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GSI
05-13-2016, 02:51 AM
I've wanted a single seat rail buggy with a motorcycle drive train for years. Something like a honda pilot on steroids. We ran across the plans for building AR51 buggies. My brother in law, Jason, decided he wanted to build one as well so he purchased the plans. I managed to buy a complete CBR900 as a donor for my buggy. It's late enough to be a fuel injected bike. It should move along a 900lb buggy plenty. Jason managed to find a ZX1000 engine.

After we got the plans in hand, we started cutting out parts on my CNC plasma table. Nesting parts together like this lets you minimize the wasted plate. There's a lot of weigh reducing holes in these parts.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20150926_173345_zpswu0vnq49.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20150926_173345_zpswu0vnq49.jpg.html)

Here's some more parts cut out. These are for the rear suspension upright. I apparently neglected to take a picture of them completed. I'll go dig them out and take a picture shortly. We kinda did some of this stuff out of order because we already had material on hand. It took a while to get 1.25 14ga tubing.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20150926_140723_zps9cev1dlr.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20150926_140723_zps9cev1dlr.jpg.html)

I do have a close up of welding them up. We used some all thread through the holes to make sure they lined up and keep the sides far enough apart.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20150927_001514_zpsnmqrjw1y.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20150927_001514_zpsnmqrjw1y.jpg.html)

GSI
05-13-2016, 03:06 AM
We cleaned the slag off of all those parts. It was a time consuming pain. This made me start looking for a better way.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20150927_145002_zpsaogy2a2l.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20150927_145002_zpsaogy2a2l.jpg.html)

The next thing we started working on was building the front spindles. Apparently I take to many close up pictures and not some of the whole part. We turned down the back of the spindle pins in the lathe. These are a standard off the shelf spindle. Probably made for a trailer or something along those lines.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20151218_213400_zpsauy014qb.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20151218_213400_zpsauy014qb.jpg.html)

I managed to cut out the sprockets on the plasma table. I think they will work just fine but I don't have any of the right chain laying around.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160217_171159_zpsih7nt3x3.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160217_171159_zpsih7nt3x3.jpg.html)

Sometimes its kind hard to get the plasma dialed in. I think I got this pretty good. It's 5/16 a-36 plate.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160217_171208_zpszrlf0vqq.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160217_171208_zpszrlf0vqq.jpg.html)

GSI
05-13-2016, 03:15 AM
We have been making a bunch of the parts such as the pedals but I'm bad about not taking pictures. I'm going to try to remember to take them while I'm working on this buggy project. We have spent hours cutting tubing on the bandsaw for these. Building two of them at the same time seems to help as you just make twice as many parts on each setup. Two definitely aren't taking twice the amount of time vs building just one. We finally got the tubing in the other day that was holding us up from putting the floor of the frame together. We laid it out on my welding table. This table makes it really easy to get things nice and square.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160508_095356_zps0xv5cxmi.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160508_095356_zps0xv5cxmi.jpg.html)

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160508_095410_zpsb4lwcy7j.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160508_095410_zpsb4lwcy7j.jpg.html)

CARLRIDDLE
05-13-2016, 10:15 AM
Great start!! No such thing as too close on pics, but agree some showing whole part are good too.
Where in N Ala are you?, I'm in NW Ga, Rome.

GSI
05-13-2016, 12:15 PM
I'm just east of Huntsville. I've been to Rome multiple times. We usually go through there headed to Atlanta.

mrniceguy
05-13-2016, 02:39 PM
Looking good. Interested to see how the sprockets go.

Wheels
05-15-2016, 03:03 AM
Damn... That table is sweet! And keep the pics coming.

GSI
05-17-2016, 01:08 AM
I think I can keep the pics coming. Now if I could just get more time to work on it.

Here's the rear suspension upright. It uses a dodge intrepid front hub bolted to it for a wheel bearing.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160513_113856_zpstz1uetwk.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160513_113856_zpstz1uetwk.jpg.html)

Here's one showing the whole front spindle.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160513_113736_zps8oue01qf.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160513_113736_zps8oue01qf.jpg.html)

We did the actual welding and final fit up the other day. We had previously been using the table to fit the tubes. We clamped it all over the place then tack welded it all together. We put all these stops on the table so we could easily and quickly line up the second frame. Jason commented that this is where this table really shines. It took us about 15 minutes to put the second one together. Most of that was me dressing the ends of some of the tubes to make them fit tightly.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160513_234421_zps5mqu2qep.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160513_234421_zps5mqu2qep.jpg.html)

