press

 

2100203593_IMG_3805-Copy.JPG.949d9691073cded28b2533c190addc7a.JPG

 

Then tested it ....

 

469125544_IMG_3808-Copy.JPG.1bff0a74ff3705aaf1f76bb4bdb02edf.JPG

 

Still not happy :(

 

So start again

 

Pipe

 

1897998657_IMG_3817-Copy.JPG.aa402bc156c9ffcb70315b5a8f984b25.JPG

 

 

plates - these were off cuts

 

1983945886_IMG_3818-Copy.JPG.753390faa48b92293c9c514c7f8edad5.JPGts

 

 

so I did the rest

 

1380403769_IMG_3819-Copy.JPG.7ccb9ccc548f3a898c2acbb02cbc4294.JPG

 

Lathe work done -

 

1845490098_IMG_3820-Copy.JPG.f021f431231748fa273614824d26b520.JPG

 

 

joined one side

 

892329626_IMG_3823-Copy.JPG.0521bc68e43f233634fbd32c74d95d11.JPG

 

 

Then thought the other side would be an issue to join - came up with this

 

1327289047_IMG_3824-Copy.JPG.17ef37e3c7ef4ea0836f366d0f086cac.JPG

 

Just weld through the holes :thumbs:

 

re-made the holder

 

MJXK9833.jpg.7cc202240a95d01302490aad1563d8a5.jpg

 

and it now does this -

 

UBOB9256.jpg.5737127ae0356c15c9bf9b8a5e54bfd3.jpg

 

641633969_IMG_3844-Copy.JPG.f03eaab31a019bea805cbed812dfc2e9.JPG

 

583850913_IMG_3882-Copy.JPG.76bdae17ddef14978e5c86b1fa541293.JPG

 

Happy (at last) :lol:

 

More coming ..................

 

Edited by Keyser
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Some more ................

 

How many AA batteries are not included?

 

727867535_IMG_3868-Copy.JPG.de9148d0028130066ecf97f5c66fa224.JPG

 

 

2059214702_IMG_3869-Copy.JPG.075f32921b271c541795910302bf1400.JPG

 

I'm keeping clear of @Beb  as he spot welds and solders a very large number of these together!!!

 

1736154852_IMG_3922-Copy.JPG.ad08ca5cf1d3a629ee0885227f9a2583.JPG

 

At least he seems happy in his work :lol:

 

1042253393_IMG_3920-Copy.JPG.0caa0dd87875b6594f95781e632db8fe.JPG

 

 

Mean while in the engineering department things got REALLY technical :scare:

 

Best way to make a template is a dirty finger

 

236037324_IMG_3913-Copy.JPG.ec51bb114e82faa38b2c8ec2694e3dba.JPG

 

then I actually got the engineering blue out

 

356079640_IMG_3915-Copy.JPG.6d7bbd3f7f6fc1cccaac2e4c9f153034.JPG

 

208577891_IMG_3918-Copy.JPG.61f2fea971953438917b23f281c35e01.JPG

 

made this

 

2139554537_IMG_3919-Copy.JPG.a873952b00ecf8350fe13cbc4cf36160.JPG

 

shaped it a bit and added a belt adjustment slider and eventually got to here

 

1342480001_IMG_3924-Copy.JPG.23c84ab64aa8fe4a260ccbf78711cd30.JPG

 

assembled

 

1100316222_IMG_3925-Copy.JPG.4c9092cf4836a158602b23b8bb4d318b.JPG

 

Finished bending the tube and welded the frame up temporarily, its just spot welded  for now in case we need to adjust things later

 

410600651_IMG_3926-Copy.JPG.0fc9c2839d842a69b9a7da73f6ef2c26.JPG

 

Size is good

 

VCPA6161.jpg.8985ed5130a987ff8e97e0b7ba7c7b0a.jpg

 

Next up front wheel mounts, this is how they did it but it's a known weak point

 

1948341894_IMG_3906-Copy.JPG.7cf0efaf313be57027669ea1930db1ea.JPG

 

my version is neater and made of a heavier metal

 

576866503_IMG_3912-Copy.JPG.1f3305f0da87708f1c889fd422899a97.JPG

 

729544513_IMG_3908-Copy.JPG.aa817721ce2cf4fa081d8b4a8cfa212f.JPG

 

Then we need axels, so I made some

 

1083197106_IMG_3901-Copy.JPG.c7f28c46826b4bdfcd47b30a82a54b79.JPG

 

Then some more old scrap

 

1622369855_IMG_3888-Copy.JPG.f7f8c88b95d0e5a39f04a7201f5f38a6.JPG

 

Cleaned up, cut and drilled

 

1340845109_IMG_3889-Copy.JPG.31064a0a40937a5bb31611c52848bb7a.JPG

 

more drilling

 

1758047921_IMG_3890-Copy.JPG.f6ea57fe9dbca33a887605736d0e7cd5.JPG

 

add axel

 

2056307891_IMG_3891-Copy.JPG.e4e1c356d43b706e9704c5c21b2f41ba.JPG

 

test before welding

 

714723729_IMG_3892-Copy.JPG.bc0241b772261829c2918e3fbe78344f.JPG

 

weld

 

854350790_IMG_3893-Copy.JPG.d23e55b0868f565493cb0775fbff72d6.JPG

 

1630186250_IMG_3895-Copy.JPG.8cd55ad845d6d95425e8c8b771031611.JPG

 

Make a hub carrier

 

1911709228_IMG_3896-Copy.JPG.d30980a43b22b959b16cfcc27d40f93a.JPG

 

all tacked together

 

IMG_3927.jpg.f45f18954dbfeca8fbce28cd8333bdcd.jpg

 

 

Rear axel next ..............................

 

 

 

 

 

 

 

 

Edited by Keyser
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Rear axel ..........

 

Rusty hex bar

 

1455549350_IMG_3897-Copy.JPG.2d8838af23dba72bf8e8dcd25a94d6f8.JPG

 

 

Clean and cut

 

994162490_IMG_3898-Copy.JPG.416a14d5f3a937a815742b7ef977c25c.JPG

 

onto the lathe to drill out

 

1306760282_IMG_3899-Copy.JPG.5b525ac8a662d68c1bcc1af1ee485b12.JPG

 

so i get these

 

36385728_IMG_3900-Copy.JPG.c8f7c023cf42bc068e650fb4c9024791.JPG

 

welded onto another home made axel

 

IMG_3929.jpg.ebd52307d1a994cab564cc132d7b576d.jpg

 

they go in the cross bar

 

IMG_3930.jpg.8453e0a39324037c1579cf2e7a36cdd5.jpg

 

 

Then I added the motor mounts and tacked it all together

 

IMG_3933.jpg.b6e8332be08c7bfa9b2669177a488ecd.jpg

 

IMG_3934.jpg.c3b41eb3fa9a0969be736c705fdb69c2.jpg

 

So we are now to here

 

IMG_3932.jpg.3da4e0c6884debc8865972222840c5b9.jpg

 

 

More as soon as Beb and I get back out to the Zed Shed :)

 

 

Keyser Maximum Effort :thumbs:

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