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Title: The Weekend Warrior Chonicles
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jerm1386
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(Date Posted:03/07/2010 9:36 PM)
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This weekend I officially began construction on Weekend Warrior, my new-for-2010 kart.  It has been in planning since about christmas time and I got some minor work done early last week, but this weekend I have laid almost the entire frame since the bad weather finally went away and we got a couple days of sun!  With any luck it will be ready in 1 week for the inaugural race of 2010.  won't be 100% complete for sure, but it might roll, steer, and stop.

reasons for building this kart:
  I dislike almost everything about punishing one except its speed and steering mechanism.  it's too big, too heavy, kinda ugly, the build quality is iffy, it has been revised and patched too much, due to the weight I dont like the way it handles, and there's rust everywhere.  it's fast and I built it, but I have no love for it.

This new kart is already better built, prettier, (so far) rust free, lighter-weight, and smaller.  time will tell how it handles, but I doubt it will have punishing ones speed

This kart's flickr set can be found HERE

here's the handmade, one-piece, sheet-metal seat with silicone covering the sharp pats: seams and rivets


and the frame as of this evening


it's built mostly with EMT conduit.  not terribly strong, but lightweight (and dirt cheap!).  so there's plenty of triangulation to strengthen it  I estimate the frame in this picture is somewhere around 30-40lb.

the steering shaft is held in place by pillow-block bearings with set screws.  the quick-release knuckle will be very close to the upper bearing, and the cockpit will be small, so there's is no possibility of the shaft escaping during a race.


still left for this week:  suspension, brakes, and steering.  in the future, it will have body work and lights.
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Numbersix
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Re:The Weekend Warrior Chonicles
(Date Posted:03/08/2010 7:17 AM)

 Wow, Jeremy.  You're really going to town on this one.  Looks like you used black pipe to build your roll bar and down tubes.  Good.  A bit stronger then EMT conduit.  I can see the Carterham 7 body starting to take shape in the layout too.  Hope this one works well for you.
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jerm1386
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Re:The Weekend Warrior Chonicles
(Date Posted:03/08/2010 8:01 AM)

 Thanks!  This kart doesn't even roll yet and I like it better than punishing one.  Putting a lot more care and consideration into the build, too, like double-checking the welds, grinding down extraneous weld material, cleaning the weld surfaces, etc.  The roll bar, down tubes, and one lateral tube are all that thicker-wall pipe so the cockpit should hold up pretty well unless I decide to play chicken with a greyhound.

you should try to come down this weekend for our first race, and if you wanted to come down Saturday night, you wouldn't have to worry about a place to stay!
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drscope
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RE:The Weekend Warrior Chonicles
(Date Posted:03/08/2010 9:51 AM)

NumberSix, we may even have a loaner car for you to drive!

At this point, it looks like White Lightning and Blue By You are taken, but the DW1386X is very close to being ready to roll.  A couple more hours is all it needs and maybe by tomorrow night it will be ready to go on the trailer.

Also if Jeremy gets enough done this week, I'm sure he'll be running Weekend Warrior, so that means Punishing One may also be open for the rest of us to fight over!
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Numbersix
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Re:The Weekend Warrior Chonicles
(Date Posted:03/08/2010 10:53 AM)

 Jeremy, Fran,

   Thanks.  your offer is most generous, but I have a ton of things to catch up on here and one of them is getting the kart out (no that the snow has melted) and getting to work on it.  As for the fellow that offered to do welding on it, I need to get together with him this week and show him what needs to be done.  Whether he has time to do it remains to be seen.  As for him starting up a group here, he's actually talked about moving out of state now due to uncontrolled taxes and levees on just about everything.  So I'm pretty sure he won't be into doing a project like this right now for himself.  I just hope he has the time to do a little welding for me. 
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RE:The Weekend Warrior Chonicles
(Date Posted:03/08/2010 7:23 PM)

Well, you could always throw your stuff in the car and head down here Saturday morning or Friday night!  It's not THAT far!

