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Ian

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Posts posted by Ian


  1. There was no way the exhaust system I had built would fit back on with a transfer box and a dive shaft in the way, the only part that fits is the big bore pipe that runs down the side of the engine through the frame!

     

    So a bit of a re-make is needed, I started at the front after slicing off the bits that fit into the engine..

    The only tube I have enoug of is a bit bigger than I had been using, so how to go from something small to the bigger blue bit size!

     

    FTX543.jpg.e0919b89d2781c5d34c0431cde1d6e8c.jpg

     

     

    Find a bit of tube that's slightly bigger than the small bit but slightly smaller than the big blue bit and make four long-ish cuts in it.

     

    FTX544.jpg.9b3ea3ff3a043fadec5af3b281093ab4.jpg

     

     

    A hose clip squeezes it down to size.

     

    FTX545.jpg.2bc850f78e348d000bc697e48a5b425f.jpg

     

     

    Welded on and extra tube trimmed off.

     

    FTX546.jpg.10015461bf2d05937bc32ec90ff82091.jpg

     

     

    Welds cleaned back.

     

    FTX547.jpg.35b43a5a710beaa69078666d68d8131d.jpg

     

     

    A bit of hammer work soon had the other end a bit wider.

     

    FTX548.jpg.05be3f43b79a8893a8721e1493d42d8e.jpg

     

     

    Welded on to the big bore pipe.

     

    FTX549.jpg.99a3042b3b22d8cf837d95ace7031818.jpg

     

     

    Lot's of careful welding later had the gaps filled up.

     

    FTX550.jpg.9e4e0f7ba2825028c30587e987e0c537.jpg

     

     

    Test fitted to the engine, one side cleaned up.

     

    FTX551.jpg.838f21ce2c43c918a60d9862099d3f54.jpg

     

    FTX552.jpg.ad2d57ae15eddead74aecc7d4bd85a0d.jpg

     

     

    Now I have these made I can work out how the next part of the system.... But that's something for Friday..

     

     

    Oh... the slight change of plan...

     

    With the UJ's etc removed I found there is just enough space to fit this er... final drive? 90'd drive thingy from the very same Honda Silverwing that gave it's engine up for Why Not all those years ago!

     

    FTX540.jpg.c0af9d10bf38ad2bc207f7302290d744.jpg

     

     

    I will need to fit a chain n sprocket to get the power from the bike gearbox into the 90'd drive thingy which has a 5 to 1 ratio (I can "gear" that ratio out), and yes it will spin the right way :D:thumbs:

     

    FTX541.jpg.0a14c131dc98199adbe46e9e7d55ea85.jpg

     

     

    And to finish off a couple of photos of the unit I had taken to put it on Fleabay.. Quite glad I didn't get around to listing it :D

     

    20171123_093729.jpg.cda307f3126b4a39f91bc5778cb5e606.jpg

     

    20171123_093839.jpg.43506f6aa7d49fe7e26d2300bb9c7074.jpg


  2. Here's the jig thingy I make to keep the shafts parallel. It doesn't lok that much but both the tubes are a nice snuff fit on the shafts they have to fit on.

    A lot of time was spent making sure both tubes are parallel to each other.. Trim, measure, trim, measure, trim, measure.. Weld measure, weld a bit more, measure.. You get the picture.

     

    FTX535.jpg.63c793bbdee07e62f29f4307a4bf13a7.jpg

     

     

    Fitted.. The shafts are now parallel to each so I can start working out how to mount the bearing plate.

     

    FTX536.jpg.7bdaaefa4a20679bf88d55f230dfbef8.jpg

     

     

    Out of interest I put the foot rest/guard thingy on to check it still fitted...  Not bad, I will only have to loose a small amount of foot space to fit a sprocket with guard of course.

     

    FTX538.jpg.32c3497c6e304407624ef6d46f985db2.jpg

     

    FTX539.jpg.77beb3fbd114f9f83f7d3f66b79937ac.jpg

     

     

    It was roughly at this point that a couple of comments left on Farcebook had me thinking about how safe the right turn UJ set-up actually would be.. Tight UJ angles and high spinning speeds are not the best mix!

     

    Sooooooo.....

     

    I started on the exhaust instead :lol::D

     

     


  3. On 22/11/2017 at 9:52 AM, Stormin said:

    Somehow I don't think I'd be wanting to do a strip down. :D

     

    You or MadTrax Norm? :lol:

     

    And onwards with the story, another slight change of plan coming up shortly..

     

    The outter bearing needs something strong to bolt on to, so I dug out a bit of 8mm plate and set to on the lathe.

     

    FTX527.jpg.e0682d2676852d5a493fd6323624a672.jpg

     

    FTX526.jpg.ed6aff01adbfb86dfef903816b2c9a27.jpg

     

     

    It will fit somewhere here, to make life more interesting the plate needs to be removable or I won't be able to get the transfer box back out the frame!

     

    FTX528.jpg.b47b783cd34445d3f02d3d1e78dfcb5a.jpg

     

     

    Before I started on the mountings I thought it would be wise to tidy up this bit of frame first.

     

    FTX529.jpg.acf6f4f975bf2c30d7e18d191c57707f.jpg

     

     

    Mostly chopped out..

     

    FTX530.jpg.d275bc515598833490565f16fbbfca9c.jpg

     

     

    That looks better.1f44d.png

     

    FTX531.jpg.15f55a9b10101c6ea8422a6e129eada3.jpg

     

     

    Plate and bearing set back in the frame a tad, it fit's rather well..

     

    FTX532.jpg.51fa33d1d04e9b26c250d19011600271.jpg

     

     

    Plenty of UJ clearance by the transfer box.

     

    FTX534.jpg.de7a46a69d01052f58caa59eed9ab645.jpg

     

     

    Before I can start mounting the plate I need to make sure both shafts are parallel to each other..

     

    FTX533.jpg.8dacee0bec58d85eb1def1fe4b638bc1.jpg


  4. Now the fun part, getting drive from the Honda bike gearbox which points towards the back, out the left side of the frame. :D

     

    A thank you to Nigel at this point for getting a shaft, pulley and UJ off the remains of a Kubota flail mower before it went off for scrap... It really was that rotten!