I almost ran out of clamps. There's only one more on the end of the table where I have been keeping them. I'll be getting some more shortly. I also used all the ball lock bolts that hold stuff down to the table.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160513_234437_zpsoizlvmie.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160513_234437_zpsoizlvmie.jpg.html)

I'm excited to see these. Up to this point all we have been doing is making parts and pieces. This actually is beginning to look like something.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160514_001704_zps9uab5d8w.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160514_001704_zps9uab5d8w.jpg.html)

SuzukiSteve
05-17-2016, 02:28 AM
Looking Good. I wonder if you could tumble those parts in one of those small cement mixers to get the slag off.

GSI
05-17-2016, 11:01 AM
I have one of those cement mixers and have thought about trying it. I probably should buy some media and give it a go with some parts. I was kinda afraid it would dent up the parts pretty bad as some will end up hung on the paddle and end up falling.

SuzukiSteve
05-17-2016, 03:17 PM
I suppose it might on really thin parts but, if you get it sand blasted before paint it would probably clean all the little dings up.

GSI
06-06-2016, 01:32 PM
I may have to try that at some point.

Jason and I got some time to work on the buggy Sunday afternoon. I've been extremely busy in the shop so things are probably going to progress slowly until things slow down. I can only work on this when I have room in the shop. As a result, we will probably do some things in a weird order. We want to make progress when we have the opportunity. I received an order of material this week that had some of the od sizes of tubing used to make these buggies. We decided to go ahead and turn out the rear bearing carriers. The spool will pass through this that holds the rear brake rotor and sprocket as well as hooks up to the cv joints. We cut the material to rough length with the bandsaw then threw it in the lathe to face the ends. This is 3" .188 wall DOM.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160605_115552_zps5gnfinsd.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160605_115552_zps5gnfinsd.jpg.html)

These were good for Jason to be involved in making. He's learning to use the lathe. We didn't take a bunch of pictures as we were kinda trying to concentrate on what we were doing. Doing this kind of work without a digital read out is pretty tedious. I really should outfit this lathe with a DRO. The end result was good. These should work fine.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160605_155014_zpstghom7yu.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160605_155014_zpstghom7yu.jpg.html)

That's all we had time to work on this round.

wjfawb0
06-16-2016, 05:54 PM
It's good to see more AR51s in the making. I took mine for a 5 mile spin around the block over the weekend to clean the injectors.

GSI
06-19-2016, 11:24 AM
I wish I had more time and money to devote to these. We'll get them finished. It just won't be in record time or anything. I noticed you're only about 2 hours from me. We'll have to give you an excuse to clean the injectors some more once we get these done. Ever ride at Prentice Cooper?

wjfawb0
06-19-2016, 01:38 PM
I've jeeped at Prentice Cooper a few times. The speed limit there is 25mph about everywhere if not less, so I haven't taken the buggy. I would if I had someone to ride around with. There's an track in north Georgia that would probably be fun too. I'd be cautious about mixing it up with dirt bikes, though. My buggy has heavier steel tube than the plans call for, so it's probably a good bit over 1000lbs. Rides like a cadillac over whoops.

GSI
06-20-2016, 11:32 AM
I forgot about the 25 mph speed limit. We have ridden dirt bikes there several times. Never seen the speed limit being enforced. I don't have any way to know speed on my dirt bike. I'd be up for some other places as well. We have a decent sized rally cross course close by. I'm definitely going to have to take it out there when I get it finished.

GSI
09-20-2016, 05:41 PM
We managed to make some more progress on this. We received all the material for the nose so we started off cutting tubing. After cutting everything, we had to drill 4 holes in 4 pieces of tubing. They need to line up pretty well because there are plates with weld nuts that get slid inside of the tubing to provide mounting points. Our Bridgeport is a great way to do this.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_105908_zpsqkzpdlzw.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_105908_zpsqkzpdlzw.jpg.html)

Once the pieces were drill and welded the inserts in, we used a square to lay them out. You can see the directions book in the background suggesting to o do it this way. It sure makes it way easy and quick.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_111640_zpsmgmyjcrb.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_111640_zpsmgmyjcrb.jpg.html)


Another sub assembly needed to be made before we could put the nose together. The jig table makes this pretty easy. We had to do several so we put the 90s on to make it easy to load a second set of tubing without having to do a bunch of centering again.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/IMG_0433_zpshoz90p4e.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/IMG_0433_zpshoz90p4e.jpg.html)

