PDA

View Full Version : Starting my first build!



ljack
02-22-2009, 11:04 AM
Hey guys! I said I would report back as soon as I started working on my own Loderunner.
Well, I'm proud to announce, that today I offically started building! :sunny:

Had a short welding course a month ago, but now it's beginnig to get serious...
I've had lots of steel around for a week now, but today I did the first cuts.
Hopefully I progress fast enough, that my LodeRunner is finished in summer.

I'll post a few pics, as soon as there is something to see... :cool4:

Patrike
02-22-2009, 11:28 AM
I am looking forward to watching your progress as this is on the top of my list of one of two builds after my Kyoto is completed.

Cheers



Hey guys! I said I would report back as soon as I started working on my own Loderunner.
Well, I'm proud to announce, that today I offically started building! :sunny:

Had a short welding course a month ago, but now it's beginnig to get serious...
I've had lots of steel around for a week now, but today I did the first cuts.
Hopefully I progress fast enough, that my LodeRunner is finished in summer.

I'll post a few pics, as soon as there is something to see... :cool4:

trikeman
02-22-2009, 11:31 AM
If I haven't already said so, Welcome aboard ljack. I look forward to seeing your progress.

MoeMac
02-22-2009, 12:41 PM
Hey guys! I said I would report back as soon as I started working on my own Loderunner.
Well, I'm proud to announce, that today I offically started building! :sunny:

Had a short welding course a month ago, but now it's beginnig to get serious...
I've had lots of steel around for a week now, but today I did the first cuts.
Hopefully I progress fast enough, that my LodeRunner is finished in summer.

I'll post a few pics, as soon as there is something to see... :cool4:

Welcome aboard! We are all Zombies that consumes PICS cause we all learn from each other and bends are our energy bars! Yum Yum! :punk:

SirJoey
02-22-2009, 01:39 PM
Welcome to the Krew, Ljack!
Lookin' forward to those pics! :)


http://img384.imageshack.us/img384/7131/sirjoeysigmedij1.gif

John Lewis
02-22-2009, 10:27 PM
Welcome , Ljack.

Glad to see someone else infected with the bug. There is no cure.

Like the others said, We like to see photos. Its not real until then.:jester:

John Lewis

JayRay
02-24-2009, 01:56 AM
Hey Ljack,
Welcome to the fold!
Looking forward to seeing
your build :builder2: progress.
Jay

ljack
02-24-2009, 01:40 PM
Thanks so much for your warm welcome!
I've attached a link to my first pictures (http://photobucket.com/loderunnerjack). Not much to see so far, only a little glimpse into my workshop. I've also did a quick test, how well the 4 parts for the rear square fit together.
Looks quite nice, although there are some corners with about 1mm space between the parts. Is this tolerable for welding, or should I try to grind the parts to fit?
Also I didn't cut those parts with the angle grinder, since I was not satisfied with the precision of the results I was getting. So I took the handsaw and had a little workout... (Took me about 30min per part, but it's never to early to learn patience :jester:)
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8733.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8733.jpg)
BTW: How can you attach pics so that they only show up as a small preview?

trikeman
02-24-2009, 04:27 PM
Its not completely necessary with 16 ga steel, but I often leave a small gap intentionally to help with penetration. Cut a few 2" pieces from the tubing you are using and weld them together. Then, cut them apart perpindicular to the weld and you will see how your penetration is going to be at a particular setting. Its always good to do a few practice pieces of the type and thickness you are going to weld before you put the torch to the real thing.

If you are getting adequate penetration on your test pieces without a gap, you are golden. The gaps do sometimes make it too easy to blow through.

Welding 16ga is always a balancing act between getting enough penetration and not burning through. What are you going to weld it with?

I actually like using my hacksaw on 16ga. With a good bi-metal blade it is not too bad, but I sometimes have trouble cutting straight. I can even use the hand saw at night when the neighbors are asleep. Now that I have one of those Harbor Freight el-cheapo `4" crosscut abrasive saws, I am getting lazy, but it goes through steel like butta.

JayRay
02-25-2009, 02:58 AM
Ljack,
If you use a service like
www.photobucket.com
or
www.imagebam.com
you would store your pictures in
galleries on their servers and they
give you the links with thumbnails
to put in your posts.
Both sites require setting up an
account but it is free to do so.

DUH! :1eye: I just looked at your progress
photos and see you are using Photobucket.
You can cut the "IMG Thumb - Forums & Bulletin Boards"
link from them and paste it in your post.
It shows up as an option when you view
your photo in the Main screen.

