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Gaps filled waiting for them to dry
Spent a few hours in the shed this weekend building up the hood frame and shaping the radiator. Its starting to look a bit like a car.



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Well, I spent most of my available shop time roughing in round parts on the lathe; collecting a pile of cylindrical parts; postponing the more satisfying but more careful task of fitting them all together. I needed help bending the front axle. The bending setup that I could piece together needed the strength of 4 arms to pull it around. Thanks again Marco. I stumbled upon a 1920ish dashboard clock on eBay; not working, no bids. $15 and it was mine. The innards are almost entirely made of brass. After an examination, I decided to repair it sometime later (during one dark rainy winter ni...



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More metal was scrounged up this week; a short piece of brass, an even shorter piece of bearing bronze, copper sheet trimmings (from making head gaskets nearly two decades ago), cast aluminum plate (scrapped from tooling fixtures), and a large block of 6061 that was once an injection mold. The plate was too big for the bandsaw so it was cut into smaller pieces with a drill bit. I'll weld two pieces to the engine cases for making new mounts. I turned a hub for mounting the final drive sprocket which I found in my toolbox. It fits a Ducati single and shows no sign of use. With 45 teeth, it...



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IMG 1031
Floorpan cut and laid in place, firewall bulkhead trial in position and front wheels fitted.




 



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I continued to steer clear of work this week as well as last and noodle about in the home shop. A little progress was made on both sides of the firewall. I bought a single 28" trailer leaf spring assembly for $22.45 and separated its four leafs. I used an old reground endmill to point the ends of the third leaf. The chips came off hot and blue in color and I had to move up and down the flutes hunting for a sharp edge. In the spirit of sustainability, I'll resharpen it on Tuesday when I finish shaping the springs at work. I made an aluminum saddle to hold the spring to the chassis. I don't k...




 



IMG 1020
I wouldn't fly in it but I think it will be ok on terra firma. Ive been cutting, welding and swearing for about 4 weeks now, and have enjoyed every minute of it. The contributions on this forum are fantastic and have helped me immensely. So far I have a simple chassis constructed and am working through the installation and fettling of the rear axle. Need to overcome the slop between the rear hubs and the axle before I can move on. One more kart is being born in the UK woohoo !




 



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A little more progress was made on my cyclecar within the confines of my small drawing tablet and often distracted imagination. This week I slept in a tent, rowed a boat, and ate a lot of roasted marshmallows; no internet, CAD programs, G-code, or machine tools. I built parts by scribbling. Everything works on paper; it all fits together, moves smoothly, handles the loads without breaking, and is really fun to take out for a drive. This week, the project seemed to assemble itself, and in the evenings I sat back and imagined my handy work.




 



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Five weeks ago, I selected a cyclecar for inspiration, roughed out a design direction in my head, pulled the motorcycle parts out of the corners of my house, and climbed into a couple of metal recycling bins. I've been very lucky with what I've kept and moved around over the last couple of decades and have been surprised by their alignment with this project. This fortuitous situation has allowed me to dream, design, and build with absolute reckless abandon. This week however was spent crunching some numbers. The Honda CB160 engine parts I'm using, when put together, may produce 16 hp @ 10,000 ...




 



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This week found me thinking about brakes. I dug up these motorcycle hub parts that I think belong together. They are probably from a Ducati single; something about them looks Italian made. The air vents on the backing plate were fake so I opened them up on the mill. I also pressed out the bearings and removed the spoke flanges on the lathe. I'll set these parts aside for now until I have an axle to attach them. The cockpit is fun to work on. I made the seat and front bulkhead from a piece of 0.050 aluminum sheet. The alloy is 5052 and feels hard but was able to form the large diameter bend...




 



I'm tied up until Aug 22 as chairman of the largest outdoor automotive fleamarket in a 500 km radius hosted by the NB Antique Auto Club. Once that has been completed, I expect to start some serious garage time putting together my CK chassis. All my mechanical, electrical, wheels, suspension parts, engine, etc are sitting there waiting to have a chassis to call home..... I've been checking out other "bodystyles" that CKC members have built.....wow, there are some unbelievable karts out there. Just when I saw something I liked, another one was on the next page!!!!! I have decided to build mine ...




 



Not sure where to begin, where can I obtain possible plans for a cycle kart?




 



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Progress was made on the chassis. A few bits were machined from steel scrap; tubing was salvaged and scalloped; and everything was tacked together with the TiG welder. The middle bulkhead was pop riveted together from 0.060 aluminum sheet and tubing. I found 6 rubber vibration isolators I bought years ago for fixing chairs; so I thought I'd use them to float the body from the chassis and engine assembly. I am planning on passing a propeller shaft through the right side frame tube. Total cost after 3 weeks of "whistling while I work" engineering: holding at $2.97




 



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I sorted through my supply of old bearings this week. Perhaps they will do after a good flushing and I'll try and work them into the design where I can. Some chassis ideas were worked out in CAD. The screen shots show an incomplete design, however I did revise after checking the scrap bin at work and the leftover tubing I have available from past projects. Chassis pieces were cut to length and set aside for welding. I made progress on the steering wheel and column; wrapped the wheel with friction tape that I bought from the Home Depot. Total cost after thoroughly enjoying being a cyclekar...




 



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It may be possible to build a cyclekart from what I can find laying around the house. The CB160 cases have been knocking around here for about a decade and spent the last two weeks in the recycling bin at work. After bringing them back home, I explored the possibility of building a horizontal twin engine from the parts. The steering wheel spider was CNC milled from a 1/4" thick aluminum plate salvaged from the cutoff bin; two identically milled parts that nest together. I think that the crank that I pressed apart is from a CB175. The bearing races don't match the bores in the cases; hmmm...




 



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Modifying a few engine castings




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