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routercnc
18-03-2019, 10:23 PM
Having built my new CNC machine and thought I had better make something fun with it. I had been asking around for anyone with a Kettler type pedal car and I was offered one for free from a friend !

So I've drawn up the CAD, and we are off again on another video series. I need to get this one done quickly though, ideally before the summer, so my young daughter can get the most out of it.

There are some electrics involved later in the project so there may be questions . . . .

Episode 1: Getting started

https://youtu.be/dAQRTkef46U

Clive S
18-03-2019, 10:43 PM
Nice project, Have you thought about a remote Osh#~e button:beer:

routercnc
19-03-2019, 06:21 AM
Nice project, Have you thought about a remote Osh#~e button:beer:
Funnily enough I was talking to a friend about maybe doing that and he showed my the cheap blipper modules on eBay where you can remotely control a set of relays. These could cut power if required and have a 200 m ? range

Iím gearing this to go at a fast jog so hopefully I can keep up, plus there will be an ignition key and isolator on the kart.

routercnc
06-04-2019, 09:38 AM
For anyone interested here is episode 2 of the electric kart conversion, making the foot rest and throttle pedal . . . enjoy !



https://youtu.be/QfwMvkTqU_A

routercnc
15-05-2019, 07:18 AM
Episode 3 has been out a while for those interested . . .

https://youtu.be/MuFKH7YzIzg



And here is the new episode 4:

https://youtu.be/RRcvbDO1FgE

Clive S
15-05-2019, 08:37 AM
Very nice as always. If I may make a comment have you thought about the ware against the housing of the back of the spur idler gears.

I always enjoy the Vid's

routercnc
15-05-2019, 12:24 PM
Very nice as always. If I may make a comment have you thought about the ware against the housing of the back of the spur idler gears.

I always enjoy the Vid's

Yes I thought about that quite a lot and discussed with colleagues. In the end I decided not to add anything further since they only turn very slowly ( just when cornering perhaps 1 revolution every second or so) and she might grow out of it before serious wear occurs. It will get a dab of grease on final assembly.

Steven Ksiezak
23-05-2019, 08:28 AM
Hi routercnc, I am totally new to this site so still getting to grips with it. I tried to send you a message via another thread so I am not sure that will work so apologies if you are reading this for the second time. I was reading your story about how you bought your warco machine as I would like to buy one for the exact same reason you stated in your 2015 post. I just wondered how you feel about it after having it for 4 years and the company in general. I am thinking about the wm250. I am an abslute beginner but do not want to buy a chinese lathe. I would be grateful for your insights and feedback after all this time. Many thanks in advance.

magicniner
23-05-2019, 09:04 AM
You don't send messages via threads, just click on the intended recipient's name in one of their posts and from the menu which pops up you click Private Message.
Or start your own thread with a sensible title ;-)

routercnc
23-05-2019, 11:31 PM
Hi Steven

Apologies I have a lot on at the moment so only drop in here occasionally and donít always log (therefore pms notifications donít appear).

Iíll reply here for the benefit of others instead of a pm. Iím guessing you replied to my old lathe thread so when Iím near a pc Iíll copy this over.

I would buy this lathe again without hesitation and donít regret it one bit. The VFD means easy speed control with loads of torque, it comes with a good 3 jaw & 4 jaw which I use a lot and a face plate which Iíve never used plus fixed and travelling steady rests. Itís quiet and I can make accurate parts on it. Has 3 speed settings for the lead-screw.

I added quick change tool post and DROs from day one and strongly recommend these also.

Be aware this lathe like many similar models are all made in China. Search out Weiss machines (?). But as I say no issues at all and Warco have been fantastic to deal with. Iíve bought lots of stuff from them and been very pleased with their products.

Other similar products are sold by Amadeal, Chester, ArcEuro if you want to have a look around but at the time the Warco was the better spec for the money (on the lathe)

routercnc
27-06-2019, 07:50 PM
Episode 5 is now ready. This time we broach out keyways in the drive gears for the differential, and machine out the HTD drive pulley. Enjoy !


https://youtu.be/ieZvENTv_js

AndyUK
27-06-2019, 09:17 PM
Episode 5 is now ready. This time we broach out keyways in the drive gears for the differential, and machine out the HTD drive pulley. Enjoy !


https://youtu.be/ieZvENTv_jsLoved it - but slightly disturbing end ;)

Sent from my SM-G950F using Tapatalk

routercnc
27-06-2019, 10:02 PM
Loved it - but slightly disturbing end ;)

Sent from my SM-G950F using Tapatalk

My daughter thought it was hilarious and insisted I left it in 🤭

AndyGuid
28-06-2019, 03:43 PM
Loved it - but slightly disturbing end ;)

Thanks, that made me go back and watch till the very end. Oh the humanity of it!:hysterical::hysterical::hysterical:

routercnc
22-07-2019, 06:08 PM
For those following along - episode 6 . . . .


https://youtu.be/IMj1uNHemIY

For those not following along . . . OK, as you were

Clive S
22-07-2019, 06:53 PM
For those following along - episode 6 . . . .


