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Race Car Fabrication There is a lot of cool fabriaction going on the race car industry, show us what you got.


Race Car Fabrication There is a lot of cool fabriaction going on the race car industry, show us what you got.

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  #1  
Old 07-11-2008, 07:52 PM
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600 cc Kart

Gonna get started on this new toy in the near future, as soon as I finish my frame jig. One pic is a mockup of some parts..

Dimensions : 65" whb, 50" tread, 2" ground clearence, 36" tall, target weight of 380- 400 lbs.

2007 600 RR Honda on Alcohol 118hp , 6 speed, 4 wheel disc, 5 point harness etc. it will have an 18 square ft top wing also. its a kart on steroids..

We have open track days here at PIR and Firebird road course's, so there's plenty of places to drive it,.. Plus the local Autocross races.
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  #2  
Old 07-11-2008, 08:38 PM
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Look'n great Dallas!!!
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  #3  
Old 07-31-2008, 04:45 PM
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That thing looks mean!
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Old 07-31-2008, 06:04 PM
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Thats cool. Any dragraceing planed?
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Old 07-31-2008, 07:25 PM
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Yeah ,, we could make a pass down the strip just to get an ET..( not a drag racer) mostly were gonna race on a road course when they have open track play days, an do some Solo SCCA stuff. almost have the frame jig built. I have all the parts and steel , so it should be a pretty fast build.. I 'll post pics as it comes together.
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Old 08-18-2008, 08:33 PM
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All rightty.. moving along, finally finished the frame jig table this weekend, its 8ft long x 24in wide x 28in tall , I decided to make it a knockdown version so I could store it easier when I'm done. I had a couple of 8x3 inch I beams (tempered steel) that I picked up for free from a mobile home place .They were the tongues off double wides and are taken off the mobile homes after they are setup and usually scraped or junked. I cut them apart and cutoff the brackets and stuff.
I used equipment levelers in each leg, it sits very solid with no movement when all assembled and leveled, also if a future project requires a wider table, I can fab up some wider bolt in crossmembers. The chassis jig crossmembers will be 2x2 .250 tube that I can tack weld to the top rails of the I beam where needed. now I can get busy bending up the tubes for this monster Kart....
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Old 08-19-2008, 08:51 AM
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cool
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Old 08-19-2008, 09:40 AM
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Nice stuff I need to look in to something like that.
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Old 08-19-2008, 04:32 PM
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Nice idea with the bolt together table! I'm gonna be building one of those this winter and will steel that idea from you. Subscribing to watch!
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  #10  
Old 08-19-2008, 06:48 PM
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When you take it to the track give me a jingle. I would love to watch you race it.
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  #11  
Old 08-20-2008, 09:20 AM
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We can do that..I'll shoot ya a PM.
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Old 08-24-2008, 07:48 PM
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Back on it this weekend, first thing I needed to do was fab some clamps for the jig cross tubes, simple enough to do, they clamp on the ends of the tubes and the top lip of the I-beams. Once that was done and the tubes postioned and squared with the jig table, I began to layout the spots for the frame tube guides that are welded on to the cross tubes , first finding the centerline of the jig table , then located the proper distance Lf & Rt of centerline, To help keep every thing square,while welding the guides, I used a piece of square tube 1.25 the same size as the DOM tube I will be useing for the chassis and welded the guides on . Now the chassis tubes fit snug and will be held in place without movement while the frame gets built. I positioned the lower frame rails in place, then squared and leveled each tube just like the directions said.....LOL
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Old 08-24-2008, 08:12 PM
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My hats off to Chris , Bend-Tech Pro is pretty sweet, every part I have bent has turned out according to the bend data on BT-Pro. The tubes fit like a glove or a tube which ever works ..LOL

With the all the lower chassis tubes fabed up and in place in the jig, the fitting of the front bumper / frt axle tube required that the 2 lower rails be notched to accept it properly, this was done useing the JD2 notcher, I like this tool. I can clamp it on a tube thats in place and get the correct notch everytime. I mocked up the frt axle tube , found the cangle of intersect , position the notcher according to the reference marks ,Ta Da,, it fits perfect..!

This coming together faster than I anticipated. the front spindle / kingpin bosses are next, these are the spindles I will use that I held up in place for a photo shot.

The brakes have been an issue since I got the idea for this build, The rear will have a 10" rotor with a Wilwood caliper, plus a second caliper plumbed to a smaller Master cylinder with a hand lever for E-brake turns...
The fronts have been a design problem,, I finally located a billet hub that with a small amount of machining , I can fit an 8 1/2 inch rotor with a Wilwood caliper on it and it will fit insde of a 10'' Weld wheel (beadlocks too) .. This should stop on a dime..! okay a quarter..LOL
Next weekend is 4 days off....Yippee..!
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Last edited by Dqracer; 08-25-2008 at 09:10 AM.
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  #14  
Old 08-25-2008, 11:56 AM
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Nice work!
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Old 09-01-2008, 01:59 AM
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Smile

Put a few hours in this week on the kart. I coulda used my buddies mill to machine the front axle forthe king pin bosses , but ,I figured I'd do it without the mill , just to show it can be done accurately with simple hand tools ...LOL , I setup the axle on my welding table at the angle it would be in the car,(20 degs) then useing the JD2 notcher and an angle finder (machinist grade) I set it at 6 degs Caster and 10 degs for the spindle, bored the holes
.875 . worked like a charm.

With the axle back in place and tacked to the frame rails , I built the lower X brace, I luv coping these tubes at the intersect,,(NOT),, to many trips to the freakin' grinder , but they fit perfect..LOL

Next, I set the engine up there just for fun and measurements.
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Old 09-01-2008, 02:20 AM
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I luv it when the wife leaves ya be , and you can disappear to the shop. I made a pattern for the rear axle bearing mounting plates, the axle bearings are mounted in double shear beween the plates, I used a spare axle to position them on the rear of the frame squared , leveled and tacked in place.
Next, I started bending the main roll cage hoops, ( manual bender) then tacked them in place, Yeah ,, BT-Pro..
I have been tacking everything in place with the Mig, just cause it fast, once its all together I'll Tig the entire chassis.
Startin' to look like somethin'...the wife wants to know what I'm gonna do with it...
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Old 09-01-2008, 05:54 AM
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looking good
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Old 09-01-2008, 09:48 AM
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Bent up the front braces for the axle and cage hoops, then added the side bars, and rear hoop around the engine, next was the shoulder bar and hoops behind drivers head, of course I was dying to go for a ride so I jumped in to see what the view was like from the drivers seat....
I mocked up the axle I will be using and brake disc to figure out the rear motor mount support and caliper mount point. Startin' to get some characater to it.... Now, we are into the engineering and fab of the control systems for this beast. I like this part of a build... my goal is to keep everything as simple as I can,, regardless of the confines of the configuration.
I'm thinkin this is gonna be a fun vehicle to practice Driftin' with....
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Old 09-01-2008, 11:16 AM
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Couple more pics. Next we'll fab up the aluminum seat, then figure out the ergonomically correct placement of the controls , : steering wheel , shifter , pedals, gauge & swich console. It will have a dual master cyclinder w/ a balance bar in the pedal for adjustable brake bias. The steering wheel has a quick disconnect hub, also it will have rack and pinion steering. I'd really like to fab up an aluminum fuel tank , but ,I'll be useing Alcohol, (for the motor..LOL ) and the 2 don't like each other very much. Anyone know of a coating that I can treat the inside of the tank that is alcohol compatible...?
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Old 09-01-2008, 12:32 PM
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This is a cool build, keep up the great work!
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