Todd Hildebrandt's Journal

Motor Cover

Fri, 26 Jun 2015 22:03:22 -0500

Todd Hildebrandt's Journal --

Dad gave me a gas tank from a WD tractor. It matches the hood and grille I am using. Tonight I got it mounted in place. It has the boat tail look without completely covering and causing heat issues (I think).

<Gas tank motor cover>

<relief cut for carb>

Posted 2015-06-26 22:03:22 by Todd Hildebrandt

Go Pedal Stuff

Sat, 06 Jun 2015 22:14:15 -0500

Todd Hildebrandt's Journal --

Had to re make the go pedal. I made the frame narrower than I first intended and the other wouldn't fit. So like I have done before, I ripped off Dennis. :D The stud on the carb was his too as the predator unit didn't look stout enough for me. Found out I can't drill a grade 5 bolt but a grade 2 worked. I may have got a bad nyloc nut and used thread locker on the motor linkage. To be clear, only on the first nut to secure the stud loosely on the arm.

<Standard CK accelerator stuff>

Posted 2015-06-06 22:14:15 by Todd Hildebrandt

Still At It

Mon, 25 May 2015 08:17:52 -0500

Todd Hildebrandt's Journal --

Had some other projects creep into the picture and slow to post an update. Picked up some 3/8" rod and a yoke a couple weeks back. Threaded end and put a jamb nut on. Did more welding on the front axle. Needs some grinding and fish plates and caps. Picked up a seat for a John Deere gator, just fits between the frame rails. Welded the cross bracing in the rear, the brake mount and the motor plate.

<Brake rod w/yoke>	<John Deere gator seat>	<Bracing and brake set up>
<Bracing and motor plate>

Posted 2015-05-25 08:17:52 by Todd Hildebrandt

Adjuster Update

Sun, 10 May 2015 22:50:34 -0500

Todd Hildebrandt's Journal --

OK, can't leave well enough alone and made an upgrade. The bolt wasn't going to be long enough and I made this solution. A piece of all thread and a coupling nut. I turned down and knurled half of the coupling nut. Next ran the coupling nut up the all thread with a normal nut. Twist the all thread in to the bracket moving the motor to the rear. Turn the coupling nut down to 1/8" from the bracket and tighten the normal nut behind it. Take the adjusting bolt back out and drill through the middle of the coupling nut for a roll pin or peened pin. Loosen the normal nut and cut the excess all thread off and dress with a file. Total cost of upgrade, less than $5 and priceless time on the lathe having fun.

<WP 000605>

Posted 2015-05-10 22:50:34 by Todd Hildebrandt

Motor Plate And Adjuster

Thu, 07 May 2015 20:54:33 -0500

Todd Hildebrandt's Journal --

Today the motor plate got made. Dad had a large chunk of 2X6X3/16 that seemed to be perfect for the cause. The too thin plate (for my taste) that came from BMI served as a useful template. My mini mill isn't here yet so I had to armstrong the slots. A motor adjuster was also made from scraps. It can unbolt from the motor plate and go in the tool box after use.

<WP 000597>	<WP 000598>	<WP 000596>
<WP 000599>

Posted 2015-05-07 20:54:33 by Todd Hildebrandt

Front Axle

Wed, 06 May 2015 20:43:42 -0500

Todd Hildebrandt's Journal --

Used 1 1/2 square X 1/8" and got this tacked together. Also tried a different axle mount using the 3 holes in the spring.

<front axle>

<axle upright>

<axle mount>

Posted 2015-05-06 20:43:42 by Todd Hildebrandt

Front Wheels And Spindles

Sun, 03 May 2015 22:52:49 -0500

Todd Hildebrandt's Journal --

Today I felt like working on the wheels and spindles. Put the lathe to use on making spacers, actually just parting them. I had some 1" aluminum with 3/4" bore. Used it for spindle spacers, bearing spacer and outer washer. Also took Dennis' throttle return spring bracket idea and added a twist.

<spacers>	<on spindles>	<outside>
<Throttle return spring bracket>

Posted 2015-05-03 22:52:49 by Todd Hildebrandt

Working On Brakes And Motor

Sat, 02 May 2015 20:08:42 -0500

Todd Hildebrandt's Journal --

Made the bracket for the brake caliper. I think it looks stout. Also cut a brace out of left over 1X3 for the motor. Got cute and drilled a hole for the axle to pass through. Next is the motor plate, I have a thin one but feel a 1/4" will be better.

