flyingbrick Posted October 9, 2014 Share Posted October 9, 2014 Exactly hahahahahhaha Quote Link to comment Share on other sites More sharing options...
artyone Posted October 11, 2014 Share Posted October 11, 2014 This is similar to the first Red Bull Trolley Derby car I made in the sense that I made the underlying body from plywood, about 4mm, then glued on thin sheets of expanded polyurethane foam at about 25mm so I could then sand out the kind of shapes we'd get rolling on an english wheel... compound curves? Then after I had the shapes I took it all to a fibreglass places for coupla coats. Since then I've played with polystyrene and didn't realise that polyester resins melted it so then used bog over polystyrene which if mixed slightly cold for a slower cure didn't create enough heat to melt the polystyrene. Then came seeing if the expanded polyurethane foam we buy in spray cans would adhere to polystyrene... and it did. What I haven't properly tried is sculpting in polystyrene then applying a thin coat of epoxy resin and then matting out using a polyester resin. So what I've learned is that the two cheapies, polystyrene and polyester resin don't work together and have yet to try a barrier coat of epoxy between them but distinctly dislike sculpting polystyrene whilst on the other hand love the nature of polyurethane foam in blocks and sheets but it is really expensive and decidedly brittle though the spray type cans in a big enough size are just affordable once you get the way of using them sussed. 2 Quote Link to comment Share on other sites More sharing options...
lajdobb Posted November 4, 2014 Share Posted November 4, 2014 Dear JR, Triggered by an article in Octane about cycle karts I browsed the internet and found the story of your build. As my current project, the restoration of a '65 Bobsy Vanguard Formula Vee, imported by me from the US wich is almost ready I'm looking for a new project. Fell in love with your little car with it's off side engine as per origialAustin, and wonder if you will share information. Chassis dimensions and a drawing would be most welcome as info on the flat springs used up front en the sprocket sizes used on the engine, clutch and the rer axle. All of this only if you think it's OK to duplicate by me. If you reply you can also use my direct Email address, lucvandobben@hetnet.nl Look very much forward to your reply, . Best regards, Lucas van Dobben the Netherlands 3 Quote Link to comment Share on other sites More sharing options...
JR Posted November 4, 2014 Author Share Posted November 4, 2014 Hi Lucas I have just sent you an email, I am more than happy to share any info you want. There are some other projects on here than may give you some ideas too: //oldschool.co.nz/index.php?/topic/44164-flibois-cyclecar/ //oldschool.co.nz/index.php?/topic/43827-cycle-car-built-from-old-junk/ I hope you start a build thread when you start building. John 1 Quote Link to comment Share on other sites More sharing options...
JR Posted March 23, 2015 Author Share Posted March 23, 2015 I hadn't touched this thing for months. Moved house/city/job... I finally got stuck into it last night. Here is the start of the boat tail Im going to make a few more ribs and then put something that is shapable in there and fiberglass over the lot. It will be hollow, I have perferated the ribs so when its stronger I can cut the inside parts out. I was going to use cut up polyurethane foam sheets and shape them but I had an idea of using expanding foam. Has anyone used that stuff before? Is it workable? Will I be able to sand it? 9 Quote Link to comment Share on other sites More sharing options...
flyingbrick Posted March 23, 2015 Share Posted March 23, 2015 That expanding to shit is bloody terrible for anything other than filling holes. Bunngings sells a few different types of expanded foam. Quote Link to comment Share on other sites More sharing options...
mutiny Posted March 23, 2015 Share Posted March 23, 2015 you living back down these ways now john? Quote Link to comment Share on other sites More sharing options...
JR Posted March 23, 2015 Author Share Posted March 23, 2015 Yeah man, Im a wee bit out in the whoops though... Oxford way. Quote Link to comment Share on other sites More sharing options...
thegreatestben Posted March 23, 2015 Share Posted March 23, 2015 I used that foam recently. It's easy to cut with a sharp blade. Very horrible and sticky before it's dry though. You might want to consider using polystyrene or similar and shaping with a hot wire cutter which can be knocked up out of bits from jaycar. Quote Link to comment Share on other sites More sharing options...
JR Posted March 24, 2015 Author Share Posted March 24, 2015 This back part has been a bit of a mision. I don't have an artistic bone in my body so designing these curves has been tough. I made them out of cardboad first. I am leaning towards using the expandable foam stuff and shaping it with a knife then fiberglassing over? Does any one have a reason to think this wont work, or have a better idea? Cheers 1 Quote Link to comment Share on other sites More sharing options...
flyingbrick Posted March 24, 2015 Share Posted March 24, 2015 Yeah stretch cloth over it. Then soak in resin. Then glass. Then bog. May want to put thin stringers over it first Quote Link to comment Share on other sites More sharing options...
Ned Posted March 24, 2015 Share Posted March 24, 2015 expanding foam is a dick IMHO. Especially if it doesnt set quite right and then its terribly sticky once you cut it open and you just want to kill people 30 seconds in! polystyrene cuts ok with hot wire cutter, and sands well with some rough sand paper. Just buy some 30mm thick sheets from mitre10 and cut to rough size and glue in place. Just be aware if you use something like liquid nails, that the nichrome wire wont like cutting through it all that well. It will do it, but not the best Quote Link to comment Share on other sites More sharing options...
mutiny Posted March 24, 2015 Share Posted March 24, 2015 Yeah man, Im a wee bit out in the whoops though... Oxford way. awesome man, hope to see you round some time soon, gimme a yell if you need to use my old mans joinery workshop 1 Quote Link to comment Share on other sites More sharing options...
BlownCorona Posted March 25, 2015 Share Posted March 25, 2015 i vote for fabric and dope for the tail cone. with your chosen career you should be able to appreciate the vintage authenticity of thin wooden frames and doped canvas coverings! its how ill be doing mine if i bail on the sheet metal and solid rivet plans 3 Quote Link to comment Share on other sites More sharing options...
JR Posted March 26, 2015 Author Share Posted March 26, 2015 That would be cool but I really want it to look like this I am leaning towards strip planking now, then glass over the top. I should be able to get it look pretty slick strip planking I reckon. 4 Quote Link to comment Share on other sites More sharing options...
JR Posted April 2, 2015 Author Share Posted April 2, 2015 I have gone down the strip planking road. Cheers Skinner (Mutiny) for supplying, cutting and putting through the thicknesser some nice Rimu for me! He wouldnt even accept beers as payment.. G.C. So here is where I am at... The back part it removable and fits nice and tight Its going to be a slow process as I have to wait for the glue to dry between strips.. If I do a good enough job ill just put a clear layer of fiberglass over it and leave the wood showing. Plan B = bog, glass and paint. 6 Quote Link to comment Share on other sites More sharing options...
flyingbrick Posted April 2, 2015 Share Posted April 2, 2015 Best option by far. Quote Link to comment Share on other sites More sharing options...
downtrail Posted April 2, 2015 Share Posted April 2, 2015 Very cool dude! Quote Link to comment Share on other sites More sharing options...
mutiny Posted April 2, 2015 Share Posted April 2, 2015 God damn that's gonna look awesome, How you looking for quantities at this stage? 1 Quote Link to comment Share on other sites More sharing options...
felixx Posted April 2, 2015 Share Posted April 2, 2015 WOW this is just amazing! Quote Link to comment Share on other sites More sharing options...
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