For those not following along . . . OK, as you were

You put me to shame :beer: nice work as always

routercnc
22-07-2019, 07:33 PM
Thank you. Not sure my daughter shares the same appreciation though - she just wants to get on it and whizz about !

routercnc
12-08-2019, 06:58 AM
Episode 7 is ready. This time, flanges . . . . plus bonus music (!)


https://youtu.be/iE6VYHP8_f8

Clive S
12-08-2019, 07:39 AM
I see you now are cheating with a bit of help from a budding engineer:yahoo: Yet another good vid.

routercnc
12-08-2019, 08:33 AM
Iíll let you into a secret. She does all of my machining; I just sort it out in the post production to make me look good !

routercnc
30-09-2019, 06:51 AM
In this episode we sort out a few issues on the rear axle . . . .!


https://youtu.be/ximmVFRRQwA

Clive S
30-09-2019, 09:52 AM
Enjoyed watching this, it took me back to when I had to make a pulley I first made them on the router in mdf to make sure the pitch was correct.

A few picks here including the cock up :- https://photos.app.goo.gl/t5dJpvh7dBWzp9TFA

pratt77
30-09-2019, 10:02 AM
Thanks a lot for sharing these videos, routercnc. I really enjoy watching them. I'm also working on a CNC machine and now and, thanks to you, I'm also thinking about doing something like this after finishing it. I will try to finish it by next summer because we will buy apartment in Portugal with a garden soon and I want my son to have fun outside.

routercnc
30-09-2019, 04:24 PM
Hi Clive
Yes, one wrong number in the calculations and the pitch spacing was wrong. An MDF prototype would have been a good idea. By the way I canít open the pictures on my phone as it needs an app or something.
I Ďinvestedí time writing a spreadsheet that works out the key geometry for any HTD 5 gear size you want. Watch me never need it again !

Hi pratt77
Thanks. Sounds interesting. Remember you donít need anything as ambitious as my machine to make small parts. Whatever you build just leave yourself plenty of time as these projects eat up the months !

routercnc
09-11-2019, 07:10 AM
Finally got some motion on the rear axle . . .


https://youtu.be/JjbuflSEWpc

Doddy
09-11-2019, 08:35 AM
As always, superb work, but you have an awful lot more patience (or engineering pleasure) than myself. Not tempted with shake proof washers on the bolts for the cover?

routercnc
09-11-2019, 08:47 AM
Thank you. Yes, I think it needs something but clearance is a bit tight to the main plate. I'll see what might fit in there, or probably just loctite it after the first proper run.

Kitwn
09-11-2019, 09:54 AM
I Ďinvestedí time writing a spreadsheet that works out the key geometry for any HTD 5 gear size you want. Watch me never need it again !

The rather splendid 'Gearotic' software from Art Fennerty will design many common styles of timing pulley for you, along with gears, gear trains, sprockets, ratchets, clock escapements and more wonders than you could ever imagine. All for one modest updates-for-life payment.

https://www.gear2motion.com/

kit

routercnc
09-11-2019, 10:41 AM
Thanks Kit. Looks very interesting and comprehensive and as it is written or co-written by Art Fennerty (of Mach3 fame) Iím sure it will be a good product
At $120 I would need to make sure I was going to use it for something though.

Nealieboyee
09-11-2019, 08:38 PM
Great videos! I left a question on your latest one. More a curiosity really.

routercnc
09-11-2019, 09:52 PM
Great videos! I left a question on your latest one. More a curiosity really.
I went slow on the tube cut because:
Part stuck out of the vice a long way
Tube thin and may resonate
That aluminium grade likes to chip weld

Nealieboyee
09-11-2019, 09:59 PM
Thanks!

Kitwn
10-11-2019, 02:10 AM
Thanks Kit. Looks very interesting and comprehensive and as it is written or co-written by Art Fennerty (of Mach3 fame) Iím sure it will be a good product
At $120 I would need to make sure I was going to use it for something though.

Strangely enough I actually found it while looking for software to design HTD5 pulleys a few years back. Then I discovered it was designed to provide all the tools you need to design a wooden clock and decided to try one as a good project for my new and very flakey wooden-framed CNC router and was hooked. I have since designed a couple of quartz/GPS-locked, all wooden gears, electrically driven pendulum clocks, one of which has a working prototype, and have plans for constructing some other designs once I finally get a bandsaw and a stock of suitable hardwoods later this month. Be warned, this software can lead to a serious addiction!