Great progress by the way!
I love those Harbor Freight magnets.
I do not think the small gap will make any
difference. Not that I am an expert... LOL
It is most important to keep the box square.
Weld, check, weld, check, etc...

Looking forward to more photos.
Jay

savarin
02-25-2009, 03:29 AM
Practice with the small gap, 1mm is a tiny gap.
The gap should give you better penetration but it does need a bit more practice.

SirJoey
02-25-2009, 05:36 AM
Ljack, I use those mags too.
I have 'em in 3 different sizes, & use 'em a LOT!
In fact, I don't know how I ever got by without 'em!


http://img384.imageshack.us/img384/7131/sirjoeysigmedij1.gif

Patrike
02-25-2009, 09:28 AM
Crikey Mate - those are not gaps. Wait til you blow a hole then you will know what it will be like to try and weld a gap, sadly, I have to much experience in that.
Looking good. I love those Mags as well. I am going to pic a few more up of the big ones. Keep them clear from when you grinding -- they will pick up allot of metal bits -- you need a compressor to clean them up.

Cheers


Looks quite nice, although there are some corners with about 1mm space between the parts.

rickairmed
02-25-2009, 10:54 AM
ljack as others have said those litle gaps wont hurt a thing when you go to weld it up . I have probably 30 of those magnets in the large and small sizes I catc them onsale and grab more of them regularly. They even put the large ones onsale for .99 cents all the time.

Rick

ljack
02-25-2009, 04:21 PM
Thanks a bunch for your feedback!
I'm on hold with the welding, since the weather is to bad for working outdoors. So I'll keep cutting parts 'til the weather is getting better.

I bought a lot of scrap metal so I can improve my welding before I do the first welds on my LodeRunner. Sounds good, that the "gaps" don't really matter :cheesy:

The mags are pretty cool, although they are pretty expensive around here. Had to pay 5-8 Euros per piece :thinking: Oh well, they are worth every cent...

P.S.: I really love this community! I feel like I've been a Zombie all my life, I just didn't know it :punk:

trikeman
02-25-2009, 05:11 PM
Crikey Mate - those are not gaps. Wait til you blow a hole then you will know what it will be like to try and weld a gap, sadly, I have to much experience in that.
Looking good. I love those Mags as well. I am going to pic a few more up of the big ones. Keep them clear from when you grinding -- they will pick up allot of metal bits -- you need a compressor to clean them up.

Cheers

I clean my mags by taking the wire brush to them a few strokes, while holding them over the trash can. It works pretty well, although a few small filings will remain.

TheKid
02-25-2009, 05:37 PM
Try tack welding each joint in rotation, with each tack about 1/4" apart. Leave the magnets on the inside corners until all the other seams are welded. Then just "connect the dots", again, rotating on each corner. This will help prevent burn through, especially where you have gaps. After all the seams are done, do the same rotation for the inside seams. Removing the magnets before the other seams are welded solid often causes the the corners to go out of square due to heat warping.

Patrike
02-26-2009, 08:50 AM
Your from Austria -- the rumor here is that you guys import your weather - just call up the weather bureau and request a few nice days:sunny:

Patrick


Thanks a bunch for your feedback!
I'm on hold with the welding, since the weather is to bad for working outdoors. So I'll keep cutting parts 'til the weather is getting better.

ljack
02-27-2009, 03:04 PM
Still no welding action, but I've done a few new parts.
Also the bearings I ordered arrived (thanks lumo for the hint!). It really gives me a kick to already see a lot of steel in a nice arrangement in front of me.
Of course there is still lots and lots of work to be done, but my motivation couldn't be higher :sunny:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8738.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8738.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8739.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8739.jpg)
As for the weather, yes, I could import great weather, but it's quite pricey. As a teacher, that's no option for me :scholar:

ljack
03-10-2009, 04:47 PM
Finally some welding action!
The rear square is a bit more than tack welded. The weather is fine and I finally got me my very own welder. It works fine and the welds don't look too shabby. :punk:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8758.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8758.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8760.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8760.jpg)
I hope the weather stays that way, so I can keep my pace...

rickairmed
03-10-2009, 08:08 PM
ljack looks like your moving right along now put some nice beads on those joints once their tacked all the way around and your good to go :D.

Rick

GregLWB
03-10-2009, 11:27 PM
With all the cutting and prefitting you did it should progress pretty fast now that you have a welder. I can see that attention to detail is your thing and I can't wait to see it finished.

Greg

Patrike
03-11-2009, 08:21 AM
With all the cutting and prefitting you did it should progress pretty fast now that you have a welder. I can see that attention to detail is your thing and I can't wait to see it finished.

