The Craftmans Shop > PowerSports

My Sidewinder build

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cedge:
Tim...
OUTSTANDING!!!  Guys, I've seen this project up close and personal. Tim puts out some excellent work between all the distractions he has to deal with. Glad to see him finally taking a bit of his time to have some fun. I'm gonna be keeping a close eye on this project. Tim, stock up on iced tea... I'll be dropping in on ya.

Steve

seanol:
zeusrekning
I went with a JD2 and converted it to vertical bending and air over hydraulic. You can also get plans on the web to build one using Pro Tools dies. Try http://www.offroadfabnet.com/index.php as they are pretty active for that.

Good luck and nice start,
Sean

zeusrekning:
Ok guys , I finally made some more progress on the buggy :D

Ive been working on the suspension components for the last couple free weekends.
I made a fixture ,per the Sidewinder plans, to help build the front arms and make them symettrical.
The front arms were a pain for me to make because it was alot of grinding to fit check then grind again.

The rear swing-arm intimidated me but it was actually easier in my opinion, mostly because all the angled cuts were well drawn out in the plans.

The biggest challenge was coping (fish mouthing) the rear brace to match the axle tube. I wasnt feeling up to cutting the angles to match and grinding to fit so I rigged the part up onto my drill press.


It worked well once I got everything aligned and postioned as needed. The hole saw was not to happy to say the least but we came through it.

Using an annular cutter for the pivot tube hole.


Here are some pics of the nearly finished pieces. Still need some berrys knocked off and cleaned up.






Heres the link to my photobucket, There are alot of redundant pics but some that arent.

http://s261.photobucket.com/albums/ii41/zeusrekning/Sidewinder/?start=0


So as I sit, the frame and suspension is "basically" complete.I am waitng to get my parts from the water jet guy, I have places my order from "The Edge"
I would guess mounting the motor and making the tank are the next big hurdles.

P.S.
I just have to throw these in.These are a couple pics of my old kart.

 

sbwhart:
Well done Tim you've made some real great progress fantastic bit of fabrication.

Thanks for showing

Stew

zeusrekning:
!!!UPDATE TIME!!!

Well I got my stuff from The Edge this week.
Im still waiting on all the parts from my waterjet guy, looks like it may
be a couple of weeks on that.

So I knocked out the front spindles. I used preheat treated 4140,
It comes in around 30 rockwell. It is not too hard but stiffened up a bit.
And machines very well, IMO better that annealed.

Here are some pics of the turning, I didnt take any pics of coping the end
to fit the spindle tube but it was straight foward. I just made a 5deg angled cut with an endmill.







Today I went and picked up some aluminum for the gas tank.
Then I decided to work on a tank lid. I really wanted to use the
cap off the GS500 tank. It is a cool flush mount cap.So I had to make a recessed
piece to weld to the tank top, so that I could use the flush mount cap.

Heres a pic of the tank. I had no intention of using it originally
so sitting out side it got mud and paint on it. :)


Under the cap.


First thing I did was make the center plug out of some stainless steel.
This is where the locking section goes.







Next was making the recessed piece that would weld to the tank.

Sawing took almost 45min with my dull blade.


Chucked it up, faced and turned back as much as I could.
Then flipped it and faced to length and turned back the other half.
During the last facing operation I used the turning tool to scribe a center line for locating.


Then, I bored the center section, to the correct depth for the cap.


One thing I noticed , was that the center of the filler tube (SS piece)
Needed to be off center of the recess in the alum. On the GS tank I measued the offset at 3/16".
This has to do with the way the cap hinges and for the locking mechanisim to clear.



I mounted the 4 jaw chuck and got my part mounted so it was offcenter .188".





I then pressed my SS piece in, I wanted to keep my orientation in the 4 jaw chuck so I could bore the
SS piece so I used the tailstock as to help persuade the two to mate.




Well I just realized I didnt take a pic of the finished part. LOL
After that last pic I bored the SS to diameter, then put a 60degree taper like is on the
original. Then polished it us.

Here is a pic with the cap mounted.

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