We'll be doing a big work day on saturday, so we can not only get your car all welded up, but we can have it ready to go for Sunday morning!

Lets be honest, if you stay home, you ARN'T going to get anything done anyway!

As for your buddy moving out because of taxes, where is he going to go?  The problem is EVERYWHERE now.  There is no place to go to escape the tax man any more.  And with the federal budget in the mess it's in, things will only get worse everywhere.

So he might as well build a soap box car and forget about his troubles for a while as he rolls down hill in more ways then one!
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jerm1386
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RE:The Weekend Warrior Chonicles
(Date Posted:03/18/2010 7:07 AM)

alright, i put in a LOT of work to this kart the week before the race, but due to time and poor weather, i didn't take many pictures until last night, which is a real shame because I can't show the entire proces sstep-by step.  Maybe once I take everything apart to re-grind and paint the frame I can get some better pictures.

the next thing I had to do after getting the base frame together was to add the suspension mounts.  here you can see the frame extensions on the rear where the suspension arms will mount.  rather than A-arms, they ended up being more like T-arms


and here's the steering wheel.  one good weld, one crappy weld.  it's mounted ona  quick-release knuckle because my karts are always cramped and hard to get into/out of, and removing the wheel helps somewhat.  eventually the bottom excess of the bars were cut away so as to pose less danger to my legs


then the a-arms were done up and mounted to the kart.  the spindles had not yet been made and were just the kingpin.


all the mounting tubes were connected and the seat was permanently attached (slightly off-center)


the spindles were made, then the brakes and wheels were attached.  for the first race the suspensionw as fixed in place due to issues with excessive bump steer and incomplete shock mounts

(rear)

(front)

then the brake cables were run to the rear drums.  for this first race I didn't hook up the front drums


finally, seat belts were mounted!  these look very nice and they're much more manageable than the three-inch belts i have in punishing one


the rear belts have a tendency to slide around, off my shoulders so I'll have to weld some tabs onto the rear bar to limit their movement

after all that, I was finished!  well, finished enough to get it rolling for a race.  it's not fast, it has very poor brakes, no suspension, a fairly twistable frame (if you stand on the front, someone else can easily lift one of the rear wheels off the ground while the other stays put), and no bodywork.  this all will change except perhaps the twistable frame.  there's not much I can think of to remedy that since I occupy most of the internal space


here's a shot of it next to punishing one, my old kart.  this one is shorter, skinnier, lighter, better designed, and overall much better-looking


and one last glamour shot


As always the entire set (with more photos) is up on flickr



(Message edited by jerm1386 On 05/27/2010 4:58 PM)
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RE:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 9:57 AM)

suspension has been put into place and new brake pads have been reground and attached.  the brakes do rub right now but once they're burned in it should be much better.  but best of all, the kart actually stops when I apply the brakes, and the brakes disengage by themselves rather than becoming locked on.

here is a video of the suspension tests.  follow the link below the video if you want to see it in HD

Suspension tests from Jeremy Ashinghurst on Vimeo.

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markWoody
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RE:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 10:52 AM)

Looking Good !
Are you going to add bodywork ?
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Re:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 10:55 AM)

 eventually, yes.  but that's after I get the brakes and suspension fully worked out.  so maybe in time for the may race I'll have something, but not for next week
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RE:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 11:10 AM)

Why not?  We have 1 more Saturday to work on it!  How bad could it be to build a body and do the rest of the things we need to do for the next race?
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jerm1386
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Re:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 11:16 AM)

haha, because I'm pacing myself and trying not to rush. remember?

to be honest, there's not a lot left to do structurally before a body is the next step (just attaching front brakes and reworking the steering system).  but I want to give it a while to set in and see how I like it first so I can change things if I need to.  But part of me really cant wait to have the body on it!

on a related note, do you have any shim stock?  that would help get some of the play out of my A-arms.
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RE:The Weekend Warrior Chonicles
(Date Posted:04/04/2010 5:24 PM)

alright so here's a small update from what went on this Saturday.

it's been a couple weeks since I touched the kart, so really all I was expecting was to get the new brake shoes on but instead i got the rear suspension, too, plus the camera mounts and i started to put in hardware for the front brakes.  the cables haven't been run yet, though, but they'll be done for the april race.