    The UJ in question, heavy duty and with no play in the bearings at all :thumbs:

     

    FTX512.jpg.50bf4e834dfd709c1af0df588e0ff19c.jpg

     

     

    One side of the UJ is easy to attach as I have the shaft and roll pin that came out of it..

     

    FTX513.jpg.d69a94ce870d9f5f73fcd1ee0017d178.jpg

     

     

    The other end has or (should I say had) some rather large splines!

     

    FTX514.jpg.676fccaf1a2a4ef11f099f948d78780a.jpg

     

     

    I'd be lost without a lathe, taking the OD down to size before cutting it off.

     

    FTX515.jpg.145c6b3be5ce02b5ace1c29d1afae5cb.jpg

     

     

    Boring the ID out, a couple of arty flying cooling fluid shots :D

     

    FTX517.jpg.997fe692e716983dea29e102458a75a6.jpg

     

    FTX516.jpg.874d1f376e932c137c87654a66679879.jpg

     

     

    The finished sleeve, yes it was turned down from a lump of steel the same shape and size it's standing on! :lol:

     

    FTX518.jpg.331f00efcb0a3edcc1f3838465ba9e2c.jpg

     

     

    UJ, shaft and sleeve..

     

    FTX519.jpg.b6e7d14906bdd6c1db150ce69004662f.jpg

     

     

    A nice tight fit..  The sleeve has now been welded into the end of the UJ, yet another roll pin will hold it all together.

     

    FTX520.jpg.fc70fc3e3c56f203b4e45d0a985c091d.jpg

     

     

    Starting at the back, or is it the front!... Er.. Back of engine :D  we have a UJ with splines in one end to slide over the output shaft on the bike gearbox.

     

    FTX525.jpg.03b9c9f7a8fc46998057d703437f0445.jpg

     

     

    A shaft then goes through another bearing and into the Kubota UJ..

     

    FTX524.jpg.c8a489076989e945692bd4fe944c242a.jpg

     

     

    And comes out through the left side of the frame and another bearing.

     

    FTX522.jpg.f1aeff47917c0573c393c89c40206cdc.jpg

     

     

    A chain and a couple of sprockets will give me drive into the transfer box :D

     

    FTX523.jpg.d546b129783df01be8a2439f8adef601.jpg

     

     

    As you can see I have some metalwork to do to hold everything in the right place.. Space is tight but shafts and UJ's turn as the should without hitting anything or feeling "notchy" which proves the concept of it will all work :D

     

     


  5. With all the front drive train bolted back on the foot rest thingy needed a little trim to clear a UJ.. I will add a cover over the shafts/UJ's to add some leg protection should something go bang and start flapping about the place.

     

    FTX499.jpg.c20a57999860c4e4a079ae586dab1c24.jpg

     

     

    Before I started to cut any more metal out I put some strength back in with a nice bit of curved tube that clears the UJ

    When the frame is stripped back down I will add some extra metal to tie the tubes together neatly.

     

    FTX502.jpg.af80da638621f87c5a4857ca773866ae.jpg

     

     

    This join between old and new tubes just had to go!

     

    FTX503.jpg.1560520028c18deebe23ae8f371b485c.jpg

     

     

    Hhmmm, nice rust inside one of the few remaining bits of the original FourTrax frame... It felt good to remove it :D

     

    FTX504.jpg.7fe55a7b002957fb86fc7f7321a8e26e.jpg

     

     

    There is no neat way of joining big and little tube together, at least the other end is easy :D

     

    FTX505.jpg.641ab3e707e2436513836c0ab0edbcd1.jpg

     

     

    For extra strength a length of steel bar has been added inside, you can just about see it where the tubes join.. The steel bar does go all the way up and in the larger tube.

     

    FTX506.jpg.4c8f3eec4b29ecaf31d219b7cffc9c18.jpg

     

     

    I like getting good value for money, think I might of got the maximum use out of this cutting disc :lol:

     

    FTX507.jpg.f04e6ce15ca2b2f821bafe02a0c427b0.jpg

     

     

    Compair it to a new disc!!    While on the subject, some cheap cutting discs are better than others, I can't remember the make (Germany is mentioned on the Fleabay ad) but they are by far the fastest wearing most easily broken disc's I have ever bought!

     

    FTX508.jpg.6d1522cf061a6dd87bb268ee03bdc22a.jpg

     

     

    That looks better..

     

    FTX509.jpg.f46c93123cfd7b199e8d9434d8dab558.jpg

     

     

    Way better than the bit I removed :D

     

    FTX510.jpg.2c61e218eb5a9c69bda7961ab9a830b4.jpg


  6. On 08/11/2017 at 10:50 AM, ranger said:

    Great workmanship and thought going into this project Ian, grand job. :thumbs:

    I hate to say this but, :hide: in the photo of your driveshaft, it looks like the shaft yokes are out of phase.

    All shafts I've had dealings with, (apart from steering shafts installed at high angles, which don't spin at high speed), always have the shaft inner yokes in line to aid in cancelling out vibrations, not a problem if the whole assembly runs in a dead straight line, but when angles are involved?

    Not a criticism , just an observation . You don't want that coming adrift at any speed close to your leg The ideal perhaps, would be a pair of CV joints, if there's room.

     

     

     

    Well spotted Doug, I had an idea that the yokes both should be in a certain position but wasn't sure which.. Guess I should of googled it first!   At least I had a 50/50 chance of getting it right :D

    The shaft also had a slight length problem as something had moved during welding, so in the vice the shaft went to have a weld cut down.

     

    FTX488.jpg.8b1fa7cd1282af54db54bfa70afe1774.jpg

     

     

    Welded back up at the right length with the UJ's in phase :D

     

    FTX489.jpg.81ddd31c4305769e278188d6d8ca8e98.jpg

     

     

    The shaft out the TB is way too hard to drill, so the UJ is held on with a couple of grub screws.. I will add a couple more for peace of mind..

     

    FTX490.jpg.229afa1fbb8c535545462e6a71d82e65.jpg

     

     

    The UJ's that fit on the shaft with bearings are a very tight fit on the shaft, so I drilled them out to fit some nice tight roll pins.. The bolts are only there at the mo to make it easier to take things apart (many times) during building and will be replaced with roll pins.

