Rear End

Today's task was to re-assemble the rear end.  It only took us 2 attempts to make sure all was correct.  Had a little problem remembering the axle bearing housings go on the same side.  Take it all apart!  That's OK... I won't forget next time.

Bottom of the steering column.  All snug and secure.

 Both housings on the inside.  I am sure glad Dad caught the "play" in the axle.  Funny how I don't have photos of the WRONG way.

All secure and ready.  The hangers and grommets are on for the bottom frame.

Hangers. Some pieces I did not paint.  Keeps a reminder of what it originally was like.

Brakes and tanks next time. Maybe the pedal mechanisms.

Re-Assembly Started

January 24, 2012 --  On a frigid, 15 degree Friday, Dad and I cleaned engine parts in the garage, instead of the barn,  with the best all-around cleanser: Gasoline.  Sorry, no pictures.

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Finally... Parts are going back together!

As Dad says, "this is the easy stuff"

Removing the material that protected the allen holes

 Just a bunch of metal tubing and rough welds

Clean! and ready for a bushing

 Dad hammering out some dings

First piece back on.. the rear floor pan

 Rivets.  Randy, thanks for the tool

 Riveting the front floor panel. This is the bottom.  That is Chrome spraypaint.. not bad for Rattlecan

 Top, painted flat black

 This is the fiberglass seat form.  Took awhile to figure how we did this.  Rivets are too short.

 Then we remembered the mangled little bolts in the storage box. So we scrounged for some bolts. 

 That fits!  Just bend it over to secure it  (oh, then we found the unmangled little bolts that were removed from that spot. Oh well!)

 Gleaming!

 The seat form is not long enough to rivet on the back tube. Notice the cuts on the side, so we may need to strap it after seat testing.

****I was checking out tear-down photos and found out there is a metal sheet that goes here... ****

 Riveting Snaps

  Upholstery!

 Headrest

 Steering!   Had to remember and figure out the order of washers and bearings

 Ready to be tightened

Almost a kart again!  Now the hard part starts....

Painting the Frame

Over Christmas I was able to find Lodge's Sandblasting, who prepped the frame for painting. The old blue paint and original red paint was stripped away.

Hauling it from sandblasting to be painted. Great day to transfer bare ferrous-metals! Just don't drop in the snow!

I was able to use the spray booth at my workplace. Wonderful! I would have loved to hang it to paint, but this worked just fine. Here it is ready to go.

Raw metal. No primer yet.

Notice foam filler protecting the allen holes in the collars.

The sandblaster hit the cracks with a little weld, but I may need to hit it again my self.

There is some primer on the cross member.

AHHH... Color! It is a bit darker than I anticipated. But it is a standard color for enamel in a spray can. Rattlecan is a new term I have found.

Protecting the bushing slots

She's Blue!

I have some metalic aluminum spray enamel that I may use on some details.

Next up is cleaning up all the other parts, rebuilding the frame, and rebuilding the engine.

Fun in the "off" season

Here are some images of my first "mod" for rFactor, the Red Devil kart. rFactor is designed for users to create vehicles and tracks. The kart was created with Blender, a free 3D modeling program. I recreated the Indianapolis Raceway Park road course with Bob's Track Builder.

These images are from an early version. The bad shadows and head movements have been fixed.

pits at IRP, looking east towards the 5/8 mile oval.  Old main tower at far right.

pits at IRP

IRP backstretch. notice old tower at right

on the grid at IRP

scramble at start

driver's eye view, too far left coming out of 1 at IRP

Here is a link to a video:
http://www.youtube.com/watch?v=VAO39V0cOkA
 (bonus points for guessing who the driver/kart is based on)

If interested:
http://rfactor.net/

Bare Bones!

frame detail

headrest mount collar... CRACKS!!!

just waiting to be put back together again!

frame on wall. The floor panels are off. Sandblasting will be next week.

Chassis Tear Down

In the background are the extra tires and other parts. PRICELESS!

Engine mount and axle... OUR nemesis!

No engine mount, but there is the one of the Airheart brakes

collar

dad

margay spindles

accelorator cable

frame

special tool.

Axle

Hammer and chisel used to pop-off some rivets holding seat box.

The 'hanger'... frame is upside-down.

Drilling out a few rivets.