Nothing to lose really.

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A bit more done today, this time with manufactured spacers for the 90mm drum hubs.
First one isn't quite right, so the next one will have a dimension change, or I can use spacer shims.
 
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... one for the metal-bashers amongst us.
I used to be fearful of bending thick-walled steel tube before our late friend John Price made me a tube bender with a 10-ton bottle-jack.
As you can see..... I now bend tubes with IMPUNITY.


Here's a finished 25x2mm tube. I learned that ideally you should make these things in 2 halves, internally sleeve them and then join them together.
The 90° bend consumes 7 & 1/2" of tubing and you cannot produce a "U" with a short base section.
 
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Finished bending all the tubing up for the rear axle(s) cage framing.
I bent them as close to 90° as I could.
The plan is to make 3 "U" shaped bridges to span around the 2WD unit and brace the two halves to keep them in alignment.


Bender cleaned & oiled and put away again.
 
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Dan

I though there was to be a bigger diameter tube for the axle to main boom and only 2 smaller tubes to keep it all together ?

More like this with one further tube ?



Paul
 
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Dan

I though there was to be a bigger diameter tube for the axle to main boom and only 2 smaller tubes to keep it all together ?

More like this with one further tube ?



Paul
Yes, maybe just like that, but minus the toe-in/out adjusters. Others I have seen have a 2 or 3-way cage.
 
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Well today went very badly. :(
Ruined one piece of my bent 25mm steel trying to get the profiles cut to meet a 32mm tube at 45° - start again with piece 2.
I got the electric hot-metal glue gun all fired up and my tungsten went up like a sparkler - No Gas! Strange because it was a 2/3 full tank when I last used it.
I put my standby 10L bottle on checked decent gas flow, sparked it up.....and couldn't see a darned thing - batteries flat in the mask.
Put new batteries in the mask, still couldn't see well enough in the poor lighting.
Gave up and came indoors. :mad:
 
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Dan

Wow a catalogue of woe , I assumed you turned to the bottle once indoors ?

I though you had a mask mounted light for welding ?

Paul
 
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Dan

Wow a catalogue of woe , I assumed you turned to the bottle once indoors ?

I though you had a mask mounted light for welding ?

Paul
Yes, indeed. Mask light was deployed but still not enough background illumination.
Off to get a new 20L refill today. :)
 
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Gas refill and more tungsten's acquired.

Well, its on there. I didn't like the weld appearance so flap-disked the lumpiness out of them.
More to do, but I was aching a bit so packed it in.

 
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OK, it has been a while but both of the braces are now on.
The braces are at about 120° to each other so I hope they will hold the inside ends of the axle-tubes in reasonable alignment.
Next step is to attach outboard framework that hold the outboard ends in place to a frame. A decision need to be made as to whether suspension is to be a feature or not.
The eagle-eyed amongst you will notice that this cage framework is NOT central. This is purposeful as an IGH LH side aligned output will provide the INPUT to the 2WD unit.

 
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Next step is to attach outboard framework that hold the outboard ends in place to a frame. A decision need to be made as to whether suspension is to be a feature or not.
A problem ?
Yes I keep finding pictures like this :-


Paul
 
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My friend in the North snagged me a working Sturmey Archer XRF8-W hub at a cycle-jumble. :)
It was missing a few bits (changer, axle anti-turn lock-washers, dome nuts and needed a different sprocket), but its was otherwise in great condition. Thanks Paul!
Here it is cabled up and working. It may become the IGH for the current project.

Thank you paul.
 
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DannyC

Jokingly I said to Dan if I see a SA 8 speed should I buy it ? and low and behold there was one !

It had a label on saying brought in as noisy and hard to shift , they could not find anything wrong with it however had no bike to put it in so 'sold as seen ' , I assume the original bike either got another fitted or was converted to derailleur .

Glad you got it working , and such a simple fix.

All we need now is something to bolt it to :D(y)

Paul
 
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All we need now is something to bolt it to :D(y)
The "something to bolt it to" is an ongoing Umm-ing and Ahh-ing process while I shuffle from foot to foot and suck my teeth. ;)

I do have a stub of a previous project that "could" be pressed into service as a host for this 2WD axle malarkey. It is a suspension capable component.
I would need to work out "How" it might be pressed into service along with the IGH mid-drive.
I may be being a bit ambitious but perhaps it could (like me) be the rear end of a pantomime horse with different front ends bolted/clipped on.
I am still mulling all of this over. :)
 
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The "something to bolt it to" is an ongoing Umm-ing and Ahh-ing process while I shuffle from foot to foot and suck my teeth. ;)
You do that verbally I abuse soft woods and deploy hundreds of screws and brackets .....

I may be being a bit ambitious but perhaps it could (like me) be the rear end of a pantomime horse
You heard it hear folks , Dans the a**e end of a horse .....



Paul
 
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Started on the backplate fixing tabs today.
I cut some 3mm plates and tacked them together at the corners. I marked the centre hole for them to slip over the axle-tube.
I checked that they fitted snugly over the axle-tube.
I will shape and trim them to look smart.
A stub of 12mm bar will be tapped with M6 thread to hold a bolt to secure the backplate from turning.


 
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That's a big hole you drilled there mister ?

is that the direction you expect the cable to come from ? sort of above and pointing downwards ?

Paul
 
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