     

    FTX492.jpg.3bc00072b6d35f830de9b4492364f1cc.jpg

     

    FTX491.jpg.8ee70a5f262a9750a8fa9f8f4e1df537.jpg

     

     

    One of the UJ's being a MAN steering coloum UJ is normally held onto a shaft with a nut and bolt one side..
    Fine if it's being used for steering but as it will be turning a lot faster it would of been out of balance!

    My solution was to cut most of the clamping bit off but leave enough to get a bolt through and clamp it tightly.
    (The drill bit is only there to line the holes up for putting a roll pin through)

     

    FTX494.jpg.ff8548b12782223b6f18fe93357e09f5.jpg

     

    FTX495.jpg.6d3f8a11a4c6c398d6723a1656b08a59.jpg

     

     

    Part welded up.. A little at a time as I didn't want to fry the UJ.
     

    FTX496.jpg.a74353db47d6303e8c207bf1ce2b1a25.jpg

     

     

    The bolt head and tread were cut off before more welding, then some shaping.. Still a little more to take off..

     

    FTX497.jpg.2734534de8eb5dc5be4fbe5d35afb743.jpg

     

    FTX498.jpg.9f5776b9c3cacde16e71260d3351c0b3.jpg

     

     

    Oh, and I found a rather nice if rusty steel bar buried in the workshop, I guess I will be re-making the TB input shaft sleeve, but this time out of one piece..
    It's a good job I have just got some more cutting tips and cooling fluid for the lathe :D

     

    FTX493.jpg.d3f8979832afa484047cadb114090576.jpg


  7. Not much to report, Monday was spent arguing with a car radio, and yesterday my knees were so bad I was only in the workshop for a little while..

     

    But I did manage to get the front driveshaft welded up..

     

    FTX486.jpg.4790528be8baa851416a35182a23f1dd.jpg

     

     

    I don't think the welds are going to break :D

     

    FTX487.jpg.e5ade7c9eb97550378aa03262dc9b276.jpg

     

     

    Almost forgot, the latest MadTrax video... Enjoy :thumbs:

     

     


  8. On 25/10/2017 at 6:12 PM, ranger said:

    If you're going to use those steering shafts for drive shafts, how about balance? Those clamping thingy's look a bit offset.

     

    HI Doug, I've had another thought on the clamp thingys.. Rather than take metal off of one side to balance the UJ's, it would be better and stronger to add metal to one side and build it up with weld (making sure not to let things get too hot) until both sides match..

     

     

    While waiting for the bearings to turn up, I thought I'd make a start on a sleeve to fit over the input shaft on the TB..

    Not the best photo (I will get a better one) but here's the shaft in question.

     

    FTX427.jpg.7b0ba3d4bbe71d6dfc6f17042cffcffc.jpg

     

     

    The only bit of steel bar I have which is long enough is made from very hard steel and looks like it has been used to hold a JCB bucket on... That sort of hardness!

    Anyway, I can make it in two parts and weld them together which would make it easier turning the tapered part half way down the shaft inside..

    These two lumps I made years ago as pivot points for a dozer blade that was going to go on the 6x6..

    A lot of turning to get them down to size!

     

    At least one is mostly done :)

     

    FTX469.jpg.f9249631dd636be63834460ed65c19c8.jpg

     

     

    Woo Hoo... The bearings arrived :thumbs:

    Here's the TB to front end bearing mocked in place..

     

    FTX468.jpg.4b1698735cd2d98e89b57de25ffdda4d.jpg

     

     

    Best start getting the bearings mounted then.. First up something to bolt them to.. Well, a couple of somethings..

     

    FTX470.jpg.14b7b5a0b6ccff3d6cca5ac53ea8e7b5.jpg

     

     

    Bolted on. The black bit of steel across the lower bearing bolts is just to keep the bearing square to each other.

    You can just see where I welded on some tempoary bracing to the drive shaft to stop anything moving about withough the axle stand and other bits that were holding the bearings etc in place.

     

    FTX471.jpg.1276a7344dfcf72566de0528cd09a0c4.jpg

     

     

    If you flip the bearings over you can see the captive nuts that have been welded on... Don't think they are going anywhere :lol::D

     

    FTX472.jpg.6abb75850f63961ee33f76c0067c411f.jpg

     

     

    Now the fun bit.. Making four somethings to bridge the gap between the back of the bearings and the chassis/frame..

     

    FTX473.jpg.a735013775b71e137bbb00fc1e7ad169.jpg

     

     

    Starting with a bit of CAD (cardboard aided design) work.. :lol:

     

    FTX474.jpg.e4fa613a038e5a14d5716c2153f91832.jpg

     

     

    Which goes somewhere here.. Rather hard to hold it in place and take a farto at the same time!

     

    FTX475.jpg.3407f98a1d822478d6d1924ca24da03b.jpg

     

     

    Roughly cut out of steel..

     

    FTX476.jpg.0488e418c7cfe5f4f99cc601c4809b92.jpg

     

     

    That looks better.

     

    FTX477.jpg.2b2cb8acebf8604ede7118a9d1242a51.jpg

     

     

    Four of em made and tacked in place..

     

    FTX478.jpg.c304ce865765f649c6009df2a7ac90d9.jpg

     

     

    Bearings off..

     

    FTX479.jpg.7b2866514d6a55f9723945ec3a04ee68.jpg

     

     

    Fully welded up... Almost..  It will be easier to weld the extreme top on bottoms where the brackets fit on the frame without the engine in and sump guard in place, so that can wait until stripdown time.

     

    FTX480.jpg.02d97297e5ecbb8284c1a17a4ff0cca3.jpg

     

     

    Welds ground down, a nice curve at the back to clear the engine.

     

    FTX482.jpg.c2515a31583df1b074d436259c4a907c.jpg

     

     

    And most importantly, there is still plenty of UJ clearance here..

     

    FTX483.jpg.f22206e0f386ffca78be4a288906f9be.jpg

     

     

    And here :thumbs:

     

    FTX485.jpg.0ec6ee09fc30e8e33a009dd25bcb65e8.jpg

     

     

    And to finish off this update, a photo of the bearings etc quickly bolted on for this very photo.. The mounts were still very hot from welding and grinding so I didn't want the bearings sitting getting hot for too long..