<1/4" angle iron for caliper mount>

<Bolt on to make service easier>

<motor brace with axle pass through>

Posted 2015-05-02 20:08:42 by Todd Hildebrandt

Major Hurdle Crossed

Mon, 27 Apr 2015 20:47:09 -0500

Todd Hildebrandt's Journal --

Frame is welded, jig blocks removed, front springs on, axle installed, rotor & sprocket on, and rear wheels set on. For a short weekend it feels like I accomplished a ton.

<WP 000577>

<WP 000578>

<WP 000579>

Posted 2015-04-27 20:47:09 by Todd Hildebrandt

Frame Almost Done

Mon, 27 Apr 2015 20:41:16 -0500

Todd Hildebrandt's Journal --

Everything is ready to burn in place.

<Snackle pivot>	<rear axle mounting, crush sleeve inside>	<front frame>
<rear frame>

Posted 2015-04-27 20:41:16 by Todd Hildebrandt

Getting Jiggy

Mon, 27 Apr 2015 19:58:01 -0500

Todd Hildebrandt's Journal --

I was going to cut up a wood 2x4 for jigging my frame. Then at work I find a bunch of boards from the karate class in the trash. Took them to dad's and ripped them 2 1/2" wide. After screwing two pieces together in an L shape they were screwed to the lay out board. A witness line was marked at the front axle center line to help get the rails back in place quickly after drilling them.

<ready to weld>

<blocks screwed to the table>

<A witness line so it gets back in place>

Posted 2015-04-27 19:58:01 by Todd Hildebrandt

Progress Continues

Sat, 25 Apr 2015 20:52:04 -0500

Todd Hildebrandt's Journal --

The part causing the most worry so far is done, rear wheels to hubs. BMW chassis video #5 was an incredible help. Also, completed the cutting of the chassis cross members. Next plan is to cut wood blocks to fasten to the frame table. That will make it a jig, so when I pull the side rails out to drill it will all fit back together quicker and hold while welding.

<WP 000566>

<WP 000567>

<WP 000568>

Posted 2015-04-25 20:52:04 by Todd Hildebrandt

Frame Table

Mon, 20 Apr 2015 21:06:44 -0500

Todd Hildebrandt's Journal --

Took a build tip from Dennis (been doing a lot of that) and bought some 3/4" counter top press board for frame layout. Got all the cross members penciled in on the board along with the axle locations.

<WP 000561>	<WP 000560>	<WP 000562>
<WP 000563>

Posted 2015-04-20 21:06:44 by Todd Hildebrandt

Frame Rails Shaped

Sun, 19 Apr 2015 22:24:43 -0500

Todd Hildebrandt's Journal --

Friday I was able to start closing in the taper on one of the fronts. Today they are all done.

<Front frame rail>	<Rounded rear rail>	<Cross members next>
<WP 000558>

Posted 2015-04-19 22:24:43 by Todd Hildebrandt

Hump Day In The CK Workshop

Wed, 15 Apr 2015 19:08:15 -0500

Todd Hildebrandt's Journal --

As promised, the outer hub plate that was finished last night. (forgot camera in the house) Today I was able to trim the frame and shape it. Tomorrow I'll see if I can get a 1/16x15/16 strap to weld the frame shut.

<outer hub plate>

<Front frame horn>

<Rear frame horn>

Posted 2015-04-15 19:08:15 by Todd Hildebrandt

Rear Hubs

Tue, 14 Apr 2015 20:03:56 -0500

Todd Hildebrandt's Journal --

Yesterday I drove 80 miles to a friends shop to trade a stainless tank for some lathe and mill time/lessons. We cut down the center hubs for axle nut clearance. Then I got a lesson on setting up work in a 4 jaw chuck. So the asuza hubs went in the lathe and were turned down to fit the Honda wheels. One is nice and snug the other is a hair loose. Today I mocked up the stylized hood so you guys could see what I'm talking about. It may be a little long, better than short. Another task from today was outer bolt plates. I want to sandwich the Honda hub between the asuza hub and the outer plate. The plate should be 4 5/8 inch but I had some 4 3/8 inch circles in 1/4 inch. Found the center then hit it with the 1 7/8 inch hole saw. The plate will ride on the 4 ribs and around the hub, it will be trimmed down flush with plate. Pictures of that tomorrow.

