Ed's 'StreetRunner' Quad Build

SirJoey

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My cozy little nook in the corner!
I've been awol for a few weeks here. Looks like you've made more huge progress on 'er, Ed!
This isn't going to be one of those "never ending" projects, is it? :unsure:
***
 
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I've been awol for a few weeks here. Looks like you've made more huge progress on 'er, Ed!
This isn't going to be one of those "never ending" projects, is it? :unsure:
***
So nice to hear from you again. Of ALL the projects that I've started, over the years, this one has really got me hooked. I really want to bring this to a running, driveable conclusion. Whether it ever ends...well that depends......
 
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Hub Mock-up Update

Just finished cutting out, a new 3 1/2" flange out of hardboard.

I'm happy to report that it appears to be just the ticket. I used the 6 1/2" spokes to start and they just fell into place.
I've got the complete wheel laced as of this moment. Again not torqued.

Next is to cut out, the metal flanges and try them (with clamps) to see if the spokes will tighten up correctly all the way around.

So as of this moment, my final hub dimensions will be :

Outer spoke flange 2 3/4" diameter
Inner spoke flange 3 1/2" diameter
Disc brake adapter flange 3"

Hub barrel length 3 1/4" (overall)

Outer spokes are 7 "
Inner spokes are 6 1/2"

Looks like I will have a cross 4 pattern for the outer spokes,(7")
and a, cross 2 pattern for the inner spokes (6 1/2").
 
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First metal flange

As I'm leaving the two flanges, different sizes, I have enough spokes without ruining another wheel.



Started work on the inner flange. I had a bit of an Oops though.
I dulled my step drill bit. It stopped cutting, which happens with these cheaper HF drill bits, BUT this time it is my fault.
I didn't 'see' that the drill bit was trying to drill out the drill press table. So now I have a minnie slice at the top of the hole.
Doesn't hurt anything... well maybe my pride.

If all goes well tomorrow, I should have one hub semi-complete.
Enough, so that I can lace it up and see if it's OK to make a second set.
I have an eye appointment tomorrow, so I'm looking forward to seeing everything much clearer.

 
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the spoke lengths I sent you were for 3x lacing. Why are you going with 2x and 4x?
don't forget to champher the spoke holes.
also the distance between flanges appears wider?
 
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the spoke lengths I sent you were for 3x lacing. Why are you going with 2x and 4x?
don't forget to champher the spoke holes.
also the distance between flanges appears wider?
Today's work will be to finish the flanges, including the chamfers.
Securing them on the barrel and re-lacing to see how they fit with no 'give' in the flange plate.

The 4x is the original pattern of the wheel. It will be used for the outside spokes.

I was surprised when I laced up the mock-up flanges that I only got 2x for the inner flange.
The 2x is the only pattern where the spokes fit correctly. (using the 6 1/2" spokes)

There is no change in the 2 1/2" ID distance between the flanges. Due to how things fit together.
(the two spoke flanges, the disc adapter flange, and the axle/axle barrel length).

When I get the hub flanges made, I will try to see if there is a chance the 7" will still work, thus creating a 3x/4x pattern.
But I'm doubting it. Maybe it would work if I had the 6 3/4" (172mm) spokes, but I would rather make the hub diameter to match with the spokes that I already have. So at the present the major variable is just that, the diameter of the flange.

The final answer will come as I continue to narrow down the inner flange diameter.
 
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How it all fits together...step by step

Three flange plates completed.

It's 110 degrees (F) in my shop. But I was able to get the first hub completed to a point where I can do a trial lacing.
I will try to work on that later when the evening temp is cooler.
There is one slight change in dimensions. I will lace up the wheel first then reveal what was changed.



Press fitting the first bearing cup



Welding outer flange in place.



Sliding on the inner flange plate and press-fitting the other bearing cup.



Brake disc adapter installed and welded in place.



Inner flange plate secured ready for welding in place.



The inner flange plate aligned with outer spoke holes (half hole offset) and welded in place.



So far so good. Now if it will lace up correctly, we will have a winner.
 
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I brought my wheel inside where it was cooler.

I got it laced up first go....lucky me!
So I'm really pleased.
I changed the diameter of the outside flange from 2 3/4" to 3 "
Also increased the spacing between the flanges by adding 1/8".
7" spokes on the outer flange, 6 1/2" spokes for the inner flange.
The cross pattern ended up being 3x for both sides.

All that remains is to torque and true it. (The fun part)
One more tear down to repaint and add a couple more tack welds and cosmetic work.

I will complete the wheel before starting on the next set of flanges.
Two reasons:
Just in case there is some unforeseen problem.
And I'm eager to see the finished wheel, and how it fits on the spindle with bearings and all.
I'm thinking of making a 'knock-off' spinner for the outer nut.




 
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The wheel is snugged up and the tire is back on.

Here's a couple of ideas for making a knock off wheel spinner

 
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How about one of them fancy ones that doesn't rotate? Extra effort for sure but could be a talking point as it rocks somewhat as you pull up. Maybe a fancy Ford logo design?
 
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Looking very sharp there Ed', terrific work as always.
 
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How about one of them fancy ones that doesn't rotate? Extra effort for sure but could be a talking point as it rocks somewhat as you pull up. Maybe a fancy Ford logo design?
Man! As if I don't have enough ideas floating around banging off the inside of my cavernous skull.

I now have to add this one to the mix.....when will it ever stop?😱😧 I need therapy.

Timing is everything.....here's my latest version.



FYI The only reason I thought about using a 'Knockoff' spinner is to cover the bare axle nut.
There's no room left on the axle for much else.
In fact, I was/am planning on making the axle nut as part of the spinner. I will weld the nut (into) the plate used to make the spinner. Might use an acorn nut instead if I have one with the right threads.
 
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