     

    FTX484.jpg.40dd0d0204ac1ea85c8800268532c549.jpg


  9. To get the drive from the Honda bike gearbox to the TB I had to find a way of turning the drive direction around by 90'd..

    One of the steering UJ's fitted with the the splined section from the original CX/trike propshaft..

     

    FTX453.jpg.c9f86e5db80a883b7df32e3082a96dd6.jpg

     

     

    The shaft will run diagonally between the engine and TB with a nice meaty bearing to hold it in place.

     

    FTX454.jpg.fba79d2d48ba1f32fafe48884427fa61.jpg

     

     

    And via this double UJ thingy the drive will come out the side of the frame through another meaty bearing and put the drive in the same orientation as the TB input shaft..

     

    FTX455.jpg.a4146025802376257f7bf9b433b7054a.jpg

     

     

    Working out space for the TB to front drive shaft.

     

    FTX457.jpg.6b037011a303407915ca5991f43867ab.jpg

     

     

    Using a mixture of different shafts and UJ's there is plenty of space to run the front drive up the side of the engine.

     

    FTX458.jpg.dfda0f27477bf8ef657cb2c72435021e.jpg

     

     

    Hhhmm... Maybe not quite the same size where they need to be joined!

     

    FTX459.jpg.7ce3afe85defa6d77750029dcdc0441e.jpg

     

     

    A bit of lathe work later..

     

    FTX460.jpg.b86fab99e25eee8a9fe9dd5759bc991e.jpg

     

     

    Ta-Daa :lol:

     

    FTX461.jpg.daecf6d38220586775c0b39934e164d6.jpg

     

     

    Not fully fitted together in this photo as I don't know the exact length yet, but you get the idea :)

     

    FTX463.jpg.3a2b108fc5e507b9ca512fda7f25db1f.jpg

     

     

    Popping back around to the other side of MadTrax for a mo, the pulley (I will be using chain and sprockets) is about the right size to give me an idea how much space I need to create to fit a bearing in.

     

    FTX465.jpg.b97f097c021f210a1e1fe3d3a854a91d.jpg

     

     

    I need to slice some of the frame out here, but I planned to do that anyway to get rid of the un-needed swing arm mount.. It's the only bit left that says "I've welded a few extra tubes to a bike frame" :lol::D

     

    FTX466.jpg.ce305e5d9dcfb2e1edba10027ff0296b.jpg

     

     

    The bearings arrived Wednesday but I've not had a chance to do anything with them.. That's fun for tomorrow :D

     

     


  10. On 25/10/2017 at 6:12 PM, ranger said:

    If you're going to use those steering shafts for drive shafts, how about balance? Those clamping thingy's look a bit offset.

     

    Well spotted :)

    The off-set bits of the UJ's will be ground down to make them..er... Not off-set :lol:

    As I will be grinding off the bits where the clamping bolts go I will need another way of making sure the UJ's don't come off the shafts..

    On the Quadzilla roll pins were used, so that would be the way to go I think..

     

    The TB didn't officially have a mount around the input shaft I thought it might be wise to make one as a lot of forces will be going into the TB there..
    A cardboard template taking shape, pencils being just the right size to screww into an M8 thread 1f600.png

     

    FTX441.jpg.06d5a8fbd87b8371bc2b1a8f62785d66.jpg

     

     

    As I didn't have a big enough bit of strong plate to make the bracket from I had to make it in two parts.

     

    FTX442.jpg.c6307cd5f18a5e9e7324c0b1a765e97c.jpgFTX443.jpg.bc97d0df77cc4dc6033d07af9517eee9.jpg

     

     

    Two of the bolt holes on the TB didn't stick out as much as the other two, so to level things up a couple of spacers were added to the inside of the plate.

     

    FTX444.jpg.bca504f1fea81f1c8c62d736be1e7334.jpg

     

     

    Welds cleaned up. The chain driller hole is slowly getting filed round. By doing it a bit at a time it breaks the bordom/arm ache up into managable bite sized chunks :lol: 

     

    FTX445.jpg.3aeec0be435377b6da9a02f4091ddcc9.jpg

     

     

    Bolted back on with a few extras.
    The top right hand bolt bolts into a threaded tube thats welded to the strut tower.
    As any "tabs with captive nuts" type things would get in the way of reoving the TB, I had to come up with another mounting spot.

     

    FTX446.jpg.8f905b785029f0089ac0c1ceec1d7b9c.jpg

     

     

    Something like this..
    It was also a good time to mark out a bolt hole.

     

    FTX447.jpg.a5ea32ce3f667f5e1bebaa23b11c8008.jpg

     

    FTX448.jpg.823a27bb64bc1053dd1047baa00f5bf1.jpg

     

     

    Off with the bracket them slice the top off the foot rest mount..
    Drill it, weld a captive nut inside then weld it all back onto the frame... Top mounting point sorted

     

    FTX449.jpg.6dea2b8c856a33ffd311324a74d933c0.jpg

     

    FTX450.jpg.35031f7e121c03437f2eace82bd17a32.jpg

     

     

     


  11. A big thank you to Rex at this point for turning up at the workshop one day sporting a couple of massive MAN truck steering columns. Thanks mate 1f44d.png

     

    FTX430.jpg.47919922241ddb41658aac66f7ab427d.jpg

     

     

    I can't use two of the UJ's as they have a plastic center bit.

    "I have since found out that the plastic bit is only a cover so I can use them"

     

    FTX431.jpg.8b94ab1b48f484d22a7a4867d95e06b9.jpg

     

     

    But I can use the shafts and other UJ's (one of which is a double) to get the power from the GB (gearbox) to the TB input shaft... But more on that when I get to sort it.

     

    FTX432.jpg.8f3541b23a2eee61cec2d22cbf75f9f5.jpg

     

     

    With my Murex TradeMig finally fixed I decided to celebrate and make some mounts for the TB.
    Two of the mounts were cut off the remains of the Quadzilla frame which gave me a good start.
    Space is so tight getting the TB in and out of the frame I have to make all the mounts removable from the frame so they don't get in the way!
    I welded on a couple of captive nut before welding this bit to the frame.
    Once the TB has been taken out again I can fully weld it up.

