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#Post#: 9989--------------------------------------------------
No 21 “How are you going to make it?” …..... “I have absolutely
NO idea”
By: Granville Date: December 30, 2023, 9:16 am
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How it started (13 October 2023)
So this all started from a pop up on the Facebooks, I like the
men's fashion of the 1930s and the car styling so I think the
Facebook algorithm popped up a “You may like this”.
They look fun, those Cyclekart things ...Google search and
about four hours of YouTube vids about Cyclekarts late and I
announced to my ever suffering girlfriend.
“I'm going to make one of those”
“Oh no not another crazy hobby, they look like brum” came the
reply.
And then she said “How are you going to make it?”
…..... “I have absolutely NO idea”
So after cleaning out the garage and binning all those “It will
come in one day” items, I had a little bit of space to create my
masterpiece.
Inspiration
Next thing was to find an inspiration car, I went though a
bunch, changing my mind no end I really liked the Bugatti 37,
but also Alfa Rameo, I then sort of settled on an Austin special
that I liked the look of, a bit used a bit rough round the
edges, that was the sort of look I think I'm after, like its
just been pulled out of a shed and put on the track, rather than
from some pristine workshop.
[attachimg=1]
Planning Stage and there is a Cyclekart meeting coming up
I found out there was a Cyclekart meeting at Stretton Circuit it
was in about three weeks time, Ill wait till then before I get
anything or spend any money that would be the sensible thing to
do ...... The next day I on the interweb buying loads of bits
that I knew I would need, I had a plan in my head, I had found
my inspiration car and I was on the way to building it....If
only I had a clue about what I was doing.
The one thing I did use in the planning stage is a program
called “Big Print” it enabled me to scale up pictures to give me
a better understanding of a Cyclekart in a 1-1 scale
[attachimg=2]
Parts Start Arriving (2 November 2023)
First thing to arrive were the wheels they were the cheap eBay
pit bike ones I checked all the spokes and a couple were a bit
loose, the join on the rim was a bit rough so I filed it down to
try and cut down on punctures, but for the money they were OK, I
could also space them out a meter apart and 1650mm length to
give me a visual on how much garage space it would take up.
(while no one is looking you have to sit on the floor, hold an
imaginary steering wheel and go Brum Brum, its the Law)
[attachimg=4]
[attachimg=3]
Tyres and tubes arrived and were fitted so next on my list was a
way for the rims to fit to the 25mm solid axel that was on its
way in the post, I ordered the Adapter plates and spacers from
Gemini
Cyclekart meeting (8 November 2023)
WOW some cracking looking Cyclekarts and a great chance to find
out as much as I could from those who had already built one.
Loads of information gained I also managed to pick up a 69
tooth sprocket from the meeting as well as some friction damper
plates from Mark Underdown. So more parts to add to those
already arriving.
All the way home I was going over what I had learnt and what
others had told me, “Keep it simple, keep it low.” but should I
go single wheel drive, or fixed wheels maybe even a
differential, what size drive sprockets, maybe even a jack shaft
so I could play about with gearing, one thing for for sure, I
was having some way of keeping my bum dry when it rained and the
Kart was parked in the pits and I was defanatly pinching this
idea.
[attachimg=5]
Cyclekart scavenger hunt (15 November 2023)
I picked up a free leather chair, so will be working on making a
leather seat for the Kart when I get some time off work. Also
found a scrap heater cover that will make a nice radiator grill
for the front end. Unfortunately when I came to strip the chair
down it stunk of cigarettes so abandoned that idea.
Postman also delivered an Austin Badge but it could be a while
before it gets put on.
[attachimg=6]
#Post#: 9992--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Granville Date: December 30, 2023, 9:32 am
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Gathering loads of stuff together
The space I cleared in the garage is now filling up with parts
and I have treated myself to a new foldable workbench and a
little electric heater. 75x25 steel ordered but so far all I
have done is cut down the £12 trailer spring to try and work out
how much it will flex as its quite thick.
[attachimg=3]
Front Axel (19 November 2023)
There was a delay on 75x25 steel for the frame so with a couple
of days off work I made a "thing" to hang some front wheels off
of. Studying all about steering geometry, king pin angles and
stuff like that, didn't know I would be interested in any of
that before discovering Cyclekarts. Its thin wall rectangular
box section cut to shape, then 4 mm flat bar bent and welded top
and bottom. I used parts from the OK'e stub axel kit as well.
[attachimg=2]
Sliding engine mount (26 November 2023)
I wanted to come up with an easy way to move the engine to
tighten the drive chain, The engine bolts to the H part, loosen
the four sliding bolts and use a socket on the threaded bar to
slide the engine. Hopefully this will keep everything in line
when adjusting chain tension.