We put some tabs on them and called them done for now.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/IMG_0437_zpspfdtpg8x.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/IMG_0437_zpspfdtpg8x.jpg.html)

We cut out this alignment plate on our cnc plasma and bolted it to the inserts that we had welded in previously. This let us line up the sub assembly and the front lower control arm mount.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_152004_zpskb59julo.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_152004_zpskb59julo.jpg.html)

We rolled it up on it's front so we could put in the spacer tubes. It was close but not quite the correct dimensions we had to pull it in line.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_150228_zpsbbccbcjx.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_150228_zpsbbccbcjx.jpg.html)

We had to make one more sub assembly before we could put the nose together.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_174720_zpsqx1xfevz.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_174720_zpsqx1xfevz.jpg.html)

Here's one of the nose pieces with everything all tacked together.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/20160918_181933_zpsyc8qy8f8.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/20160918_181933_zpsyc8qy8f8.jpg.html)

Linden318
09-21-2016, 03:00 AM
Beautiful work. I really like the jig(s) you have set up there. Makes the process go so much smoother when everything is lined up and square!


Sent from my iPhone using Tapatalk

RickS.
09-23-2016, 06:41 PM
Looking really great. Good to see two more coming together.

Rat4020
09-24-2016, 02:35 PM
Man I keep on lookin at yer frickin table SWEET oh and the ar progress is great also!!!

daaboots
09-26-2016, 07:17 PM
Now that's a welding table!

GSI
09-29-2016, 11:45 AM
That jig table is one of the best things I have ever bought shop wise. It makes things go quicker and it's much easier to be accurate with your parts. It's also great for doing multiples. It's really cutting down the layout time for building a second buggy. Now if I could just get more time to work on the buggy...

Rcn11thacr
04-07-2017, 01:27 PM
Any updates on this build?

GSI
04-21-2017, 02:58 AM
Not as much as I would like. I've had a lot of things that have taken up my time instead of working on my buggy project. We made all the bushings for the front and rear control arms the other day. We decided to give a try making them in our newly accquired VMC. Getting the VMC delivered, setup, and tooled up is only of the things that has taken up my buggy project time. It's also a steep learning curve to go from manual machinery to running a cnc mill.

We cut all the bar stock to length. We cut the piece a bit longer as to have enough to hold onto. The excess was to be machined off afterwards in the second operation.
http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0418172104_zps3j5h8vhg.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0418172104_zps3j5h8vhg.jpg.html)

Here's Jason, my BIL who is building the second buggy, running bushings in our VMC.
http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0418172251_Burst01_zpscvq1h816.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0418172251_Burst01_zpscvq1h816.jpg.html)

Two full sets of bushings done with the first operation.
http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0418172349_zpsi1bsjmnk.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0418172349_zpsi1bsjmnk.jpg.html)

On to the second operation. This was just facing the shoulder to length and chamfering the holes.
http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0419170902a_zpshpnaaihq.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0419170902a_zpshpnaaihq.jpg.html)

Here's the full sets all done with 5 spares.
http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0419170935b_zpsrfqdd36a.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0419170935b_zpsrfqdd36a.jpg.html)

Rcn11thacr
05-04-2017, 02:41 PM
Nice work!

K-fab
05-06-2017, 05:40 PM
It's also a steep learning curve to go from manual machinery to running a cnc mill.Enjoying G coding? Different world from just a DRO, eh?

Nice work! Perfect beginning VMC project too.

Bullnerd
05-06-2017, 08:32 PM
Yeah, nice machine and nice job on the bushings.

Delrin is a good material to practice on, its like wax.

What happened to that tool box? Fire sale?

GSI
05-07-2017, 01:35 PM
What DRO? My old bridgeport only has the dials. Yeah it's a big jump learning all the G code. The thing still scares me at times when it rapids somewhere and I think it's going to slam into the part, etc. I've got the rapids turned down to 100 IPM right now as I keep making one offs so I'm running a bunch of programs for the first time. At least at that speed I might actually get the E stop button before stuff starts flying around. It is awesome what you can do with one though. Bad thing is it makes me want to buy a CNC lathe and another VMC.

Delrin is awesome. I've used it before but not at this kinda quantity.

I really should paint that toolbox. It came out of the Saginaw steering plant that closed down due to bankruptcy. It's not scorched. The paint just sucks. I wish I could have gotten some more of them.