     

    FTX433.jpg.4f8276df5551e82d933122da645a852f.jpg

     

     

    MMmmm, some nice strong welds 1f603.png

     

    FTX434.jpg.caf12eafdbad8fbe103842013f1ca174.jpg

     

     

    This bracket bolts the TB to the frame, but I didn't like the look of it.

     

    FTX435.jpg.580e43ec7f1880e2780b6e507ffa37cf.jpg

     

     

    So the corners were sliced off.

     

    FTX436.jpg.f1905c1ac24e47b14251350815bc9a2d.jpg

     

     

    And some new metal was added to put the strenth back in the bracket.
    Will you look at those pretty colours, yep I'd say my Mig is now working better than ever and producing the heat it needs to do a very strong weld 1f603.png

     

    FTX437.jpg.74a466311a65edd336350d80dbf002e8.jpg

     

     

    That looks better..

     

    FTX438.jpg.ff3f2ea42d4c412f3b1f3a252554bf19.jpg

     

     

    The TB mount the other side. Nice and strong (well it will be when I can fully weld it up when the TB comes out), but I'm not sure I like the shape of it so a few mods will need to be done.

     

    FTX439.jpg.222e815056a409a8305eb45f61fbb51e.jpg

     

    FTX440.jpg.1b7e0c46301eee5925552a00dc43c42d.jpg

     

     

    That will do for now, it's given you all plenty to read :D

     

    More to come later..

    17 minutes ago, Stormin said:

    Sounds to me you could be right about things being welded up. Maybe a half shaft broke at sometime. I think you'll need to split the box.

     

    The trouble is I can't split the box with it in the frame, and I can't get it out!

     


  12. Still no luck getting the rear diff out, but I did take the input shaft out to try and see what's going on inside..
    No diff inside but both cogs look in great shape.

     

    FTX420.jpg.7717e5aaa45becab411efec45a8af0e9.jpg

     

    FTX421.jpg.e38eadc5fbb0b1cfc11985b04d79646d.jpg

     

    FTX422.jpg.c6834afc45e33b0e872f8c6c07553497.jpg

     

     

    Getting drive from the Honda bike gearbox was always going to be fun as there isn't much space!

     

    FTX417.jpg.8aaf5a6e57665104458a76ca4d19c923.jpg

     

     

    The only thing I could do was move the transfer box as far back as possible.
    So out came the Quadzilla battery tray, followed by a slice taken out of a rear strut tower.

     

    FTX418.jpg.dbbe952241f31a2b8924f6b1934afb78.jpg

     

    FTX419.jpg.b2fd32689e5a81552fa3965097699066.jpg

     

     

    The transfer box/rear diff coupler limits how far box the TB (transfer box) can be moved back.

     

    FTX425.jpg.c49687f0179829093e91ecea26bc0baf.jpg

     

     

    But notch cut out of the strut tower allowed me to move the TB back a good 1/2 inch.. Not much but it all helps.

     

    FTX426.jpg.28976f5aae71bd06a863778084cab6a8.jpg

     

     

    At this point I still didn't have a working Mig welder and couldn't really do any more on the project, so I tidied the bench and had a think.

     

    FTX423.jpg.cef2cc99a40df138dc5c7be2a60fb697.jpg

     

     

    A change of plan getting the drive to the front er... I keep going to call them "diff's" but they dont have a diff in them!
    Anyway, you know what I mean.
    Rather than go the chain and sprockets way I meantioned in my last update, I will be using the Quadzilla drive shafts, all I need is one more UJ tyo get the shafts around the engine.
    Of course the front part of the exhaust won't fit because of a drive shaft in the way, but hey, it's only metal 1f603.png

     

    FTX424.jpg.ab0122340b849f91ee51fdc81eacefa3.jpg

     

     

    While on the subject of shafts, this is part of the drive shaft that fit's on the bike gearbox, the problem is the splines inside don't go all the way to the UJ, so I can't just cut it to length!
    The only way to do it is to slice a bit out the middle and weld the splined section back on much closer to the UJ.
    I need to shorten this so it will fit onto the gearbox splines and leave enough room for the UJ on the shaft that runs from the TB to the front axle.
    To make it easier to line the two bits back up for welding I needed to machine the slined end to an even size outside.

     

    FTX428.jpg.0cceb8b70c466ad37d142872c55e9ddd.jpg

     

     

    As the UJ isn't designed to be taken apart (thanks for that Honda!) I had to be inventive and find a way to hold it all steady in the lathe.
    It's been a long time since I've used a steady rest, but it did the job well and the machining went smoothly.

     

    FTX429.jpg.db2ac60cc55d7e2016d77c4f21e05b7c.jpg

     

     

     


  13. On 20/09/2017 at 9:41 AM, Stormin said:

    A skid plate under the front end might be an idea, Ian. Stop the front getting caught on anything sticking up or digging in a hump.

     

    On 20/09/2017 at 5:34 PM, nigel said:

     

    On 20/09/2017 at 5:57 PM, Stormin said:

    I could see there's one under the diff, Nigel. :P I was meaning where the frame comes down. The diff plate could be extended to curve up in front of it.

     

     

    I see what you mean Norm, I'm sure something "in keeping" can be made :D

     

    Quite a bit of updateing to do, not sure I will make it all in one sitting as I've a lot to get done today!

     

    Before I started to slice MadTrax open for a transfer box implant, he was taken off the bench and wheeled outside so we could have a good look.

     

    FTX399.jpg.941f1f840c9af152dbaf9202a1d06f20.jpg

     

    FTX400.jpg.c47732c86fd42dbc4d3cdc7d6d540ada.jpg

     

    FTX401.jpg.16876becafb2633656c7e3e89ee104e3.jpg

     

    FTX402.jpg.2f715f4255d69ddc64732660d0690474.jpg

     

     

    Back on the bench the rear end was stripped off, a bit of grinder work later and the transfer box was almost in.