<WP 000549>

<WP 000548>

<Stylized hood>

Posted 2015-04-14 20:03:56 by Todd Hildebrandt

Frame Work

Mon, 13 Apr 2015 06:57:41 -0500

Todd Hildebrandt's Journal --

Got the chevy off the lift and organized the shop a little bit, time to start the frame. I remembered a trick a late friend of mine (Ron would've loved CK's) did making hot rods, tag board templates. Taking an empty cereal box I layed out the frame profile, remember to account for the thickness of the frame rail. The next trick is to put down tape to transfer the the cut lines. I set the rails up and started playing with the widths. It getting narrower than first thought. I also put the tractor nose up for a quick visual.

<Tag board template>	<Front frame layed out>	<Rear frame layed out>
<Setting the grille on>

Posted 2015-04-13 06:57:41 by Todd Hildebrandt

Shackles Finished

Sun, 12 Apr 2015 20:59:45 -0500

Todd Hildebrandt's Journal --

Had some solid round stock to make the bungs for the frame to carry the shackle. When the lathe started the belt snapped. Finally got a new drive belt and finished that project today.

<drilling out the frame bung>

<shackles>

Posted 2015-04-12 20:59:45 by Todd Hildebrandt

Major Component Purchased

Mon, 06 Apr 2015 22:12:36 -0500

Todd Hildebrandt's Journal --

Today the frame steel came in, it was just under 24 foot. They were nice enough to cut the two main rails at 8 foot for free. I thought $104 was pretty good since online would have been $40 more. A few more parts showed up today. The tires were supposed to be here but UPS left them in Minneapolis. Work is progressing on the 49 Chevy, it is close to being able to come of the lift. Yay, space to build the cyclekart.

Posted 2015-04-06 22:12:36 by Todd Hildebrandt

Happy Easter

Sun, 05 Apr 2015 18:39:07 -0500

Todd Hildebrandt's Journal --

Was up late last night, not hiding eggs, but watching Dennis' BMW videos. Holy cow that was worth more than the cost of the internet. I feel educated and now can say, I have inspiration from all three of his builds going in mine. Today some time was spent with a hammer and dolly. The Allis Chalmers grille and hood had indications of hard use. Found some 1 3/4" flared exhaust tips in the shop, those will be used to like side draft carbs. Also located was (2) 1 1 /2" U shaped mandrel, they will make up the header. Then back on the '49 Chevy pickup, I'll need it out when the cyclekart starts getting assembled.

Posted 2015-04-05 18:39:07 by Todd Hildebrandt

More Progress

Thu, 02 Apr 2015 21:08:18 -0500

Todd Hildebrandt's Journal --

I think all the major needs are here or on order. Started planning my front axle on CAD (Cardboard Aided Design). LOL, I think I learned that here. Dennis helped with some info from the Monocar, thanks buddy. Also saw something on the Marmon Wasp that was interesting. Using 1 1/2" square tube 1/8: wall. Here are my designs, Feel free to chime in.

<WP 000525>

<WP 000526>

Posted 2015-04-02 21:08:18 by Todd Hildebrandt

Baby Steps

Tue, 31 Mar 2015 20:20:16 -0500

Todd Hildebrandt's Journal --

Placed a couple more orders for parts. Fell into some unexpected cash and might get the tires coming too. Started design work on the frame. It's a hybrid of Old #27 and the Monocar just a little wider, I'm a big guy. 8 foot side rails, 66 inch wheel base, 24 inch rear width, 20 inch front. Hopefully that won't make me feel squeezed on the sides. Made the go/whoa pedal system. It should also hold the base of the steering column. Was going to go with a rack&pinion but ordered steering links also. I'll have both on hand when I get to that point.