I can't remember if I linked to it before, but this link is to the GPS-locked prototype. https://vimeo.com/343781598

Kit

routercnc
19-11-2019, 10:12 PM
This episode is all the B's . . . .


https://youtu.be/huSV6ve4boc

Clive S
20-11-2019, 03:08 AM
You forgot the other B Blx. Still keeping an eye on this from Down Under. :beer:

routercnc
20-11-2019, 05:43 AM
You forgot the other B Blx. Still keeping an eye on this from Down Under. :beer:

Well spotted, that was a bonus one ! Happy hols

routercnc
28-11-2019, 06:53 AM
Electrics !


https://youtu.be/cm_qnhLfVpY

Clive S
28-11-2019, 12:05 PM
Beautiful as always, Very informative re the throttle electronics looking forward to the next one :beer:
Still Down Under.

routercnc
28-11-2019, 12:57 PM
Not the perfect throttle solution but it should work.

One more video should finish this thing. And doing the finishing work of course!

routercnc
16-12-2019, 06:33 AM
Final episode in this series . . .!


https://youtu.be/tKOz9j0lqBw

Have a great break, and see you in the new year (maybe with a very different project)

Clive S
16-12-2019, 07:56 AM
Thanks for a a great series of interesting and entertaining vids. Your daughter will be very proud of you. Looking forward to the next project.
All the best and a Happy new year. :beer:

routercnc
16-12-2019, 10:37 AM
Thanks Clive. Yes she loves it :onthego:
We managed to get out on it Saturday morning between the rain showers and it was only the cold weather that eventually brought her back inside the house.

Hope you all have a good break :very_drunk: !

A_Camera
19-12-2019, 02:17 PM
Final episode in this series . . .!


https://youtu.be/tKOz9j0lqBw

Have a great break, and see you in the new year (maybe with a very different project)

Very nice work. Thank you for sharing all the details. It was really interesting to follow your build and the high quality of the work.

I would just comment on two things. One is the charger. I don't know the one you have used, but here in Sweden we had several home fires started by cheap chargers, so personally I'd go for a high quality, branded one. As I said, I don't know the one you are using, so it may be a high quality one, not just a cheap Chinese "design" with half of the safety features left out.

The other thing, which I'd modify is the break switch. I noticed that you are using normally open switch. That is in my opinion not a good idea for any sort of break. I would change it to be normally closed, so that in case the wiring fails, the kart stops automatically. I noticed that you soldered the wires, and that means it will not last forever, corrosion will take it's toll and you will not know when that happens until she can't stop because the break stopped working.

Doddy
19-12-2019, 03:22 PM
... corrosion will take it's toll and you will not know when that happens until she can't stop because the break stopped working.

I think you may have figured out next year's project - emergency drogue chute and zero/zero ejection system,

routercnc
19-12-2019, 08:22 PM
I think you may have figured out next year's project - emergency drogue chute and zero/zero ejection system,

:biggrin: Not quite but it made me chuckle - closest we will get to that is probably a seat belt.

A_camera,
The charger is a new model sent to me by Banggood (for free to show in the video) for 12V or 24V lead acid batteries. So far it has worked fine and we've had several charges out of it, usually while I'm nearby. My main complaint so far (as noted in the video) is that the UK plug they supply has no fuse. My plan is to open the unit and see if I can solder on a fused cable and plug. That will give me a chance to look it over at least.
However, I have no issues with anyone choosing a known branded one for peace of mind, especially if they plan to do unattended charging.

As for the brake system:
The brake is not electrically operating - it runs mechanically via a brake cable to the brake disc. The switch is just to turn off the throttle to stop them both being on at the same time. In practice if you press both pedals together (without the inhibit switch) the speed controller instantly switches off due to the motor going over current so you will always override the motor and come to a halt - it's actually not very powerful (300W) when compared to the power of the disc brakes. So even without that system it will stop pretty quickly. I decided to include that feature since it was easy to do. On a much more powerful system that might not be the case.

By the way if the wire breaks the kart still will not stop. You have to press the pedal. It just means that it won't automatically cut the throttle, although as I've found out it doesn't amount to much extra safety in this case.

I understand your general point though and what it means if you think about it is that all the electric bikes running around that use that type of controller (there must be a few!) will have a switch to make a connection when the brake is applied. I know on our CNC machine limits we break the signal to indicate a fault, but this controller is wired up the opposite way around. I'm personally not too worried though for the reasons above.

I'm glad most people have found it interesting, that does make the effort involved in filming and editing and uploading worth it. Most importantly my daughter absolutely loves it and only comes in when she gets too cold (wind chill effect maybe?). Happy holidays.