     

    FTX403.jpg.3f1152ecd21f2d81043c5eec97870725.jpg

     

    FTX404.jpg.1119bda7b6eb74c39c60ea7f00ab61d4.jpg

     

    FTX405.jpg.3c0fb256ab66c9d103b91bed34dc9665.jpg

     

     

    By almost, I mean the box fitted in but splines wouldn't quite line up..
    By connecting the diff and tranfer box shafts I get drive to the rear diff but it also dictates exactly where the TF box has to go.

     

    FTX406.jpg.3a6a71273844e36eb6841aac6f49896f.jpg

     

     

    And this is the point where I need some help guys..
    The front and rear came from a 2012 Quadzilla 325E 4x4.
    The problem is I can't get the rear half shafts out of the diff!
    All the research I've done says inside the rear end is a crown wheel that has a shaft with splines on each end running through it.
    The end of the half shaft should have internal splines that push over the "crown wheel shaft" and is held in place by and expanding spring/washer thingy.
    I can pull the end of the half shaft out of the er.. diff/and or crown wheel case only a certain amount and then it feels like there is an internal "cir clip" holding the shaft in..
    Also as you will see from the photo the end of the half shaft has external splines not internal ones like the internet whould have me believe!
    My thoughts are it does have a diff in the back, but someone has cracked the case open and welded it up to make a "locked" rear end.. There is plenty of signs that someone has been in the rear end before, lot's of mastic type sealer on the case joins!

    Oh, the diff won't come out of the frame without taking the end of the half shafts out first!

     

    FTX408.jpg.7e492fc63df5c51eb2fa311b1ad726cc.jpg

     

     

     

    To join the transfer box to the rear diff I needed the longest length of slined section from one of the Quadzilla prop shafts..

     

    FTX411.jpg.8ac6e9a6f064cdfbeca03c90875fc6d1.jpg

     

     

    You might say the UJ was a bit worn!

     

    FTX410.jpg.c8182b93db8564e270682df968cb3e9e.jpg

     

     

    The "coupler" needs a bit of work but transfer box and rear diff joined

     

    FTX412.jpg.7c5cd28906cf8b792141ee6c4e0799cf.jpg

     

     

    A shaft with 2 UJ's comes out of the front of the transfer box.

     

    FTX413.jpg.f31386a56443420987455b5ecb854241.jpg

     

     

    Which will fit onto a nice sturdy shaft running forward with bearings to hold it in place.
    The thin walled white tube is for illustration purposes only 1f603.png

     

    FTX414.jpg.f1fe85c3369aed9f2b4686b39ce1345e.jpg

     

     

    The front of the shaft will connect to the front diff via some very strong chain and sprockets.

     

    FTX415.jpg.9491c66d9818b9574a0073b2cb929f69.jpg

     

    Disclaimer...  " The above chain idea has now been changed but I've put it in as it's part of the MadTrax story" :lol:

     

     

    Nows a good point to drop in a video..

     

     


  14. Owdo all, MadTrax is coming along nicely, along with a lot of new tube the looks have changed as well :)

     

    By only doing one corner at a time the Quadzilla strut towers have gone, I think the tube looks much better.

     

    FTX386.jpg.9f0d481b6f5582b83000921fae648f06.jpg

     

    FTX387.jpg.4056821cee212bc22f0a3efb965d1e2e.jpg

     

    FTX388.jpg.4607248e54eb197be67e961b542b04ac.jpg

     

     

    A new nose taking shape.

     

    FTX389.jpg.38b07d56e8e873810abee3bf1c5ff919.jpg

     

     

    You can also see some new tube connecting the top of the struts to MadTrax's frame just in front of the gas tank..  The photo's don't show it too well but the curves match and line up with other tube..

     

    FTX390.jpg.399f184f59556806bd7934194cedc870.jpg

     

    FTX391.jpg.7e3126ca027639dad35ea384e6cb84b3.jpg

     

    FTX392.jpg.bd3f4143c268b1e2fde588d12dde803b.jpg

     

     

    Nose job finished, not as pointy as the first one and it looks all the better for it... No chance of it digging in and throwing me over the bars now :lol:

     

    FTX393.jpg.6a784dfbcf8cce4e3f5b821dcd58dc09.jpg

     

    FTX394.jpg.796de51a677c624df6a44d62008431d9.jpg

     

     

    A single tube connects the nose to the frame, hopefully there is still enough space left to get the diff out when I need to :lol:

     

    FTX395.jpg.73cee13951cfe566d8a874c7e71f3d69.jpg

     

     

    When I cut the front off it left four open tubes on the frame, so they needed to be tied into the new front end... 

     

    FTX397.jpg.9f47c05e21a30fd7cfff766018312a6c.jpg

     

     

    The two tower tubes will be joined together, something like this only cut to fit and without the hand to hold it up :D

     

    FTX398.jpg.0a1522c37c7fefbf7de991c972024c9d.jpg

     

     

    And that's this thread upto date again... 


  15. Time to get serious with the front end..

    Not the best of photo's as someone had put an exhaust in the way, but the front is now welded to the rest of it.. I will put a load more strength in this area but it's one of those jobs best done later when the frame is stipped down (again) and I can turn it upside down.

     

    FTX381.jpg.0952b27c91e8b628c0d635d81487df32.jpg

     

     

    So I could do some structural slicing the front diff needed to be moved forward and out the way a bit..

    Of course two of the Allen Key bolts came undone with only a small fight, the front two refused to budge and eventually got chewed up..

    The only way to undo them without grinding the heads off was to weld a bit of bar to the bolt head and hope the heat would free the thread up....

     

    Which it did.  :thumbs:

     

    FTX373.jpg.8b37107584bd69d33e7a785fc70757d0.jpg

     

     

    There's no two ways about it, the Quadzilla front strut towers looked ugly, really ugly.. So why not turn it around and make them a feature :D

    With yet more tempoary bracing in place and the top of the towers already mostly wrapped in tube, half the O/S strut tower was cut out!

     

    FTX379.jpg.4e7ef8546a09d999f56846d31b27b711.jpg

     

     

    Cleaning up the welds was not fun as they were very hard!

     

    FTX375.jpg.fcac90abc9ebdb61e553ce842935393b.jpg

     

     

    Fresh tube welded back in to replace the metal I had cut out, and a Nigel holding the rear tube in place..