I also corrected the rear bump steer issue.  I moved the spindle-side alignment rod end further up, putting it in the same plane as the upper a-arm.  This way the alignment arm and the A-arm swing in the exact same arc as the suspension moves up and down, meaning they don't move relative to each other and therefore do not change alignment  at bump or droop.

Sorry, I don't have any good up-close pictures of the rear going together, but here's a shot of the rear when it was all finished.  it rides about a half inch higher now when I'm in the kart than it did before suspension, which I think is right around where it should.  this way there's room for the arms to swing up an down to absorb a good sized bump before bottoming out


the rear shocks are at a different angle than the fronts.  since they're pointed straight up, they absorb the force more directly and therefore have smaller compression with the same force.  since there is more weight on the rear and I don't have two types of springs, I just used two different geometries.
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RE:The Weekend Warrior Chonicles
(Date Posted:04/05/2010 2:49 PM)

my mind is trying hard to compliment and make fun of you all at the same time and we're just not coming up with anything...

nice work man..

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RE:The Weekend Warrior Chonicles
(Date Posted:04/05/2010 2:51 PM)

look at the last pic...


hahaha

fran in the garden with that "garden weasle looking" tool...

Get your bulbs in yet?,buddy??? 



(Message edited by uo69 On 04/05/2010 2:52 PM)
drscope
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RE:The Weekend Warrior Chonicles
(Date Posted:04/05/2010 7:13 PM)

Well actually, we did a real nice garden out front where the 150 year old english boxwood bushes got creamed by the snow.

And the vegetable garden is just waiting for tomatoe plants - it's all ready to go!

If I can just get some of the junk out of here and to the dump, maybe the place wouldn't be such a big eyesore!


Back on topic, I'm really impressed with how well he did with this thing!  And since the test run Saturday evening, I'm starting to get worried he's done gone an built another darn fast ride!
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jerm1386
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Update with pictures!
(Date Posted:04/08/2010 6:06 AM)

ok, looks like i missed an update there when I was first putting in the front suspension springs and other stuffs.

so this photo update will encompass front and rear suspension pictures, seat belt guides, and hooking up the front brakes.


mocking up the front of the kart for full droop shock placement (those are super-precision boards underneath)


the front suspension in place (where it will remain for now)


During the first race, my shoulder belts were having trouble staying on my shoulders.  Drscope suggested I make little brackets to hold them in place

since installing those, I haven't had any belt trouble on my test runs

the left rear corner.  you can see the vertical strut attached to the rollbar, and the toe-adjustment drag link has now been realigned so it's in the plane of the upper A-arm and therefore will have no bump steer


the brake pedal will all 4 brake lines going to it.  this will have to be changed eventually because the lines aren't feeding into the guides straight and there will be slightly unequal pull due to the fact that they're all at different angles


Routing the cable so they don't get caught on anything like me or the ground.  even used zip ties of my accent color: red


up for today is gussets on the lower a-arms, painting the brake drums red, and grinding down the past month's worth of welds so it looks a little less hackish
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jerm1386
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RE:The Weekend Warrior Chonicles
(Date Posted:04/09/2010 6:20 AM)

well drscope was sick today so in lieu of using lots of power tools, I just opted to paint the drums and call it a day.  I'll get the rest of the work done on the work day this saturday


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Numbersix
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RE:The Weekend Warrior Chonicles
(Date Posted:04/09/2010 7:05 AM)

Jerm,

 
(those are super-precision boards underneath)


Wow, those babies must of set you back a few bucks.   On the more serious side, your racer is looking great and the work is very impressive.  I think you should submit a resume to Chrysler Corp. and help them get back in the game.  (Boy, can you tell I'm a Mopar buff?)