GSI
05-14-2017, 05:34 PM
We started off this round cutting some more tubing.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0427172006c_zpsibljzyli.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0427172006c_zpsibljzyli.jpg.html)

Sometimes things just don't go as planned.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0427172019_zpsgeenyepd.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0427172019_zpsgeenyepd.jpg.html)

I of course forgot to order a spare blade last time I ordered stuff like this. Time to try my hand at welding it up. I figured getting it lined up good would be the first step.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0427172048_zpskyrxvxub.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0427172048_zpskyrxvxub.jpg.html)

These are pretty tedious to weld. I welded it on both sides then ground it down. I heated it up cherry red with a torch to try to anneal it. It worked out and is still on my saw a week later.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0427172054_zpsrrb40exe.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0427172054_zpsrrb40exe.jpg.html)

There's some odd notches in this part of the frame for the tubing to go through. We set them up in the mill to notch. Keep in mind since we are building two buggies that setup time isn't as much of a big deal if it means getting through the overall parts quicker. It's also hard to argue with the accuracy of using a mill. I didn't take any more pictures of stuff done in the mill but we also used it to drill all the holes in the tubes(10 ea). I'm getting fairly proficient at putting together a quick program to do things like this. I like being able to load a part in the machine and press the go button. We also made the tap plates for the motor mounts in the mill.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0427172143_zps2ivlb7hr.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0427172143_zps2ivlb7hr.jpg.html)

Laying out the next frame layer on the jig table.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0509172115_zpslermqocy.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0509172115_zpslermqocy.jpg.html)

Here it is all jigged up.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0509172128_zpsqyaxi4wg.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0509172128_zpsqyaxi4wg.jpg.html)

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0509172154_zpsyeww9htw.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0509172154_zpsyeww9htw.jpg.html)

Jason holding up the two frame sections.

http://i197.photobucket.com/albums/aa63/Griffs_photos/AR51/0509172208_Burst01_zpsudpxqr2e.jpg (http://s197.photobucket.com/user/Griffs_photos/media/AR51/0509172208_Burst01_zpsudpxqr2e.jpg.html)

Deranged
05-15-2017, 09:34 AM
Awesome! I love using the mill to notch tubes! You will make some headway now with all the plate work and tubing cut.

Justin

Bullnerd
05-15-2017, 01:43 PM
If the blade breaks, try brazing it. Sand a scarf joint,(taper each end)and braze. Shouldn't have to anneal after brazing.

Although, not sure about that blade now, might be brittle where its already affected.

GSI
05-16-2017, 02:01 AM
So far it's holding up. I think annealing it took care of the brittle issue. We cut a bunch of stuff with it today. I got another one sitting on the shelf now but I'm going to let that one ride to see how long it makes it. Welding should do fine as all the off the shelf blades I buy are welded, not brazed. Brazing is certainly a good option though. I wonder if SI Bronze brazing with a tig would work well.

Bullnerd
05-16-2017, 03:14 PM
That's cool.

K-fab
05-26-2017, 02:53 PM
WThe thing still scares me at times when it rapids somewhere and I think it's going to slam into the part, etc.LOL!

First time we fired up my VMC the installer did a tool change run and I'd never seen nor heard one being done. Is scared the crap out of me! I though the whole thing was coming apart.

And yes, the ability of the machine to move very fast is impressive. My first lesson in setting Z was bad - I ended up being about 17" below what I'd set and it took a 2.5" cutter and drove it into the piece with amazing speed and force. Fortunately the machine knew stuff wasn't right and shut down after it put the cutter about 1/4" into the material.

Bullnerd
05-26-2017, 04:36 PM
I had a fadal lose the setscrew on the z encoder while I was standing there watching it. That was interesting.

I also ran a machine many moons ago that changed tools so fast I jumped every time it did. Never got used to it.

GSI
09-17-2017, 06:46 PM
It's been to long. We got back to working on the buggies the other day. I had taken a while off due to going to ride in Colorado for two weeks and having to get ready. We made some progress on the frames. They are starting to look like a buggy. Unfortunately all my previous pictures were on photobucket.

https://farm5.staticflickr.com/4373/36890938160_a5fd9dfa29_k.jpg (https://flic.kr/p/YcVGDW)IMG_0938 (https://flic.kr/p/YcVGDW) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

https://farm5.staticflickr.com/4418/37116070452_b82f3ec735_k.jpg (https://flic.kr/p/YxPyDb)IMG_0936 (https://flic.kr/p/YxPyDb) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

https://farm5.staticflickr.com/4343/36890919160_3246f14f8f_k.jpg (https://flic.kr/p/YcVB1m)IMG_0935 (https://flic.kr/p/YcVB1m) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

https://farm5.staticflickr.com/4407/37116044192_bc17f04a58_k.jpg (https://flic.kr/p/YxPqQq)IMG_0933 (https://flic.kr/p/YxPqQq) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