[attachimg=4] [attachimg=5]
PLAN B (27 November 2023)
So ever since the Cyclekart meeting I have been thinking about a
Diff and Jack shaft set up, I like the idea if being able to
play about with different gearing set ups, it has its pros and
also cons mainly the additional cost and complications but I am
building this Cyclekart to learn new skills and I want to push
myself. So its now Plan B and I'm going down that route with my
build.
The Peerless comes with one inch shafts which are 25.4mm. I
could either order 1” bearings or get the shafts milled down to
25mm. As I wanted a key way cut in them as well I got my very
nice son in law to take them to his school and borrow their
equipment to get that bit done, leaving about 50mm each side
still at one inch for the grease seals to run on.
[attachimg=7]
75x25 steel arrived (30 November 2023)
I don't really have any photos of the chassis I think I got
carried away and forgot to take any, basic idea was to built a
plywood tray that was big enough to fit me on sat down and then
place the steel around that, the photos were taken in early
December but give you the idea of what I made.
[attachimg=8]
Jack shaft planning (1 December 2023)
I was in the garage again looking at where I needed the frame to
be to mount the jack shaft, girlfriend brings in a brew.
"Oh nice you made a little stool for your kart thing"
[attachimg=9]
I also fitted the rear wheels to the Mono Hub using the adaptor
plates and spacers, the treads coming from the Mono Hub had to
be cut down as well as filing the edge of the nuts down to get
them to fit the pit bike wheels.
[attachimg=10] [attachimg=11]
#Post#: 9993--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Granville Date: December 30, 2023, 9:39 am
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Lessons on a lathe (6 December 2023)
Today's Cyclekart learning experience having lessons from my
uncle in how to use this stuff. Last time I used a lathe was
back at school in about 1980.
[attachimg=1] [attachimg=2]
Brakes next (22 December 2023)
So with having the diff I went with twin brakes rather than just
one wheel braking, I made up two mounting plates and tacked them
in place, Ill be using some twin pot calipers from the ebay at
£24 I also want to have a handbrake of some sort but as usual “I
have absolutely NO idea” how I am going to do this yet.
[attachimg=3]
#Post#: 9994--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Granville Date: December 30, 2023, 9:48 am
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Front End Transverse front leaf spring (23-29 December 2023)
I said earlier that I wanted to push myself to use this build to
learn new skills, well so far this bit pushed me nearly all the
way. I ordered a 100 x 100x 6mm 300 long to make a couple of L
shaped brackets for the front end. I had the springs cut down
ready, the axle was built, spring hangers made and I also had
the friction plates ready to mount. Its a one day job......one
day and the rest
So first off the spring hangers caught on the insert so that bit
had to be cut out...
[attachimg=1] [attachimg=2]
The little drop link bracket I had made under the axle was
completely useless and looked crap so that got binned.... and
had to make another one this time linking upwards to the
Dampers.
[attachimg=3]
The springs were a bit too long so had to be cut down so the
spring hanger could actually swing...
so I sorted all that out and put a couple of coats of paint over
the undercoat.
Sat having a brew that evening .... Brain says “You forgot to
make a Panhard rod didn't you, you know the bit that stops the
axle just rocking side to side on the spring hangers”
So next morning first job making a Panhard rod.
[attachimg=4]
Put it all together.. looks great, put the front wheels on and
get it off the bench. All ready for a springiness test, push on
the right side it moves and springs back, push on the left side
and it goes clunk.....the Panhard rod is about 15mm too long and
catching on the friction plates......(not so gentlemanly
language is used at this point)
So back on the bench and the front end is stripped down for what
feels like the hundredth time.
Shortened Panhard rod fitted.
Photo taken before Damper drop "Up" links fitted
[attachimg=5]
#Post#: 9996--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: NewbieNick Date: December 30, 2023, 9:58 am
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Impressive work Granville, love the sliding engine mount.
Handbrake I used a mechanical brake calliper on the same disc as
the hydraulic one, page 6 of my build journal if interested ,I
think Jim has done the same on his Auto union.
Cheers Nick
#Post#: 9999--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Jimr1999 Date: December 30, 2023, 11:06 am
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Many ways to skin the cat with the hand brake, a hydraulic line
lock has been used successfully, a cable to pull the foot pedal
down, secondary calipers. As always simple as possible as long
as it works. Looking good Granville
#Post#: 10005--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: jim Date: December 31, 2023, 1:46 am
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Excellent build journal, Keep up the good work as this looks
like it'll turn into a high quality Cyclekart.
#Post#: 10033--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: edd57 Date: January 3, 2024, 3:57 am
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Looking good Granville, Very good
#Post#: 10048--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Max Venturi Date: January 4, 2024, 2:35 pm
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I can't see the photos. Is anyone else having an issue?
#Post#: 10049--------------------------------------------------
Re: No 21 “How are you going to make it?” …..... “I have absolut
ely NO idea”
By: Jimr1999 Date: January 4, 2024, 3:21 pm
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You need to be logged in to see photos usually.
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