     

    FTX374.jpg.d1047f79a1b68484d34ae613fbcd0968.jpg

     

     

    A close up for you.

     

    FTX376.jpg.7081916a7757a940e919131bcafdc19f.jpg

     

     

    And a view from the front and top.... By the time we are finished it will look way better and be much stronger than the original Quadzilla strut towers :D

     

    FTX377.jpg.cfef1407cf766f8d22cc0c2b4bec6a6f.jpg

     

    FTX378.jpg.1da1cc92e171ff329c6af2cc293f12b7.jpg

     

     

    Oh..... Much to my and Nigel's suprise I found the Quadzilla gear/transfer box the other day..  Both Nigel and I thought it had long gone!

     

    FTX382.jpg.cfb5b27d9c28c15a232de79173bbab5b.jpg

     

    FTX383.jpg.1dee2397cdcba04ff3da39d5626f29bd.jpg

     

     

    If I can make it fit in this space, MadTrax will have HI/Low ratios and a reverse.. Well 5 of em :D:lol:

     

    FTX384.jpg.9d14d3417a7cc0167b3739eaca68596d.jpg


  16. Morning all, bit more of a MadTrax update for you.. Yep, yet more slicing and welding, even more of the same to come :lol:

     

    The box section under/around the rear diff needed to come out as it just looked rubbish!!

    Slicing it off in one bit was interesting ! :lol:

     

    FTX366.jpg.3a3e89f6bb2998adb0cdeafa15a0b0e6.jpg

     


    In went some new tube..

    FTX367.jpg.118e1e91af08e2ab85bfda83101574a0.jpg

     

     

    A lot of extra tempoary bracing went in to stop things moving..

    The big blue tubes hold the rear end off the bench as I had to remove both rear wheels and move the shocks so I could get a cutting disc in..

     

    FTX380.jpg.d3f64f0b6029b36741a73e7441f0ef36.jpg

     

     

    Not fully welding in yet, but I have added a cross tube between the end of the new rails since this pic was taken..

     

    FTX368.jpg.63dc095fbd07a99280bb519fdcd5611d.jpg

     

     

    It was at this point my Murex 165 TradeMig shat it's self and decided it didn't want to produce good welds any more!
    When using it you can feel it's "pulcing" and just has lost it's amps and doesn't want to penetrate!!
    So a BIG THANK YOU to Nigel for offing me the use of his welder until I can get mine fixed which will hopefully be some time next week..
    Nigel's Mig on the right, naughty Mig on the left!

     

    FTX369.jpg.741e42602d086b0a6d56349275c165a3.jpg

     

     

    Much welding and the wheels put back on later the rear end looks like this.. Some extra strengthening and tidying up needed but it's looking good.

     

    FTX370.jpg.dd7001fca37dea7accf2b887759f96f2.jpg

     

    FTX371.jpg.c1120866564a99a3c8a647e261c0ef0b.jpg

     

     

    Another big :tthankyou: to Nigel for helping me get the new front end lined up and squared up with the rest of the frame.. This took a suprisingly long amount of time...

    Bracing was added after this photo was taken to keep it in the right place.

     

    FTX372.jpg.bc253af45c36c4f3e0e9960773a2128a.jpg


  17. On 07/09/2017 at 0:13 PM, meadowfield said:

    flipping bonkers you two!!!!

     

    Thanks for noticing mate :lol::D:thumbs:

     

     

    On 07/09/2017 at 0:25 PM, Stormin said:

    I like it. :thumbs: Just needs some rear lights.

     

    Be better than the quad for you Mark. You can go after the sheep without getting wet. :D

     

    True, but you would have trouble finding the right shape mattress to fit in the back :lol:

     


  18. On 22/08/2017 at 5:26 PM, nigel said:

    Nutter as mad as a box of 🐸 frogs 

     

    But of course old bean, of course :lol:

     

    Sorry for the slight delay in finishing this post, spare time is hard to find!

     

    Anyway...

     

    Quite a few months ago when MadTrax was being stripped down for paint I found that I couldn't get the exhaust off the engine!

    Something had closed up during welding and made the very small clearance there was too small to clear anything..

    So, the only option was to put an extra flange in the system.. Almost finished here, just need the welding finished when it's unbolted.

     

    FTX349.jpg.87852054f60275aca0bb871036094c9d.jpg

     

    FTX350.jpg.35ce33964ce98243fd819e5f3e1fe841.jpg

     

     

    And on to todays main attraction :D

     

    Never being one to take the easy option and also having a history of making drastic changes when I'm most of the way through a build, I thought the best way to bolt the new wheels on is if

    I use the matching hubs.....   And suspension.... And brakes....... And steering :lol::D

     

    With a couple of bars cut out under the seat the Quadziller rear end could be rolled in place.

     

    FTX346.jpg.2054ec7e16766277652b16147cd605a8.jpg

     

    FTX347.jpg.896b40abb604cffdcbab2b143ab2a73d.jpg

     

     

    The heavy duty sump guard came in handy, nice and flat for balancing on a widened wheel rim that was just the right height.

    With the front end stripped off, there was only one thing to do..

     

    FTX348.jpg.afd48b6cbf07501cb6d0e477c76c64c3.jpg

     

     

    Slice off her nose :D

     

    FTX351.jpg.f5a8c880a14c3c608ba83f19b1091555.jpg

     

     

    To fit this, Quadzillers front end :D

     

    FTX360.jpg.767ea1fd6002f2fe1791429101d82dad.jpg

     

     

    A little trimming later and both ends are near enough in the right places.

     

    FTX354.jpg.f34baa547a0d6573daf13ea7f9d67fb3.jpg

     

    FTX352.jpg.d0ef52ccc5bfd164754b27bb82e05495.jpg

     

     

    Lot's of measuring later the front and middle sections lined up and were held together with some tempoary bracing.

    The first two new tube to on were the rear end, I just had to give her a slightly cheeky curvy rear :lol:

     

    FTX361.jpg.87cdeb16e4d8a9fa2faa8f5fda728a8f.jpg

     

     

    No problems getting the exhaust back on, the battery box will be cut out as MadTrax has one already.

     

    FTX362.jpg.c8e87eb64b8513de1d97e9cfa6acda81.jpg

     

     

    Working out how to make the top shock mounts was interesting, but worth it as they look good. It's a shame that I ran out of welding gas as I was tack welding them on!