GSI
10-04-2017, 02:49 AM
The chassis are starting to get a bit large to drag in and out of the shop by hand. I'd much rather bring them in on forks when I have a bit of time to work on them. I decided the best way to do something about that would be to build a couple of custom stands to hold them. I'm going to bolt them to the chassis with some tabs that will line up with the mounts for the nerf bars.

First, we cut all the tubing to length and jigged it up on the table.
https://farm5.staticflickr.com/4468/37455507452_c45d23fa66_k.jpg (https://flic.kr/p/Z4Pgrf)

Then, we welded it all out and cut a top from 1/8" plate. After we're done building the buggies I plan to add extensions to the leg to use these as work benches.
https://farm5.staticflickr.com/4468/37486358371_ad116a2cc9_k.jpg (https://flic.kr/p/Z7xokD)

Deranged
10-04-2017, 09:38 AM
KILLER!! I like the table! I built one just like it for my build. It worked awesome. I was able to literally build the whole car on it.

Justin

Bullnerd
10-04-2017, 12:00 PM
Yup, and killer shop too!

GSI
01-22-2018, 02:19 AM
We got the second table welded up. Jason got plenty of welding practice doing that one.

https://farm5.staticflickr.com/4589/25699775278_0e9d83f017_k.jpg (https://flic.kr/p/Fa14PL)2018-01-07_10-58-06 (https://flic.kr/p/Fa14PL) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

We cut some tabs out on our plasma table and got the chassis mounted to the table.

https://farm5.staticflickr.com/4742/28000265909_70f40fcc00_k.jpg (https://flic.kr/p/JEhFxk)2018-01-19_07-32-28 (https://flic.kr/p/JEhFxk) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

We started bending and notching tubing. I've been notching in my bridgeport mill. I had a notcher but it broke. I haven't been real motivated to buy another one when the bridgeport is just about as quick and seems to do a better job. It will also notch anywhere in a bend.

https://farm5.staticflickr.com/4615/25862192288_6efe220d3a_k.jpg (https://flic.kr/p/FpmuK3)2018-01-16_07-23-14 (https://flic.kr/p/FpmuK3) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

It's really handy for notches like this on short piece that are hard to get a plane of bend bracket on. No problem with lining up their rotation.

https://farm5.staticflickr.com/4629/39702692782_5c243192c8_k.jpg (https://flic.kr/p/23uoFkU)2018-01-16_07-23-54 (https://flic.kr/p/23uoFkU) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

It's also really easy to put a 1-2-3 block on the table to line up multiple pieces. Keep in mind we're building two of these at once. It's nice when everything like this fits together nicely with no grinding at all.

https://farm5.staticflickr.com/4751/25862202108_5f8b01d074_k.jpg (https://flic.kr/p/FpmxEm)2018-01-16_07-24-16 (https://flic.kr/p/FpmxEm) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

Angles are also no problem. Just swing the head. It's 4 bolts to undo.

https://farm5.staticflickr.com/4626/25862207408_fbb9abd2bc_k.jpg (https://flic.kr/p/FpmzeJ)2018-01-16_07-24-37 (https://flic.kr/p/FpmzeJ) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

We got the front hoop and top bars stuck on the chassis.

https://farm5.staticflickr.com/4718/39702708212_f6fa492f11_k.jpg (https://flic.kr/p/23uoKVW)2018-01-16_07-25-10 (https://flic.kr/p/23uoKVW) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

It's starting to look like something.

https://farm5.staticflickr.com/4608/39702714112_0e81caaa81_k.jpg (https://flic.kr/p/23uoMFE)2018-01-16_07-25-27 (https://flic.kr/p/23uoMFE) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

Deranged
01-22-2018, 09:48 AM
COOL! Awesome job guys!

Justin

GSI
09-25-2018, 11:17 AM
It's been way to long but we managed to get some buggy stuff worked on the other day. I'm self employed so sometime I really don't have time to do anything. I own two different businesses and this year they have both grown a lot. Hopefully as this trend continues, I'll be able to find some more help and have more time for myself again.

