Dans Chariot #9 - Tying up loose ends.

I've been chipping away here and there over the last couple of weeks, so here's an update.

Made the inner fender covers. They're a bit bigger so we can be sure that Dan can't get his fingers caught in the wheel.







Got it all fit up to the rest of the fender just to see how it was all going to work.





Getting the holes for the axle to align was a bit of a challenge...

Bought some thing plastic sheet off of ebay to extend the outside and top of the fenders. Cut it out and bent it up.



Removed the outer cover to punch a few more holes in the back,



and put it all together.







Back to some more framework- finishing up a few of the modifications. Cut a couple of chunks out of a lawnmower handlebar, welded them together, cut 'em down, and tacked them into place. This is the bar that their basket will mount to so they can carry misc. junk.



I've been going back and forth about how to do this next part for at least a month. It's go time. I decided to just use a standard bicycle head tube and handlebars for a couple of reasons- 1st, its pretty much built, and 2nd, it's very easy to adjust or change styles of handle bars. Simple is nice. Now the chariot can double as an ultra cool stroller!







Still have lots of cleanup to do, but you get the idea.

Even managed to start on the fender mounting brackets.





Once I get the axle in, I can match the holes I made in the fender, drill the brackets, bolt the fender on, and figure out where the upper bracket needs to go.

Getting closer... My list is getting shorter.

Dan's Chariot #8 - Almost ready for a Maiden Voyage!

Man, this artsy fartsy crap sure tears up the time... Made some patterns for the leg pan sides.



Traced 'em on, cut 'em out, and made some edges. Really getting to love the edge forming machine- Being able to roll hems onto curves is great.



It'll sit something like this.



Made the other side too, and here it is sorta sitting in place.



Still need to put a hole in them for bungee cord attachment and I'll do some "racing stripes" like I did on the fenders.

Leg tie down hole and some decorations / stiffener added to the side pieces.



Think it blends with the fender pretty well. Hope I got the lines straight so everything matches!

A trip to the store for longer rivets, and lotsa holes later, its "done".



Going to sit something like this. I like it!



Drilled a few more holes and bolted it down.



Also picked up a few of these bushings at the hardware store and a bunch of nyloc nuts. Re-installed all of the seat belt hangers like this.



Put the seat, axle, wheels, and fenders back on to get an idea of how its shaping up.







I give it 2 thumbs up!



Obviously, it's a little short for me...

The fenders are just sitting there loose. Still trying to decide on the best way to extend them back just a bit more to be totally safe. Have an idea just having a hard time finding the material I want to make it out of. Soon as I get the new axle threaded for the nuts, I'm going to hook it up to a bike and see how it pulls. Maybe strap 3 or 4 50 lb bags of flour to it and see if I can break anything.

Getting closer! We even get a couple days off next week so hopefully more to follow soon. 

Dan's Chariot #7 - Modifications.

Started on some of the modifications. Took it all apart, took some measurements, and hacked the tongue off:



Took a big chunk out of the middle and tightened up the bend.



I will have to straighten the back end of it just a bit, but the theory is the tongue will plug into the trailer "stinger" style, but 90 degrees to the direction of travel, sorta like this:



Although it will be much shorter and have several gussets. Couldn't find a really tight fit for the square, so the tongue will have a gusset / spacer plate on the top and front where it plugs into the trailer to get a good fit. Holes drilled / pins installed so the tongue can be unplugged and eventually a castor wheel of some sort plugged in so they can use it as a stroller. We'll see where it goes from here!

FINALLY got my wife to stay home from school long enough that I could dedicate some time on this project. Crazy first year teachers... She gets home after 8:00 on average.

Cut the receiver down, drilled some holes, and cut some gussets out.



Start welding!



Tongue installed.



Made it a BUNCH shorter. Hope the curve is big enough to clear the tire!



Set it across two tables, and bounced my wussy 175 lbs up and down pretty good at the joint- it flexes a teensy through the tongue, but the receiver and back half of the trailer is RIGID.



While I was doing some welding, I cut the plastic sheet out and got it warming up to do some bending.







In between all of that, I made a few more brackets.







Whew. Makin progress. 

Boxed in the back of the tongue for some extra strength(?).



Stuck it back together...



The frame as it sits so far.



And with the seat and leg pan kinda sitting in place.



Plan on making some aluminum sides for the leg pan to match the fenders.

Left to do... Hmm. Finish the fenders, make some extensions out the back for them, sides for the leg pan, bolt it on, thread the new axle, get all the misc nuts and bolts I need for the seat belts, TEST IT OUT! and then paint. I think. Probably missing 3 or 4 steps still.

Well, now you're all caught up.  RREEALLLY need to get this thing done.  Lego League is going already, so that eats into a big chunk of my time and it seems like all the "extras" I get to participate in this year just because I'm a teacher are adding up quick.  It WILL be done.  Shall I make a goal? 

End of October.  Or else.