Blog / Parts
Posted on 11 September 2013 at 10:33 pm (CET)
Today I also fitted the nerfbar and hielguards. Even though it won't be going fast, I think it's a bit safer than just having the foot pegs. Also fitted the saddle. Just had to place the rear fender as well otherwise the saddle would bend too much. Don't know how strong it is. Also screwed a wooden board on the frame for the batteries to sit on, just don't think I can fit 2 car battery's on there. But I'll see when it's ready. Also tightened the wheel nuts, almost forgot they were still pretty loose.
And I received some more stainless steel bolts, nuts and rings. Now I just still need the controller mounts.
Today I received both adaptors and ofcourse I already fitted them. The metalworking company (Geraets Metaalbewerking) did a very good job, it all looks great and fits perfectly.
What used to be a rear sprocket has now become an adaptor for the new rear sprocket.
With this adaptor the rear sprocket can be placed a bit more inward so that the chain will run perfectly straight. Here you can see how the adaptor fits on the rear sprocket. They really made a lot of effort to perfectly align all the edges with the sprocket. It looks great.
And here with the bolts and nuts on it. Everywhere where different materials are touching eachother I used anti-seize paste to prevent corrosion. Sprocket is steel, adaptor is aluminium and bolts/nuts are stainless steel. Without the paste this usually wouldn't work out so well.
Here's the adaptor with the rear sprocket attached to the rear axle. It all fits very good, I was only missing 2 cap nuts. I will replace these later when I have to order some more fastening materials. Also need to get new ones for the 4 bolts on the axle. I ordered bolts with 1.5 thread, but the original bolts are 1.25. Pretty odd since I even measured this beforehand but apparently I made a mistake.
Already chose bolts with a low head to get the most clearance between the bolts and the rear swingarm which was definately a good choice. To be sure I even filed some of the welds that were sticking out. On some points there's like 1,5-2 mm clearance. So it barely fits. But it's mainly because of the Nord-locks that are inbetween. I'm really a big fan of these rings so I use them everywhere on parts that shouldn't come loose.
So rear end done, back to the front. The adaptor for the front sprocket has been modified quite a bit. The grooves for the sensor weren't equal and the side where the sprocket attaches to had to be rounded off a bit. There's also finally a keyway in there. And that ring has been made a little deeper in the middle so the bolt that comes on there has some more clearance with the quad bike's frame. So now it finally is exactly the way I wanted it from the beginning.
The keyway is also in the sprocket itself for some extra strength. I thought the 2 bolts alone wouldn't be enough with all the force that will be on here. The sprocket was very hard so they did this with a small router bit instead of broaching. Because of this it's rounded on the top but this doesn't matter at all for the key. And you won't see this anyway with the ring on there.
Here's the whole adaptor with sprocket attached to the motor's axle. There's still a very minimal amount of play though between the axle and adaptor, not sure if this will be a problem.
And with the chain on it again. I measured and turned it around a few times, the chain is sitting perfectly in the middle of the sprockets. This means it runs perfectly straight which is what I was hoping for.
Here a complete picture of what it looks like right now. Ofcourse I wouldn't really say something negative about it myself but I really do think it looks very nice now.
So I'm happy to say that this part of the project is finally done. The next step will be the controller mounts. Just still have to measure a few things and check if everything is right, then I can also have them made at the same metalworking company.
Today I received a new brake fluid hose for between the reservoir and rear brake pump. The original rubber hose was sweating back then after I filled the system with dot 5.1 brake fluid. As a temporary solution I used a fuel hose so there wouldn't get any dust or anything in the system. But now I have a real brake fluid hose which should be resistant to dot 5.1 brake fluid. Apparently these are pretty hard to find, could only find them at some of the VW Beetle shops. And one at a bike shop but the diameter was too small (5 mm, I needed 7 mm).
Just need to get some new clamps since the old ones don't fit around this thicker hose. This hose is also long enough for 2, so I'll always have a spare.
Little by little I'm already preparing for the first testride which will hopefully happen very soon.
Posted on 26 July 2013 at 09:03 pm (CET)
All 4 battery boxes are welded up now. The last one with the extra corner in it was quite tricky again. Had to make whole constructions of wooden blocks to be able to support and keep them in place while welding. This one didn't turn out as good as the other boxes but it's still good enough.
Most important is that they're all done now. Just have to even out the welds on them all now and then I can finally continue with the next step for the battery boxes.
Meanwhile I also got something in the mail again. Had to search for a long time to find the right size for these and delivery took pretty long as well but I finally have them now and they fit perfectly.
They're all rubber vacuum caps. In the clamps for the batteries that I'll be making inside of the battery boxes there'll be quite a few rivet nuts to attach everything with bolts. Like here on my testplate.
Since these will be close to the batteries I don't want to take the risk of a short circuit. So on all rivet nuts I'll place one of these vacuum caps as isolation.
Fits perfectly as the inside diameter is slightly smaller than the outside diameter of the rivet nuts. So they will always stick on there which makes it a lot safer. And the rivet nuts will be really waterproof like this as well.
Posted on 16 July 2013 at 07:16 pm (CET)
Today I received another package. All stainless steel bolts and nuts, everything's for the quad bike except the bottom 3. Also bought some anti-seize paste to prevent corrosion between the different materials.
For the rest not much news sadly, still trying to find a company that can help me with modifying the adaptor for front sprocket, making the adaptor for the rear sprocket and the mounts for the controller.