<frame design>

<gas & brake pedal assembly>

<side view>

Posted 2015-03-31 20:20:16 by Todd Hildebrandt

CycleKart Sunday

Sun, 29 Mar 2015 20:52:32 -0500

Todd Hildebrandt's Journal --

Spent a large part of today on the cyclekart dream. Placed orders with two different suppliers, maybe it was three? Then about six hours in the shop. Almost finished with the front spring hardware. There are two pieces of solid stock that need to be drilled for the shackle bolt, they will get welded in the frame. Made an attempt at reworking an old banjo wheel for a cyclekart. A length of 3/8 round stock was clamped to a 10 inch brake rotor then wrapped around it. Not as smooth as I was hoping for. But it is now a 10 1/2" wheel down from 15". Not sure if it will be used yet, the center hub is aluminum with something like a 7/8" 50 spline mount. That's above my skill level. Pictures as promised. Tomorrow is truck day, pretty sure cycle kart thoughts will happen.

<spring mounting harware almost done>

<CT90 wheels, crappy ones in the back>

<modified banjo wheel>

Posted 2015-03-29 20:52:32 by Todd Hildebrandt

Second Pair Arrived And Spring Has Sprung

Fri, 27 Mar 2015 21:35:38 -0500

Todd Hildebrandt's Journal --

Second verse same as the first. Had to do everything the same as yesterday. These are a little crustier than the first pair, the rear has three broken spokes. Pulled the springs off the shelf to check the eye bolt size. They were so close to accepting a 3/8" bolt. Brought out the torch to warm the ends and got the 3/8 bolts to fit . I found some 1 1/2 x 3 x 1/8 in the scrap bin that the spring slipped nicely inside. Cut it up to make the stationary mount, bolted them together to shape them on the belt sander. About halfway through shaping the worn out belt split and flew off. Going to grab extras tomorrow. Then proceed to making the shackles. Any opinions on a good length? Hope to have a couple pictures up by Sunday evening.

Posted 2015-03-27 21:35:38 by Todd Hildebrandt

First Pair Of Wheels Arrived

Thu, 26 Mar 2015 21:22:02 -0500

Todd Hildebrandt's Journal --

Kind of excited to see the package by the door when getting home from work. Took them in the shop and looked them over. Started working on the front wheel never having worked on a cycle wheel before. I basically busted the inner bearing leaving the outer race in the hub and drove out the outer bearing. Here is where I saved my own bacon, I clamped 2 small vice grips on the of the race where the notch in the hub is, then tapped it out with a drift. Wiped down the hub and measured it at 37mm. After looking over the rear wheel and not seeing a bacon saving notch a new plan was hatched. A drift was angled through the hub just catching the opposite bearing. Tapping with a small hammer the bearing started to move, the drift was then moved to the other side to work it out evenly, L-R-L-R. Easy peasy. Second bearing was tapped out using a 3/8 drive extension. Wiped the hub down and thought about the mods needed for mounting. Feeling good so far. Tomorrow the other pair are scheduled to arrive. A little nervous as the hubs are fully assembled. More patience and learning.

Posted 2015-03-26 21:22:02 by Todd Hildebrandt

My First Cycle Cart

Wed, 25 Mar 2015 19:58:24 -0500

Todd Hildebrandt's Journal --

I came to be fascinated with cyclekarts about a year ago. It was after looking through google and you tube for some offroad karts and collecting some parts, then up pops up Dennis' videos. HOOKED! There are 2 old trucks I am working on presently that are close to done ('49 Chevy & '46 Dodge). But I keep thinking about these machines. Last Saturday I was able to find two pairs of Honda wheels, 1969 & 1970. So, what do I have presently? Predator 212, cheap TAV2, pair of buggy seat springs, a front axle that I think is too thin (about 1/16th inch), a go kart rack&pinion, front spindles (think they are 5/8 bolt),rear hubs, Honda wheels 2 front & 2 rear w/junk tires, pedals, disc brake, sprocket (can't remember tooth count), rear bearings w/3 bolt cages, and couple steering wheels to choose from. Now for the vision. I have an old tractor nose and hood from an Allis Chalmers Stylized WD45 with some rear fenders from a couple old trucks ('50 Chevy or '50 Ford) that would make nice rear bodywork. Been thinking of copying the Old 27 chassis with a little variation, 23" wide front and rear. That should work with the sheet metal I have. The thought is it would like a county fair racer a farm boy would have assembled. Still need to locate some things, but this is a slow build. That said, I am sure dumb or repetitive questions may follow. Advice is always welcome and like my kids, I reserve the right to ignore it. Thanks for a great forum! Now its time to build, the AC45 Special.

Posted 2015-03-25 19:58:24 by Todd Hildebrandt