Greg

Yah -- GLWB is right -- detail is your thing for sure -- I think we found Brads long lost brother seperated at birth :jester:

I love the welding helmet, very racy -- just make sure you don't go too fast with the welds:rolleyes4:

Patrick

ljack
03-12-2009, 04:25 PM
I've got a little bit of progress here. (Just as I was finished with those welds, it started raining so I had to stop welding for today... :cry2:)
I grinded the tack welds and and added some nice beads :cool:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8768.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8768.jpg)
I also did the first welds on the bearing support. Looks pretty good so far.
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8766.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8766.jpg)
It seems like I've got the power dialed in pretty good. I don't burn holes too fast and also don't stick, so everything is going on just fine.
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8764.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8764.jpg)
Thanks for your kind words, I always try to do the preparation pretty exact, since it rewards me with less trouble afterwards. :sunny:
And the welding helmet is pure gold! I learned welding with a handshield (not shure if it's called that way) and it is soooo much easier with the helmet!

I just love creating stuff and seeing the progress. Right now I am thinking about inserting a bike hub into the drivetrain, so i can shift the gears there instead of on the axle. (I also think it might be easier than building the adaptor for the freewheel.)

rickairmed
03-12-2009, 06:21 PM
Ljack looks like your moving right along shouldnt be long now till your in rolling Chassis stage :D.

Rick

ljack
03-15-2009, 05:21 PM
The weather was fine on saturday, so I could weld the main boom onto the rear square. It worked out fine, its straight and level, what more could I want?
Oh yes, and it is stable. We were jumping around on the frame on the point where the seat will be, together approximately 150kg (plus the energy of us jumping up and down) and the main boom did only flex a bit, but the welds did hold up :smartass2:
I didn't have more time, so I couldn't clean the welds or anything, but it's still a bit of progress :D
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8822.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8822.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8823.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8823.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8824.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8824.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8827.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8827.jpg)

Radical Brad
03-15-2009, 05:57 PM
Great work so far!

Brad

Patrike
03-18-2009, 11:32 PM
Looking real nice, better weld than when I first started and better then mine now! Looks like your following the build exactly to plan -- if I do that one I am going to make the cargo longer. I want to make it so I can put different configurations on the back - extra buddy seat cargo box maybe a dump truck. Bob Beaches snow plow has reverse on it so I thought that might might be doable on the LodeRunner. I have a quick release self dumping wheelbarrow so that would make for great dump truck configuration:builder2:

Sleep time
Cheers
Patrick

ljack
03-22-2009, 05:44 PM
Just a quick update from my side:
It was a pretty busy week, so I couldn't do much. I'm still searching for the right donor bike for the fork and the bottombracket. In the meantime I started working on the hubs. Looks like I still have to practice a lot, so that my welds look OK most of the time :goofy:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8830.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8830.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8834.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8834.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8836.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8836.jpg)

Brad: Thanks for your encouragement! :sunny:

Patrick: Well, so far it looks pretty standard, but I want do solve the stearing a bit different and also do some modifications to the drivetrain. Maybe I'll also use a different seat. But I plan to have a rear seat as an option, so I can swap to whatever task I need my LodeRunner for :punk:

ljack
04-02-2009, 03:22 PM
Finally some time for my next update! (I was reading along JayRays thread in my spare minutes, but didn't find the time to upload images...)
Last saturday we had perfect weather, so I could spend some hours out welding! :sunny:
I welded the bearing support in place, installed a support boom (thanks to JayRay for the inspiration!) and also did the mounting plate for the inner bearings.
And then of course I finished the first hub, painted it and built it yesterday. It took some time, but now it's spinning perfectly true. I'm so proud, this is the first wheel I built from scratch. :punk:
There are quite some pics behind the thumbs :)
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8869.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8869.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8882.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8882.jpg)http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8858.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8858.jpg)

choppersrule
04-02-2009, 04:08 PM
looking good my friend keep up the good work can't wait to see it finished.

mark :taz:

JayRay
04-03-2009, 01:00 AM
Ljack,:builder2:
You are making great progress on your build!
Thank you for giving me credit but I think
you are doing just fine on your own.
It looks like you will be passing me by shortly
if the weather holds out for you!
Keep up the good work and
keep the pictures coming.
Jay :)

ljack
04-13-2009, 05:47 AM
Oh boy, it is so great to sit on a rolling chasis!
Of course I got a lot of pictures to show!