Can't wait to see the body work.  You're still thinking Carterham 7, right?  Also, do you still plan to move the steering column up to give your legs a little more room?  I had some big plans for my kart body wise.  Sadly, "best laid plans" don't always work out.

I was hoping to do a late 50's early 60's sprint car racer design.  Unfortunately the go kart frame lay out doesn't lend itself to that design.  So I'll just try something else.  The guy who said he'd do the welding is suppose to call me soon, or so he says.  I'll give him to the end of the month, then I'm going to have to fend for myself.

I've cut away the things unnecessary to the build, as mentioned before, but not throwing anything out for possible future use.  Keep up the great work.

Sincerely,
Number Six
   
   
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jerm1386
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Re:The Weekend Warrior Chonicles
(Date Posted:04/09/2010 7:37 AM)

Yes, I am definitely still thinking caterham 7

The steering shaft itself will stay where it is, but I'm thinking about moving the larger rear support (closest to me) back a couple inches to make it easier for me to get in and out.  We'll see.  it'll have to be a choice made after I put a floor in but before I do the rest of the bodywork a dding the floor might just make it a little too small to get in and out easily.

you should definitely start taking pictures and keeping a build log here on the forum.  you could even take pictures or scans of your plans or drawings
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Numbersix
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Re:The Weekend Warrior Chonicles
(Date Posted:04/09/2010 6:19 PM)

 you should definitely start taking pictures and keeping a build log here on the forum.  you could even take pictures or scans of your plans or drawings.

10-4.  I'll see hat I can do here in the next day or two.
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jerm1386
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RE:The Weekend Warrior Chonicles
(Date Posted:04/19/2010 12:15 PM)

alright, now that the basics of the kart have been proven out, it's time to really get to work on this thing.  the suspension works, the frame is solid, the brakes stop the kart.  It's pretty lightweight how it is, but I still have to put on a body (Front fenders, nose cone, main body, rear fenders, trunk area, windshield, "exhaust pipe" running board), an that will add several pounds to the kart (10 alone for the paneling, and that's .025" aluminum sheet). 

My first task before the may race is to drop the weight of the kart by 5-10lb so that the apparent weight will be the same once I put the body on.

in order to accomplish this, I will be removing, cutting down, drilling, or replacing material wherever I can in order to save weight.  the two biggest tasks are to remake the spindles and the lower A-arms.  In addition to being heavy, both the arms and the spindles weren't made according to my drawings, so I'm redoing them the right way this time.  Also, the seat is getting remade.  in going from galvanized steel sheet to aluminum sheet of the same thickness, I've brought the seat's weight down 3 pounds! (from ~4.5 to ~1.25).  Of course the new seat is also getting upholstered so that'll push its weight back up, but still: what a difference the material makes!

the seat in the kart


here's the kart naked again.  just the frame, brake pedal, and steering shaft


in that photo, I'm in the process of cutting off all extraneous tube corners.  this includes all the suspension mount points on the frame, the seat mount points, and the brake pedal point.  rather than being square now, they're all rounded

in the future I will be cutting up some end caps to go on the open holes.  once the frame is finished and powder-coated, it should be  a fairly clean look.

However, i spent most of the weekend in the basement of drscope's house, machining pieces for my new spindles and lower A arms.

this is a very very time-consuming process, but the reward is batter-looking, more precise parts.

by the may race all the vital systems should be 100% functionally complete with no major modifications planned,  the main body should be on, and painting will have begun.  by the june race it should be all complete except, possibly, the lighting system
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RE:The Weekend Warrior Chonicles
(Date Posted:04/19/2010 7:25 PM)

Jerm,

    I am humbled.

Number Six
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Re:The Weekend Warrior Chonicles
(Date Posted:04/19/2010 8:14 PM)

 I wouldn't say that so soon.  Just remember this log could also be titled "weekend warrior: Or how I learned to stop worrying and give up a normal life"

of course, in order to build all this, I had to have a plan and I had to know what I wanted, and bewteen planning and building I'm estimating I've put somewhere around 100 hours into this project (i work slowly).  Hopefully you get what you want sometime soon, too!


