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  1. JonHylands

    Jon's Warrior Build

    So, I finished one of the front axle mounts tonight: Its not perfect by any stretch, but it should be strong enough. A coat of paint and it will look quite nice, I think. The second one is welded, but not finished. Enough that I could finally cut the steering booms: I'm really impressed -...
  2. JonHylands

    Jon's Warrior Build

    So after I 3D printed the piece, I decided I didn't want to spring for a 17/32 drill bit or a 5/8-11 tap which I'm not likely to ever use again, so I decided to re-print the part with the threads formed into the holes. That worked out pretty nicely, and the 5/8" threaded rod screws into it...
  3. JonHylands

    Jon's Warrior Build

    Here's the CAD model I whipped up, and just started printing. The holes are sized so I can tap them with a 5/8-11 tap (which I will have to pick up at Princess Auto, since I don't have one that size). I'll cut the threaded rod in half, and use this piece of plastic to get around the chassis tube.
  4. JonHylands

    Jon's Warrior Build

    Here's one of the spacers in the hub: And here's the setup, with a 3' long piece of 5/8" threaded stock: I don't think I'll be able to use it as is though - the chassis tube goes through the space occupied by the threaded rod... The center of the wheels is highlighted in orange. I'll...
  5. JonHylands

    Jon's Warrior Build

    It's not a huge one, can print about 8" x 8" x 8" 20cm x 20 cm x 20 cm). Those tubes are only 10 cm long.
  6. JonHylands

    Jon's Warrior Build

    Here's the jig for the front wheels: That puts the center of the tires 30" apart. These are the two hub spacers I am 3D printing: They are about half done right now. They will slide right over the 5/8" threaded rod I bought tonight, and provide a 20mm outside diameter sleeve to fit inside...
  7. JonHylands

    Jon's Warrior Build

    That's a great idea - I will definitely look into doing that as well. Even if I can't find M20, I can find something smaller, and 3D print an M20 axle stub that slides overtop. Something like this will probably do the job nicely...
  8. JonHylands

    Jon's Warrior Build

    I'm working on a jig to hold the front tires in place while I figure out the cut and weld angles for the front arms. I already made one for the back tire a while back out of 2x10's, which you can see here: It holds the rear end tight and vertical, and holds the entire chassis in place. I'm...
  9. JonHylands

    Jon's Warrior Build

    That's actually not a bad idea. I have to chuck up the bolt in the lathe and take off a few thousandths near the head of the bolt - they get slightly larger there. I'll give it a shot, let you know what happens...
  10. JonHylands

    Jon's Warrior Build

    Here are some closeups... First, showing the clearance (or lack thereof) between the disc rotor and the axle mounting tab: Second, showing a closeup of the nut side. You can see how the nut is beveled around the outside edge, so only the inner band tightens against the inner bearing race...
  11. JonHylands

    Jon's Warrior Build

    Yeah, the spacer pushes on the side of the rotating inner race on the bearing, which is what is supposed to happen. On the outer wheel side, the edge of the nut pushes against the side of that bearing inner race. Here's a really crude and simple cross section of what I think it looks like...
  12. JonHylands

    Jon's Warrior Build

    No, I removed it from the other side. I need the clearance that the spacer provides on the rotor side - otherwise, the rotor would hit the axle mounting tab.
  13. JonHylands

    Jon's Warrior Build

    Some more random welding bits tonight... First, setup to start welding the 14.5 degree angle for the steering system: I've welded it, but going to wait until it cools down to grind it and make it look pretty. Second, I welded the little square closed at the back of the seat bottom post (no...
  14. JonHylands

    Design principles for a solar/electric/pedal outback machine

    Check out this video: Solar powered bicycle with unlimited range - Sun Biker
  15. JonHylands

    Jon's Warrior Build

    Yeah, my manager at work is a bicycle enthusiast, and he lent me his tools for it.
  16. JonHylands

    Jon's Warrior Build

    And here they are, both laced up... Definitely a lot faster for the second one.
  17. JonHylands

    Jon's Warrior Build

    So here's my first front wheel, all laced up (but not balanced yet)... I found this YouTube tutorial to be very helpful for lacing a 32-hole wheel: Lacing a Rear 32 Spoke Wheel, 3 Cross | How to Build a Bicycle Wheel There's a second part to the tutorial as well: Lacing Non-Drive Side 32...
  18. JonHylands

    Jon's Warrior Build

    Around here, right now, its almost impossible to get work done on a bike at a local bike store - they are all completely swamped. I could probably get it done at the co-op, but I prefer to be able to do it myself, so I'll see how these 3D printed tools work out.
  19. JonHylands

    Jon's Warrior Build

    Yeah, but right now I'm just putting in a brand new one, so hopefully won't need the big breaker bar...
  20. JonHylands

    Jon's Warrior Build

    So it turns out it takes a few specialty tools to put together group set parts. Specialty tools I don't have, and don't particularly want to wait for if ordered. As it happens, I have a pretty decent 3D printer that can print ABS, so I read through some of the online manuals for the parts I...
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