Kimjon's 50cc (then later ... 150cc and 400cc...then 1000cc) of awesomeness! Oh and a 2+1 wheeled machine...

[Kimjon]

[Kimjon]

Done!

goes unseen, so im not going to spend too much time planishing it. Thats rough enough...

[tortron]

When it comes on pipe

[Hillbillyracing]

On 25/11/2024 at 16:34, Kimjon said:

That'll do for now. I can see it taking shape. All the Kaos in my head, obsessive thought loops are now starting to materialize into physical parts. Pretty happy with that.

It's now got a fairly solid foundation to build off.

A 5th wheel  please

[Kimjon]

Pull start mechanism underway. Over engineering 101.

Much like the original ones. However because I'm using a vespa motor (not an Ape motor) it has e start. So the pull start is just a backup.

[Kimjon]

Choppy choppy

tig welded the sprocket to the vespa rear hub. This is the motor side sorted.

 

I machined an aluminum plug to hold everything concentric for welding.

[Kimjon]

Deck sorted. Once painted, I'll use self tappers to hold it down.

I added crimped wire straps to the tailgate.

Small steps in the right direction...

[Kimjon]

I turned up this thick stainless adapter. Part of the intake puzzle. I'm waiting on Aliexpress mandrel bends for the rest.

I also made some custom cables for choke, and made a 90° adapter for the throttle cable, to keep the height down.

[Kimjon]

Template for polycarbonate window made. Just need to source some 3mm polycarbonate sheet.

[Kimjon]

And another small job off the list, choke fitted to seat.

I've made another much longer cable, so seat can still pivot forward. This is just a dry fit to get it done.

[rusty360]

29 minutes ago, Kimjon said:

Template for polycarbonate window made. Just need to source some 3mm polycarbonate sheet.

Anything acrylic in Drury has always been awesome when I've delt with them for work.

[HighLUX]

Not sure how you will get on trying to bend the polycarb 

This fella is helpful too

https://www.bayplastic.co.nz/

[tortron]

Can do it the Kelly tarlton method

 

[Kimjon]

12 hours ago, tortron said:

Can do it the Kelly tarlton method

 

How'd he do it?

[Kimjon]

13 hours ago, HighLUX said:

Not sure how you will get on trying to bend the polycarb 

This fella is helpful too

https://www.bayplastic.co.nz/

Pretty sure polycarbonate is quite floppy, compared to acrylic that is more rigid and fragile. But my experience with either is limited to school projects made 30 years ago... aka magazine rack and other dumb shit you make back then.

[tortron]

8 hours ago, Kimjon said:

How'd he do it?

Hired out an old bakery for the ovens,  had some big concrete culvert pipes and fired the heat through them I believe. Then layer the acrylic over those to let them bend into the tunnel sections (first in the world)

[440bbm]

bitta heat and youll be away in no time if it doesnt flex enough to the curve you need instantly. 

[Kimjon]

Trial fit on chain drive 

Looks like a half link is in order. Which I've ordered and will pray to the gods of speed for it to magically solve the tension issue without the need for an idler.

[Kimjon]

Squeezing in the brake master cylinder. I purchased a forklift unit off Aliexpress to use, as it looked about right. I've never seen the original setup, as it wasn't there...so this is how it's going to be now.

[Kimjon]

The only problem was my unit sat 30mm higher than it should, due to the mounting hole orientation. After a bit of brainstorming with some people smarter than me, a combination of ideas was used to solve the problem.

The original push rod was cut, shortened and threaded in the lathe. A block of steel and the original master cylinder pin was threaded into the block, with a locking nut.

This creates the 30mm offset and allows adjustments if needed. Win-win!