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    Re: 1/2 Scale Crawler in the UK
    #41
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    This is the part where I make seats for the third time. First 2 attempts were consigned to the history books, I liked the look of the Kirkey aluminium race seats so I had a mooch around the internet and found a plan for a teeny weeny seat for a RC car.


    I liked that style and found the sizes for a kids seat.



    I changed the design to suit my buggy and the size of my kids and transferred it to sheet aluminium



    I cut them out, folded and welded them.
    The 4 cut outs on the back are harness holes. 2 at the bottom for my son, and 2 top one's for my daughter. I plan on running 4 point harnesses.



    I considered running 8mm round bar round the edges as a safe edge but I ended up using rubber edging trim. The seats are stiff enough anyway.

    I cut some 6mm ply and used some foam and black vinyl to make little pads


    I finished off the seat with more flared holes to add a little more rigidity, save a few grams and to match the floor pans



    The drivers seat is on a adjustable seat runner from a Mazda MX5 (Miata). I cut it in half and it has about 5" of adjustment.



    I still haven't mounted the passenger seat yet but all the lover mounts are in place ready.

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    Re: 1/2 Scale Crawler in the UK
    #42
    Member
    Join Date
    Dec 2014
    Location
    Detroit, MI
    Posts
    93
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    Great idea for the different size riders! How are you going to secure the unused belts when driving?
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    Re: 1/2 Scale Crawler in the UK
    #43
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    I'm probably going to use a quick release at the back of the upper harness so it can be rethreaded through quite quickly. It's not going to be a fast buggy, but it should have enough torque so it will be able to get upside down pretty quickly. I'm gonna think about arm restraints or a side net. I'm horrified just thinking if a little arm came out during a roll.

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    Re: 1/2 Scale Crawler in the UK
    #44
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    Steering. I was given a broken RZR rack. The end had been broken off, no big deal as I could afford to lose a little. So I cleaned up the ends and I shortened the outer rack on the mill



    I turned some phosphor bronze for the ends


    And pressed them into the main body


    I clamped up the Inner rack to a vee block and TIG welded back together




    Finished article



    This is where I was going to mount it. Clue... it's not there now.

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    Re: 1/2 Scale Crawler in the UK
    #45
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    So these are pretty much the last photos I had from my old job. I moved house and job just after these were taken and didn't really get a chance to touch the buggy for about 2 years as I spent a lot of time overseas. Jack was about 4 in this pic

    I got land rover style letters for the front, and make a little grille


    I made aluminium side boards but I'm probably not going to use them.
    I also folded up a dash from sheet.


    I got some little LED light from eBay



    I made a dolly for pushing it around the workshop as I broke a rose joint dragging it around.


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    Re: 1/2 Scale Crawler in the UK
    #46
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    I made a trailer to haul the buggy to my new house.


    In the garage.



    Beth in the seat. She's about 10 here.



    Beth helped me take the buggy apart to add a little paint






    It was really frustrating as all I wanted to do was get on with all the fab work I needed to do but I couldn't get on the tools.

    I managed to find a place to put it at my new workplace and do a little work on it but not nearly enough time to spend on it.

    I managed to do a little work on the trailer



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    Re: 1/2 Scale Crawler in the UK
    #47
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    So I started building the Buggy in 2014 and I moved in May 2016. So I got to pretty much a roller in those 2 years working on it part time.

    Fast forward another 2 years and I'm now finding myself with a little bit more time at least until Oct when I'll be out of the country again for around 8 months, so I'm trying to get as much done before then.

    After chatting with a colleague about the troubles I'd been having with the steering, he suggested using cables, like a car gear selector or an outboard motor on a boat. I thought it had merit so I pushed on with it. Using 2 cables working in opposition in the front and the same for the rear.

    I put my thinking cap on and cracked on with designing a way to control the cables using the rzr rack.



    These cable clamps are for the ends of the rack.



    The rack has a mount for the outer cables in the centre using existing holes.





    Fitted with the cables for the front



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    Re: 1/2 Scale Crawler in the UK
    #48
    Keeper of the Asylum K-fab's Avatar
    Join Date
    Jun 2006
    Location
    Scottsdale, AZ. 10.9 miles from the trailheads
    Posts
    9,855
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    The innovation you’ve put into your buggy is wonderful.
    I’m enjoying the build. - picture heavy posts are always fun.
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    Re: 1/2 Scale Crawler in the UK
    #49
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    Thank you for the words Richard, it does mean a lot. I've had a good few days on the buggy this week and I've got a fair bit done, well I've been busy, but as you well know, looking back, there's are only a couple of jobs ticked off!

    I set about doing some of the little niggling jobs.

    I made some misalignment spacers for the Inner tie rods front and rear.


    I also made some spacers to stand the cable ends off the linear rack.



    So that was a few hours on the lathe.

    They are fitted to the rear rack here but the front one is done also.



    I had to rethink the outer cable mount for the rear as there is a little less room in the back.

    I cut some angle steel down to mount to the top of the linear bearing mount



    I put a M5 thread insert in and you can see how the cables attach to the rack with the new spacers here.



    I used some solid bar and drill through 3mm for the Inner cable to fit through and countersunk for the outer cable to sit inside. This was then welded to the steel mount



    Here the rear rack is fitted and it's a self contained unit.




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    Re: 1/2 Scale Crawler in the UK
    #50
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    I ordered some little red LED lights for the rear from eBay. I wasn't sure how I would go about mounting them in the rear, but I decided to roll some Ali sheet up an follow the curve of the cage at the back

    Clamped it into place ready for riveting



    To be honest the lights were a little smaller than I'd expected but I can live with it!!



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