We used my cnc mill to make the piece that the chain adjuster slides in. I actually cut the 1/2" slots with a 1/4" end mill. I was able to program it to helic into the material then walk around the slots.

https://farm2.staticflickr.com/1917/29916823837_fe1791499a_k.jpg (https://flic.kr/p/MzDxrx)2018-09-22_08-37-18 (https://flic.kr/p/MzDxrx) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

We also made all the rear arm spacers on the lathe. I forgot to take any pictures. Once we had those and the chain adjuster tube, we assembled the rear carrier.

https://farm2.staticflickr.com/1851/43041956950_a6bc0b3ac8_z.jpg (https://flic.kr/p/28zthf3)2018-09-22_08-37-38 (https://flic.kr/p/28zthf3) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

Deranged
09-25-2018, 01:49 PM
As Johnny Cash once said,
"One piece at a time"



Justin

K-fab
09-27-2018, 11:16 PM
Nice work.

GSI
11-02-2018, 01:00 AM
I'm really trying to find time to work on this thing. We found a bit Sunday afternoon. We decided to deviate from the plans slightly. The chain adjuster piece is made of three pieces of plate and one piece of tubing. We decided to machine it out of a piece of aluminum instead. Like any good project, you have to make something before you can make the part for your project. We had to machine some longer soft jaws to be able to clamp this part in the vise as the pocket in the middle is roughly 7" long so I didn't want 6" vise jaws squeezing it. We machined them out of some 2" bar I had laying around. I slotted the mount holes so they can be turned upside down to be able to get more uses out of them.

We started by machining the outsides to the desired dimensions. Next, we drilled and tapped 5 holes around the perimeter. I didn't take any pictures of this going on unfortunately. We set the part down into the vise jaws and started removing material out of a large pocket.

https://farm2.staticflickr.com/1901/31737361608_25ef90cb72_k.jpg (https://flic.kr/p/QmwgTN)2018-10-28_10-15-11 (https://flic.kr/p/QmwgTN) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

I started pushing the feeds and speeds as I was using a 3 ft carbide end mill. I ended up at 4000 rpm and 43.2 IPM. It took about 7 minutes to pocket this out all the way through a piece of 1" plate. It really started piling up the chips. I ended up using compressed air blowing out of the front coolant pipe to move the chips out of the cutting area.


https://farm2.staticflickr.com/1935/30668658037_d913bbb0ca_k.jpg (https://flic.kr/p/NJ5Tya)2018-10-28_10-14-43 (https://flic.kr/p/NJ5Tya) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

You can really see the soft jaws holding the part here. I really didn't want the part to get loose or collapse from regular jaws so this worked very well.

https://farm2.staticflickr.com/1961/45559013722_6ee0874458_k.jpg (https://flic.kr/p/2cpTRwA)2018-10-28_10-15-42 (https://flic.kr/p/2cpTRwA) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

Here they are all cleaned up and deburred.

https://farm2.staticflickr.com/1950/44695874765_10f3d535ab_k.jpg (https://flic.kr/p/2b6C3or)2018-10-28_10-15-56 (https://flic.kr/p/2b6C3or) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

GSI
02-13-2019, 10:08 AM
Machined a bunch of bushings for the control arms the other day.

https://farm8.staticflickr.com/7914/45837176324_9375a474eb_k.jpg (https://flic.kr/p/2cQtvzw)2019-01-01_03-54-23 (https://flic.kr/p/2cQtvzw) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

The new machine.
https://farm5.staticflickr.com/4888/32114028098_118e1193e3_k.jpg (https://flic.kr/p/QVNMHC)2018-11-21_07-01-48 (https://flic.kr/p/QVNMHC) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

Rat4020
02-13-2019, 11:47 AM
Great to see ya keepin chugin away at these two

GSI
03-22-2019, 10:19 AM
Machined a couple of CV bells the other day on our TL-2 and our Torq cut 22 VMC. I'll keep at it but it isn't going to happen quickly due to running two businesses.

https://farm8.staticflickr.com/7864/33565180388_268ffe038b_k.jpg (https://flic.kr/p/T93jJG)2019-03-22_07-17-05 (https://flic.kr/p/T93jJG) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr

https://farm8.staticflickr.com/7900/47438544991_c9644e9c2e_k.jpg (https://flic.kr/p/2fgYWG8)Cv bell (https://flic.kr/p/2fgYWG8) by Griffin93 (https://www.flickr.com/photos/45086110@N05/), on Flickr