    I will put a bracing tube between the shock mounts.

     

    FTX363.jpg.229c8e99af0d87d80bf16ef6efda9059.jpg

     

    FTX364.jpg.21f4ab1374816ace4e8ecaa850d291c7.jpg

     

    FTX365.jpg.67c9906d3b00c73347724b344b2b3dcc.jpg

     

    And that's where the build is up to for now... More to happen when I get more gas..... (No fart jokes please) :lol::D

     


  19. On 18/01/2017 at 10:16 AM, Cub Cadet said:

    Its an absolute beast Ian, Great work!:coolphotos:

     

    Thanks mate, it's about to get beastier :D

     

    Wow was it really January I last worked on MadTrax!!

    I have been a bit distracted by an RJ, a Burban, a lathe bench etc but I am back on MadTrax's case now :D

     

    In order to keep this in some kind of order, we had best start with a video with a rather silly start :lol:

     

     

     

    As hinted at the end of the video some "slight" changes were about to happen..

     

    It was this photo that started the ball (or should it be quad) rolling :D

    The wheels came from the remain of a Quadziller quad that Nigel had stored away in a vast amount of brambles :lol:

     

    FTX358.jpg.b7ea689b9d9792a9c46234ab28d20ce1.jpg

     

    FTX359.jpg.7442de5356625eaf6c08f2a0615b3191.jpg

     

     

    There was no way the bigger wheels would bolt onto the original front hubs and rear axle as the PCD's are nowhere near the same..

    Making adaptors for the front wheels wouldn't be too bad of a job, but the rears would need at least an 8 inch wide adaptor plate each side which would do the axles bearings any good!

    Also the original rear axles internal brake wasn't working at all!!

     

    Sooooooooo...   My brain started chewing an idea over.... Then out came the tape measure to check on the idea...

     

    But your going to have to wait a little while to see the idea though I bet a few of you know already :lol:

     


  20. On 26/07/2017 at 10:07 AM, Stormin said:

    Lucky man. Road registered as well. That's a bonus.

     

    Thanks Norm, yep road registered and still on the DVLA computer..

     

     

    On 26/07/2017 at 10:27 AM, harryt said:

    Great video Ian:thumbs:

    what are you plans with the D?

     

    Thanks Harry.. Plans are not much.. Fit a 3 point on the back, maybe make pallet fork, then just a wipe over with an oily rag once in a while.. I like how she looks :D

     

     

    On 26/07/2017 at 11:49 AM, the showman said:

    Looks a nice bit of kit, new seat and a couple of rearlight lens and a wipe over with an oily rag

     

    Thanks Chris, a new seat would be good, one that will now backwards by a few inches would be better :D

    I have plenty of new lights for the back, not sure if I want to fit them though..

     

     

    On 26/07/2017 at 0:39 PM, Anglo Traction said:

    Certainly look's in better health than Andy's (Wheeledhorseman) D200 that he covered in a Thread a few years back on RS. I remember he was also mystified with those tiny WH Stickers. Nice big old lump of a Garden Tractor. 

     

    Hi Richard, yes the ol D is in quite good health, the trans whines a bit but so do I :lol:

    I remember the tiny WH sticker thing on Andy's D, plenty of them on my D!

     

     

    On 26/07/2017 at 9:06 PM, pmackellow said:

    Nice addition to your collection Ian, bet the grin is a mile wide ! :D

     

    Sorry I missed you last Saturday when I popped in, had a chat with Nigel :thumbs:

     

    Thanks Paul, good to catch up with you Friday, I seem to remember you having a big grin as you drove the D around the carpark :D

     

     

    Not much to report, the D gets better each time she is driven. The engine always starts first time every time :thumbs:

    Speaking of the engine, a new vacum fuel pump was fitted so I could get rid of the "tank on a plank" that was clamped on the front and use the D's original tank..

    The engine was also missing a cover, so I quickly folded one up from a bit of sheet steel.. Not pretty but does the job.

     

    D12.jpg.447a54787d5a8fa4cd018a5792397f97.jpg

     

     

    The D's first official duty, carting some steel panels up from the scrap pile :D

     

    D13.jpg.62e5d7b2d10959167266967d591ecf78.jpg

     

     

     


  21. Morning all, sorry I've not posted or even been on MOM of late, life has been stupidly busy to say the least!!

     

    Anyway, a long long time ago there was a thread on good old RedSquare about which wheel horse would be on your "wanted hit list".

    One of them was a GT-14 which thanks to Neil, one came my way.. A great machine which has now moved to pastures new..

    The other I'm sure you can guess from the title was a D-200 :D

     

    Nigel bought this machine from Harry with the thought of changing the engine (which had a knock according to the bloke Harry bought it from), to something a bit different..

    Then Nigel made the mistake of saying something along the lines of "I expect you will end up owning the D eventually".    Which got me thinking :D:lol:

     

    A bit of a play with the wiring  (The PTO switch had been badly by-passed) and the engine had a spark, and a temporary gravity fed fuel tank sorted out the fuel side of things..

    Much to Nigel and my surprise the engine fired right up and sounded good with sign of any knocking sounds!

    The trans is a bit noisy but that may sort it's self out with a bit of use as the Big D hadn't been used in a very long time..

     

    A few photo's for you..

     

    20170720_160510.jpg.7c585a69a3c811fb3b0c49cbd6ed0dcf.jpg

     

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    20170720_162942.jpg.238d7aca3fc535fa2dbb30a58bd7a716.jpg

     

    20170720_162954.jpg.fbc075abe3f7e07384fd220977a59f2e.jpg

     

    20170720_163005.jpg.ff53431527c5784e9d620d748cc19e7c.jpg

     

    20170720_163017.jpg.b44dd904dfaec531fc17816a25e4265b.jpg

     

    20170720_163028.jpg.aebf5bd8fd93b3000a93ab4aff80448d.jpg

     

    20170720_163035.jpg.74696857e44c345f45cb9b8ab70bf9c8.jpg

     

     

    And of course a video.... I hope to get an engine running and driving vid edited today, but for now here's an intro vid..

     

     

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