What I've done since my last update:
*) Welded the center bearings in place
*) Aligned the bearings, so they turn free
*) Cut the axle
*) Built the second rear hub and wheel
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8896.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8896.jpg)
*) Finally got my donor BMX bike so I could start with the fork assembly
*) Put on some balloon tires
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8907.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8907.jpg)
*) Cut the front frame tube
*) Drilled holes for the head tube
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8908.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8908.jpg)
*) Welded all the stuff together
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8912.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8912.jpg)
*) Be happy with the results :sunny:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8924.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8924.jpg)

Some parts of the construction are not very documented, since I totally forgot to take photos during my building frenzy.

ljack
04-13-2009, 05:51 AM
BTW: Any ideas how to cover the big holes in the bottom bracket?
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8893.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8893.jpg)

And a great tool for cutting the hole for the head tube right:
I took Vectordesigner for Mac and did an ellipse with the measurements I got from marking the head tube angle on the frame. Seconds later I had the perfect printout for the holes!
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8905.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8905.jpg)

John Lewis
04-13-2009, 08:39 AM
BTW: Any ideas how to cover the big holes in the bottom bracket?


ljack,
I have cut metal disks, curved them and brazed them in to fill larger holes. I'm sure you could arc weld them in just as easily.

With some holes you can plug them with weld and grind smooth. I don't know what a practical limit would be. If you had a washer the right size you could weld it in and then fill the hole in the washer. Brad shows something like this to cap the derailer front tube.

It's probably not a bad idea having a hole in the bottom of the BB to let water out of the bearings.

John Lewis

Patrike
04-13-2009, 10:53 AM
Looking like a sweet ride now with the wheels rolling. I love seeing the headtube through meathod. To cover the holes, if you have some flat bar that will fit over width wise you can cut a piece long enough - weld and grind off.

TheKid
04-13-2009, 03:34 PM
For cutting the hole for the head tube, a 1 3/8" hole saw works great. Just mark the angle on the sides, get the center holes for the top and bottom, and drill slowly at that angle. Makes perfect holes every time.

ljack
06-13-2009, 06:20 PM
Oh boy, over two months since my last update.
Well, at first the weather was putting me on hold for 2 weeks. Then I welded a bike trailer together with some friends, as a wedding gift for a friend of ours.
Then the weather was turning bad again, and I've been pretty busy at work.
But now I've finally got some progress to show! :jester:
(More pics are in my gallery, follow the thumbnails...)

In the meantime I made some adaptors for the disc rotors.
I also created my own seat mount, as i wanted the seat to be variable rather than the bottombracket.
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8948.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8948.jpg)
As you can see, I also modified the drivetrain. Right now I'm using a freehub with discmount, but it can be exchanged for a hub motor (I'm dreaming of a BionX...) very easily. I still have to do the chain that goes from the hubs discmount to the rear axle.
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8969.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8969.jpg)
One disc brake is already in place. I'm using the cheap but extremly powerful Magura Julie HP hydraulic brakes with 8" rotors. :punk:
http://i696.photobucket.com/albums/vv326/loderunnerjack/th_IMG_8978.jpg (http://s696.photobucket.com/albums/vv326/loderunnerjack/?action=view&current=IMG_8978.jpg)

So for now I'm quite happywith the progress of the last days.
The steering will be another tricky thing, as will be the second disc mount.
I'll also have to install pulleys, as the chain just doesn't fit under the frame.



If you had a washer the right size you could weld it in and then fill the hole in the washer.

This worked perfectly, thank you! :sunny:

back2life
06-13-2009, 11:38 PM
It looks great I am very very jealous(sp?). The LodeRunner is the first bike I want to build. I have wanted to build my own bike for about 12 years and when I found this siget last July I fell in love with the plans. It seems like things keep coming up when I am about to start collecting my tools and materials and my start date keeps getting bumped back. So as it stands now it might be next summer. I WANT IT NOW. but school and being on disability makes a squeeze. But man am I going to squeeze. There is a min mart a couple of blocks away and I am talking to them about maybe doing some graveyard shifts for the summer or maybe longer. We'll see the biggest glich in it is I can't work more than 2ohrs a week. I have to a least give it a try. Well keep buiulding and the guys here are wondeful and love to help out and enjoy seeing progress. Some day Ill get my build but until then Ill keep up with the krew here and have fun that way.

Patrike
06-14-2009, 07:49 AM
Bang up job mate!

Maddog
06-14-2009, 09:05 AM
BTW: Any ideas how to cover the big holes in the bottom bracket?

ljack,

Find a short length of copper pipe that will just slip inside the BB, then weld'er closed, slip out the pipe, dress the weld and you're done.

JayRay
06-16-2009, 12:45 AM
Ljack
It's good to see you "back on the build".
The bike is looking great!
You are almost ready for your first ride.
I am interested in seeing more photos
of your modified drive train.
Jay