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My 2017 CK build report

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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
Hi all.

I figure it's about time to give a little back to the CK community, from whom I've extracted all sorts of useful tips and ideas over the past year. I started this build in February of 2017, after stumbling across an article about cyclekarting somewhere on the web. It looked like good, cheap fun, so I dove right into building the kart you see here. There are a few things still to do (like build a seat, remove the governor, and maybe add some decals), but it's now drive-able and regularly makes runs around the neighborhood.

The kart is based on the "Stevenson Formula", as far as wheelbase, wheel type, engine, and suspension (or lack thereof) are concerned. I tried hard to find an "inspiration car" to model it after, but in the end I just let it evolve into what it wanted to be. It sort of looks like a post-war Indy car, I suppose. Really it is just a dead-simple, no-frills, bare-bones CycleKart, and oh-man is it fun to drive!

Anyway, here it is. I will post a selection of build photos as time permits.

Regards,
Tom

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Attachments:
Its soooo... RED!.jpg    67.9 KB
Its soooo... RED!.jpg

tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
Here's where it all began...


Attachments:
Basic frame layout.JPG    52.1 KB
Basic frame layout.JPG

Front axle in place.JPG    49.4 KB
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Basic chassis assembled.JPG    58 KB
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It rolls!.JPG    46.3 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
More progress...

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Attachments:
Floor pan in place.jpg    46.3 KB
Floor pan in place.jpg

Cockpit assembly.jpg    49.1 KB
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Never enough clamps.jpg    52 KB
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Brake linkage detail.jpg    51.8 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
A little more progress...


Attachments:
Rear bulkhead.jpg    46.3 KB
Rear bulkhead.jpg

Steering in place, almost ready for a test drive!.jpg    44.9 KB
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So close....jpg    56.2 KB
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Throttle cable-to-rod connector.jpg    34.3 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
And still more progress...


Attachments:
Bodywork begins.jpg    49.8 KB
Bodywork begins.jpg

Bonnet installed.jpg    43.8 KB
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New engine mount with center bearing.jpg    44.8 KB
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Rear end metalwork.jpg    54.4 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
So much work, so little time...

Between work and family obligations, progress was being made in 5-minute increments, usually very late at night. But by mid-September it was drive-able. All that effort was beginning to pay off...


Attachments:
Dad takes it for a spin.jpg    41.9 KB
Dad takes it for a spin.jpg

Pink foam plug for nose.jpg    57.6 KB
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Pink foam plug for engine air scoop.jpg    45.9 KB
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Foam plugs prepped to pull female molds.jpg    57.8 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
Making the composite parts was by far the most time-consuming part of the whole build. I probably spent more time on these two parts than anything else. Between carving the foam patterns, making the polyester/glass molds, and pulling the final epoxy/carbon parts, I put in three or four consecutive Saturdays, plus countless weeknights. The result is functional and lightweight, but not very pretty, so I decided to paint it.

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Attachments:
Carbon fiber nose mounted in place.jpg    51.5 KB
Carbon fiber nose mounted in place.jpg

Last day of bare aluminum.jpg    58.9 KB
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Sanded, cleaned, and etched aluminum.jpg    62 KB
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Primed.jpg    55.6 KB
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tomdoo Avatar
tomdoo Tom Doolittle
Pleasant Hill, CA, USA   USA
Paint was Rustoleum "Regal Red". I primed it first with self-etching primer, after scuff-sanding and a thorough cleaning with alcohol and water. It's not gonna win any awards, but it looks good enough for my purposes and will keep the aluminum from oxidizing.

It still needs a seat (leather?), and I intend to pull out the governor and perhaps do some minor engine upgrades. It needs a bit of decorating, too. With all that red surface area, its begging for stickers or other ornamentation to break up the monotony. Maybe I'll add some chrome bits?

Anyways, it's been fun. Hopefully this will help others as much as other build reports have helped me. Feel free to ask questions. I'll answer as many as I can.

Looking forward to putting this thing on a track with some other cyclekarts! I know of at least one other CK under construction within 100 miles of me. Hurry up, D! Let's go racing!

Regards, Tom


Attachments:
Rattle-can red.jpg    66.3 KB
Rattle-can red.jpg

Its soooo... RED!.jpg    67.9 KB
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CmdBentaxle Avatar
CmdBentaxle Dave D
Federal Way, WA, USA   USA
1950 CycleKart Italian "1950 Ferrari 166 F2"
Nice solid build. I'll have to study those lines and see if I can make a match with
anything.

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Rhysn Rhys Nolan
Tamworth, Staffordshire, UK   GBR
That is a great build with none of the un needed complications. And most importantly it is done with little talk smiling smiley Paint a grille in the appropriate shape and I can see early post war F1 Alfa Romeo. Great!

TheGIantTribble Avatar
Chelmsford, Essex, UK   GBR
I like that, I was thinking post war Alta when I looked at it.

Wingman26 John Owens
Shawnee, OK, USA   USA
Great looking ride there!

Team classic Brian S
Lyttelton Christchurch, Canterbury, New Zealand   NZL
Yeah,, Nice work Tom. Sound workmanship and a great result. Welcome to the club.

Denny Graham Silver Member Dennis Graham
Sandwich, IL, USA   USA
1950 Chevrolet 3600 "Old Blue"
1954 Chevrolet 3600
Thanks for posting the pics Tom. Nice straight forward Cyclekart. Now.....you gotta
submit your application to the Tieton Tech committee and see if they will accept
you for the big one this year. Or....how bout a busy weekend in sunny Phoenix,
lots of activity over that way and it would be a nice days drive if ya took the
scenic route.
Again....thanks for posting the pics, I for one like a lot of talk. That's the way we learn
and none of us, no matter how old we are, are to old to learn something from those
with the same interest as we have. This and other Forum's would be awfully dull
places to visit if it weren't for the guys talking about their projects and the work
that goes into them.
Give us a review of the test results....and let us know what the neighbors think
of you crusin' round the hood.
Time now to start on the second one????
Denny Graham
Sandwich, IL



Edited 1 time(s). Last edit at 2018-01-20 06:55 AM by Denny Graham.

CmdBentaxle Avatar
CmdBentaxle Dave D
Federal Way, WA, USA   USA
1950 CycleKart Italian "1950 Ferrari 166 F2"
I've got it!
That headrest was hard to match with the front suspension type.
A single seat Amilcar!


Attachments:
ob_773f8b_img-2042-1-copie.JPG    73.2 KB
ob_773f8b_img-2042-1-copie.JPG

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