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A Christmas Gift

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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Merry Christmas!
We have been talking about converting a "Ducati Shipping Crate" into a CycleKart Frame
for quite some time now!
Well, as a Christmas Gift, I would like to share this idea with everyone here on the Forum.
As Ducatis are shipped to dealers all over the world, these shipping crates should be easily
found at dealer near you.
They are constructed from very thin materials to help keep the shipping weight down. But because
of that they are not worth there weight in recycling costs. Thus, the are usually available "FREE,
They are also machine welded together in a jig, so they are uniform and square.
My hope was to make a video of the repurposing process, but videos are not my forte.
So, I have taken a number of stills that I will post to this thread, showing the step by step transformation
of the crate to a CK frame.
Actual measurements and cut lines will be drafted and added to this thread as I get them finalized.
At present, I am working off of the vision I had of this process, and some preliminary measurements
I planned to use.
THESE CRATES ARE A NATURAL FOR A CYCLEKART FRAME!
Got, started late in the afternoon (Christmas Eve) and was only able to get about two hours in the shop
before coming in for a Christmas Eve Dinner and a movie.
More pictures will follow soon!
Hope this helps someone!!smileys with beer
Merry Christmas
Woody
PS
This first one will be used for my Ice Racer CK project.

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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
So with the rails removed (they will go hack on in a relocated position to form the frame rails)
I have marked a couple cut lines and stuck some masking tape on the areas that will be
removed from the crate to get it down to the 20" OD of the frame.


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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Next I ground off the the 6 welds on the centre plate (future seat bottom) that held the three distinctive sections together!
After which I removed the two cross members from under that area (they will be used later).



Edited 1 time(s). Last edit at 2018-12-25 02:27 AM by Woodysrods.

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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Here is a picture of the frame rails sitting back atop the three sections to give you an idea
as to what it will look like.
Note the rear section has not yet been narrowed, as it will have the centre trough off set
to align with the rear axle drive sprocket and act as a chain guard and catch pan in case
chain breaks.


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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Frames can be made to accommodate three different styles of front suspension.
I will use quarter elliptic springs for the Ice Racer.
But I have attached photos of how a transverse spring front end can be used, and
one with a parallel leaf set up as most use.


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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Just a couple more shots, before I go to bed to wait for Santa!
More to come tomorrow if I get another hour in the shop before
Christmas Dinner with the family.
Merry Christmas
Brian

Note: So far there has been NO fabricated parts or welding!



Edited 1 time(s). Last edit at 2018-12-25 03:14 AM by Woodysrods.


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dBlast Avatar
dBlast Vince De Blasi
Maple, ON, Canada   CAN
When you were talking about a "Ducati shipping crate", for some reason I was picturing a wooden crate. Woody working with wood? Can't be! ... but this makes sense.

I can't wait to see how this turns out.

Vince.

chrisenamels Avatar
chrisenamels Silver Member Chris Brown
Llangadog, Carmarthenshire, UK   GBR
Interesting idea Brian, just looked and our nearest Ducati dealer is 95 miles away in Bristol. That 190 mile round trip negates the "free" aspect, I was hoping there'd be one in Swansea

Nadolig Llawen

Chris

Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
In reply to # 36911 by dBlast When you were talking about a "Ducati shipping crate", for some reason I was picturing a wooden crate. Woody working with wood? Can't be! ... but this makes sense.

I can't wait to see how this turns out.

Vince.
Wood........is a four letter word!eye rolling smiley
Quit talking dirty Vince.tongue sticking out smiley
Something that had not entered my mind when I started talking about these things.
My plan is to make a few for future enthusiasts that don't or can't weld.
The actual frame rails are 1 1/4" x 2 3/4" so the circumference of the tube is the same as
the 1"x 3" we have been using. They are .063 wall (1/16"winking smiley so very light.
The cross supports are 1" x 4", and the existing floor pans are the perfect size, and folded for strength.
So, the width of the frame for my Ice Racer and the next 3 frames I build will be 14" to match
the four grill shells I acquired for free.thumbs up
Brian
And Chris, you could be there and back before lunch....but I would call first. smileys with beer


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chrisenamels Avatar
chrisenamels Silver Member Chris Brown
Llangadog, Carmarthenshire, UK   GBR
Brian,

When it comes to that stage I'll have a chat with the local bike dealers, and see what is used for other makes of bike. The diesel for the journey plus the four hour or more round trip (half of it is Welsh A roads), means it's not worth going to Bristol, probably not much cheaper than having the steel delivered.

Got to get the Morgan done first, then there's the wood monocoque Austin A7 Nippy, before I start thinking about packing crates. spinning smiley sticking its tongue out

Chris

Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
So to carry on....I went back out to the shop today for an hour and cut a slim pie in the rails,
took them out to my frame table and welded them up.
Now the frame rails can be set up over the there floor sections and welded in place.
I will drill and tube the frame for the Rear Axle Pillow Blocks at 69" Wheelbase and make the
mounts for the quarter elliptic springs and the frame is close to being finished.
SLAM DUNK!smileys with beer.
Merry Christmas
Brian


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Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
So for those of you that are following along here.
The last posted pictures show the mock up of the general shape
and size.
Today I trimmed the pieces that will be used for the frame, and got more of the precise fit.
New thoughts included moving the front floor up 1/2 inch and the chain guard up 2".
I also shortened the chain guard (catch tray) 6" as it was longer than it needed to be: this
will make it easier to taper the tail for a more steam lined look.
So with the pillow blocks mounted on to of the frame, it looks like the numbers all worked out perfect,
with the end ground clearance being 4".
Original wheelbase target was 69" (to match my other CK) but 70" might be a better fit.....I will know
the exact number when I mount the front axle.
Note: if I was to be using a "Transverse Spring" style front end the wheelbase would be 68" which also
would be a comfortable wheelbase for full elliptic springs.
Front suspension options would be that of the individual builder.
Good Roads
Brian


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Denny Graham Gold Member Dennis Graham
Sandwich, IL, USA   USA
1950 Chevrolet 3600 "Old Blue"
1954 Chevrolet 3600
Burning the midnight oil I see. Man, you really got your teeth sunk into this one.
Lookin' real fine, and simple Woody, just remember to pull back on the reins if
your wild side starts to show its stuff.
dg

Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
In reply to # 36959 by Denny Graham Burning the midnight oil I see. Man, you really got your teeth sunk into this one.
Lookin' real fine, and simple Woody, just remember to pull back on the reins if
your wild side starts to show its stuff.
dg

Thanks Denny
Doing my best to keep "evil Ron" under control on this build.
My goal was to start building it as a Xmas Eve project and be driving it on New Years Day!smileys with beer
Getting company for the next two days........that will slow me down a little.
Brian

Woodysrods Avatar
Woodysrods Silver Member Brian Woods
Westbank B.C., Canada   CAN
Oh, and yesterday as the snow was falling, soI went out back and brought three more shipping crates down to the shop.
So it looks like the first week the new year I will produce 3 more CK frames for anyone interested that may not weld.smiling bouncing smiley
We will get the Ice Racing or Dirt Oval bug going here one way or another.
Brian

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