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Bernd:

--- Quote from: sbwhart on June 17, 2009, 03:05:43 PM ---Bernd

This is going to be a real interesting project I take it when you've got the frame done your going over to the wheels, are they going to be spoked ?, building up a spoked wheel should be fun.  :D

Stew


--- End quote ---

Click on the red "LINK" in the first post to see how I might do the rear wheels.

Bernd

sbwhart:
Got it Bernd don't know how I missed it first time round  :doh:

Just read the Rudy build thread through very interesting, contrasting UK and US methods and designs of engines, both equaly effective, the Rudy build is very well documented and some real good pics thanks for pointing us in that direction


Stew

rleete:
I remember that thread.  The wheels are a whole project in themselves!

Bernd:
The weekend is not even here yet and I've got some of the frame done. The first part to be made was the two side rails of the rear part of the frame. They were milled out from a piece of aluminum bar 1 1/2" thick by 4 " wide by 13 1/4" long.

Since the 1 1/2" size was already what I need I decided to mill a slot down the center 1" wide by 3/8" deep. But first the top had to have skim cut taken to make sure it was level and smooth



Once smooth I changed over to a 1/2" dia. 2 flute end mill to cut the slot.



Checking for a depth of 3/8"



Next was getting the sides to a 1/8" thickness.



Here they are finished to size.



Now to separate the soon to be channel from the block. I had made a cutter holder for a small carbide saw. This didn't work out very well as the saw would pull a chip through the cut and the saw would stop cutting. I didn't like the feel as it cut…..



…..so I changed over to my 10" table saw. I use a piece of wood under the aluminum because the ally doesn't slide very well on the cast iron table of the saw. The first channel has already been cut off.



In order to keep from getting sprayed with a shower of hot chips I make a sandwich of wood, ally and wood and use my push tool. This works very good. You need to push the work into the blade very slowly and steadily. Very nerve racking the first time you do this.



And there it is the piece sawn free from the larger piece.



Next the sawn side needs to be cleaned up and brought down to size. Using a fly cutter would have worked nice, only…..



…out on the end of the part that sticks out of the vise about 3 to 4 inches it rang like a bell leaving a very bad finish. You can't see it to good but to the right you can see that it's much smoother than on the end way out over the vise.



So back to the trusty old 1/2" two flute end mill to finish the job.


And here are the two side frame rails (channels)



I then made some cross members 1" by 3/8" by 6 3/8". All I need to do now is drill and tap holes to assemble these pieces together. Here they are just laid together loosely.



That's it for now. I need to figure out the size and how many screws I'm going to use to assemble these loose pieces. In the mean time I might start getting the rims done for the rear wheels.

Till next time.

Bernd

Stilldrillin:
Bernd,
Next time anything is protruding from the vice, support it with a screw jack.

Just a "nut & bolt" slipped under each end will stop it resonating, & trying to dodge the cutter......  :thumbup:

David D

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