(Message edited by jerm1386 On 04/20/2010 4:04 AM)
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RE:The Weekend Warrior Chonicles
(Date Posted:04/23/2010 6:48 AM)

life and a rainy day have delayed me a bit.  I was hoping to ahve the new spindles and A-arms made by now, but I'm only aprt way there.  teh A-arms are made, and I upholstered my seat but the spindles are still only halfway complete.

here's the seat being upholstered in black and red vinyl.  if anyone wants to use this material, i have PLENTY left (enough to do another half dozn seats of this size).  Maybe I can have a decent interior . . .

it looks a little medieval right now with all the rivets.  hopefully I can paint them later to match

here's 1 each of the old arms (front+rear) and the new arms, prior to adding shock mounts


and here they are complete and painted

yes, that's the very first part of my kart to get painted.  gotta start somewhere . . .



(Message edited by jerm1386 On 05/27/2010 5:00 PM)
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Numbersix
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RE:The Weekend Warrior Chonicles
(Date Posted:04/23/2010 3:57 PM)

Jerm,

    Looking good.  And leave the rivets alone, I like that medieval look.

Number Six  
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Re:The Weekend Warrior Chonicles
(Date Posted:04/28/2010 8:17 PM)

I agree with #6 - those rivets look pretty sweet.  And you're almost as obsessive about adding lightness as the guys who built the NSX. At the end of it's production run they were doing things like replacing the shift boot with a mesh one... to save 20 grams.
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RE:The Weekend Warrior Chonicles
(Date Posted:04/28/2010 9:57 PM)

Well, you guys refer to The Jerms new car as a Caterham look alike ONLY because you arn't old enough to know it's really a Lotus 7 look alike!


And when it came to lightness, Colin Chapman - the head man and founder at Lotus, was very good at adding lightness to his cars.

So good infact, that many parts often failed and many drivers were killed as a result.

So it's only fitting that because of The Jerm's obsession with lightness, that this car be referred to as a Lotus Look alike and NOT a Chaterham!
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Mother Nature is a Mean, Evil Bitch

Numbersix
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Rank:none
Score:161
Posts:161
From: USA
Registered:10/16/2009
Time spent: 5105 hours

RE:The Weekend Warrior Chonicles
(Date Posted:04/29/2010 4:54 AM)

I beg your pardon, "not old enough"?  I remember the super 7.  In fact it was a super 7 that McGoohan drove in the Prisoner.  However, I was not aware that Chapman was producing a car that was so light it was unsafe.  That's disturbing.  I'm sure that won't be the case with Jerm's racer.
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I am not a number. I am a FREE MAN!

jerm1386
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Rank:none
Score:1223
Posts:1223
From: USA
Registered:02/12/2009
Time spent: 33923 hours

Re:The Weekend Warrior Chonicles
(Date Posted:04/29/2010 6:17 AM)

 we'll see.  we've never built a kart out of conduit before and while this one is pretty well triangulated, we don't know how well it'll hold up in a crash.

chapman's motivation and mine are completely different though.  in THIS sport, being lighter doesn't make you faster in the long haul.  I just want it to be portable
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Photos: Weekend Warrior
MISFITS Karts : MISFITS Races : MISFITS Events

jerm1386
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Rank:none
Score:1223
Posts:1223
From: USA
Registered:02/12/2009
Time spent: 33923 hours

RE:The Weekend Warrior Chonicles
(Date Posted:05/27/2010 6:06 PM)

did a little bit of work yesterday.  when i put the spring mounting bolts for the rear suspension on the frame they were a bit too low and not level, meaning the kart sat too high and . . . not level.  This has been remedied.


also, the new seat is in, fully upholstered.  I'll get a good shot of it soon.

here's some of my interim steering system.  bump steer has been all but eliminated!



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Photos: Weekend Warrior
MISFITS Karts : MISFITS Races : MISFITS Events

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