Ed's 'StreetRunner' Quad Build

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Sep 12, 2012
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Apple Valley, California, USA
It's cool and no wind.

Time to get some grinding done, and finish welding the top bows.

Ground off virtually all the galvanizing.
I've got a couple of ends yet to cut off and round.

Getting real close to welding the top bows to the lower frame.

A 'BIG' step. If it's too soon, I can make the project much harder.
This part will become, heavier, (maybe 6-7 lbs @ this point), but mainly bulkier to handle.
For a one man project, that is a constant concern.


Another thought
Do I want to apply the sheet metal, with the top on the car,
or do I want to apply it, while it's off the car.

On the car, it's secure, but some of it will be hard to get too.
Off the car, not so secure, but easier to get to some parts.


Trying to visualize the steps required, and in which order, is only one of the many thought processes,
involved in building this type project. Especially for someone that's never done this before.


 
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Made a couple of mounting tabs to secure the top...
...it's getting hot, so time to stop.

First I installed a couple of 1/4" rivnuts.
These two tabs will be to keep the top from blowing up, from the high velocity winds,
this contraption is destined to go.....well maybe not.





Cutting out the tabs from a length of 1/8 x 1" flat stock.



Mounted and waiting to grind out the fishmouth, where the inside top bow will weld too.



Now it's time to watch some ladies final, tennis.
 
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Well it's over, and a Canadian won the US Open.....congratulations to Bianca Andreescu

I guess I have nothing better to do now, so back to work..I mean playing.
 
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Made some headway today, after a four day hiatus.

Went fishing, and caught this..



I made two sets. The first set ended up to short, so another set was ordered, and completed correctly this time.
A bit more grinding in the area where these tabs will weld to the top tubing, and then it's on to the back/top, for some cross pieces.
 
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9:22 am and it's still only 68 F.

Finished welding the tabs on the front of the top bows.

I'm constantly being rushed using the Hobart 140 settings for .060 thickness.
Resulting in sometimes good, sometimes bad, and once in awhile a blow through.

So this morning, I played around with the settings, trying to find what the difference between,
setting, 3 and 35, (This is the recommended setting for .060 gauge using .030 wire)
and ......2 and 35, (.048 gauge and 030 wire).

These two welds set at 2/35

Not as hot, allowing me to work the weld pool at a slower speed.
Checked inside for weld penetration, and that was good.



These two welds set at 3/35

Much hotter. Had to move much quicker, and had a blow out near the end because of the extra heat.
A little more weld penetration, not that it was/is necessary, for this thickness of metal.



I think this little experiment, has given me a better idea, about the use of the settings on my welder.
I'm going to practice some more, with the new settings, to determine whether or not, I should switch.
 
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More Practice and More

Had a go with the EMT tube. Settings 2 and 35.
Worked about the same, except welding on the curve, made it a bit more difficult.
Blew a hole, probably because I lingered to long in the spot.
Heat dis-colorization shows it was much hotter in that spot.




Had good penetration, but only where the actual weld was.
In between each weld spot the penetration was much less.



Worked awhile on the side profile.




Still trying to match to the drawing as best as I can. (Imagination vs Reality)


 
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That top is looking great, going to really put the icing on the cake.
Brad
I forgot to post these 'slight' but important design changes last night.

Trying to match the drawing, I narrowed the point at the arrows.
The result helped to maintain the 'downward curve' of the top.



The top is coming out a bit flatter, near the back, than I would like, but I'm going to stay with it.

It's coming out more like this




Adding the second tube underneath, also adds a bit of thickness/width/depth?, to the side profile,
which I thought was getting too thin near the front.



I kind of like this shot angle.

 
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Time to bend tubing 😰

Adding the bottom tube which will mate with the new side tubes.
The blocks are there to help keep the tube in line with itself.



Making minute adjustments.



Used small bolts to act as spacers. Just welded them right in.
They won't be seen when all is covered anyway.



I'm using the 2 & 35 setting for welding.
It seems to be working, and I am definitely more relaxed, and not trying to rush the weld.



Step one, side tubing.

Bending the 90 degree, and marking off the 2 " increments for bending.



One side done. Template for second side....after I get some more tubing.


 
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What ? No photos ?

That's right, no photo.

All I have managed to do, was bend the tubing for the other side, but decided a photo, really wasn't necessary ...this time.

Next set will show the new tubes welded in, as well as the new, 'arm rests'. Didn't see that coming, did you ?

Best stay tuned. There's a lot on the production line, and it's zooming by pretty quick.
 
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Oh man, without my daily "pedal car fix", I'm a goner for sure...
***
Well Sir Joey, here's your dose for today.

As promised, photos of the arm rests.
After bending two 'identical', (well virtually identical), tubes for the arm rests,
I set about getting the upper mating surfaces to match.
First I had to cut the top of the tube, so it would match, or close to, the bottom of the top tube coming down.



First stand off, cut, angled, fish mouthed, waiting to be tacked in place.



Arm rests for both sides, in place.



Now imagine yourself, getting ready for a cool ride.



And another overall look, just to see.



I may push it out in the sunlight tomorrow, for a uncluttered look.



I'm done on this part for today. Time to pack it in.
My feet are talking to me, and I best listen.
 
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Joined
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Top frame/bows and lower frame are now officially, tied together.
No magnets, no clamps, not bungee cords, no tape.

Haven't messed around with any video recording for awhile,
so thought this would be as good a time, as any.

 
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