Pedal car ...

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ChrisF
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Pedal car ...

Post by ChrisF »

Our godson started driving at the age of 18 months ....
DSCN1208 (Small).JPG
This 6V electric car has served him WELL for almost 3 years. But he is now getting to that age, and size, where the 6V just cant cope with up-hills ....

At the Age of 2 years he also got this beaut -
DSCN1263 (Small).JPG

Even this is now fast becoming just too small .....


The BergToys models seems the logical next step - http://www.bergtoys.co.za/our-products/ ... 8&catId=27

starting from 7k and soon reaching 10k for the ones that tick all the boxes ... :shock2: :naah:



now this may well be the opportunity for our first self-build project ..... :thumbup: :yahoo:


any plans and ideas are VERY WELCOME !!!! :beg:


ideally something that can pedal forward AND backward.


PS - he is now 4,5 years old
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Re: Pedal car ...

Post by Froll »

Search on pinterest, they have all sorts of things on there.
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Re: Pedal car ...

Post by ChrisF »

Thanks Roger.
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Re: Pedal car ...

Post by ChrisF »

kom nou manne ... wie het al so iets gedoen ???? :yahoo: :subscribed:
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Re: Pedal car ...

Post by Mud Dog »

One helluva lot of work, Chris. My project never got as far as fitting the old Briggs & Stratton mower motor and the kids just pushed each other around in it for a while before that became too much of a schlep for them. It was eventually flogged as an unfinished project when the kids were older.
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Re: Pedal car ...

Post by ChrisF »

Andy the red wagon will still be good for a while.

So I am considering doing this as project with the little one ... he LOVES spending time in the garage.


Maybe I should tone it done to be a BASIC pedal car, to keep the construction time down .... fine line between keeping them interested and going over board ....


o-well .... doing a fair bit of net-surfing and finding ideas .....
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Re: Pedal car ...

Post by Family_Dog »

Saw one of these sold at an Auction in JHB on DSTV over the weekend, sold to the Yankee Auctioneers who travel the world looking for bargains.

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Guy paid something like $200 for it only to be told that while nice, it was not in original condition and he could expect about half of that for resale. So contact him Chris!

* The babe in the pic is not included in the sale - sorry!


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Re: Pedal car ...

Post by ChrisF »

no wonder he got a raw deal ...

no babe ... no sale ....





Eric I think this is more about the bonding time in the garage than the final product.
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Re: Pedal car ...

Post by Family_Dog »

Ag no Chris..... I want one of those pedal cars! I remember I also had one 250 years ago when I was but a toddler - loved it! :)


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Re: Pedal car ...

Post by ChrisF »

hier kom n ding !!! :cooldude: :mocking:

En so groei Maritz uit sy Jeep uit ...
DSCN2860 (Small).JPG
en so begin ons kyk wat die mates is en waar aangepas moet word .... moet groot genoeg wees vir n paar jaar .. maar tog kompak genoeg vir n moderne erf ...
DSCN2864 (Small).JPG

Danksy ons plaaslike AgriMark ... klein kar met monster truck wheels ....
DSCN2870 (Small).JPG

die pedaal meganisme sal die plaasing van die agter sprocket bepaal, en dus ook die wydte van die voertuig -
DSCN2869 (Small).JPG
DSCN2872 (Small).JPG
cold bending the crank -
DSCN2873 (Small).JPG
DSCN2875 (Small).JPG
Die crank is gemaak van n 12mm rod .... moet nog besluit of ek dit liewer uit 16mm rod wil maak ....


primere aandrywing sal op die linker agterwiel wees, met die opsie van n "diff lock" .... :laugh2:
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Re: Pedal car ...

Post by Family_Dog »

Chris, if you do make another crank, might be an idea to first slide a piece of hose pipe on to the sections where his feet pedal. It provides a bit of a cushioning effect. I think 16mm would be a better deal than 12mm.


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Re: Pedal car ...

Post by ChrisF »

Eric jip, the 12mm just looks a tad flimsy ....

I will get some 16mm rod, then make a jig to weld it. And slip a piece of steel pipe over it, then weld up a small pedal ...


soos Andy laas gesê het - dis BAIE werk om so karretjie te bou ... sien nogal uit daarna ...



sal sekerlik die enigste trapkar wees met n pv-paneel, battery, ligte, ens .... :laugh2: :twisted: :siffler:
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Re: Pedal car ...

Post by ChrisF »

Got some 16mm rod and made a new crank, with sleaves for the pedals ...

made a jig to hold it all in place while welding ... still pulled the two centres out of allignment .....

had to make a new jig to line up the two centres, then bend, pull and clamp until it lined up. Welded the other side and left it in the jig to set until cold.
DSCN2878 (Small).JPG

with any luck the crank is now sorted, barring a bit of grinding and final welding.



made some sketches for "collars" to mount the sprockets and rear drive mechanisms. A friend will help to turn these.


Should be getting the "core structure" in place soon. Then for a custom front end that will allow some wheel travel .... :siffler:
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Re: Pedal car ...

Post by ChrisF »

sketches handed over, now the wait for a couple of parts to be turned.


plan changed from a bearing to a vesconite bush for the crank arm assembly .... now to find a local supplier and the correct size .... hope to use this on the front wheels as well ....


Once I have the vesconite I can start the steering assembly, complete with castor and camber angles ... incorporating some suspension movement for some articulation .....
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Re: Pedal car ...

Post by chopper »

Chris
Where did you find the original pedal car?
My grandson tuned 5 recently and I've been looking for something like that for him as we have wide open spaces on the farm
Thank you
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Re: Pedal car ...

Post by ChrisF »

Thinus there is an "ou oom" that sells these next to the road in Bellville. Two years back it cost only R800.

But at 4 and a half our godson has now almost grown out of it .... Clearly this oom built the prototype when his grandson was 2 or 3 years old. Even the 80mm crank length is for the very small kids.


Have you looked at the BerToys website ? http://www.bergtoys.co.za/

Look at their range for the age group 3 to 8 years - http://www.bergtoys.co.za/our-products/ ... 8&catId=21

Lot of money for a toy they will outgrow in 2 or 3 years ...

And the next size is just too big !! Their short legs cant handle the long crank length ....


One BIG benefit of the BergToys units - it has a very fancy gearbox !! Pedal forward, free wheel, back pedal to stop, then you can also pedal backward to reverse.


The way things are going I am looking at around R2k to build this unit. I will keep on posting here, thus you can avoid my school fees .... with my design you can just move the seat back, and swop out the crank every couple of years as his legs gets longer ....
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Re: Pedal car ...

Post by ChrisF »

Thinus the old red Jeep did its service, and is now a perfect tool to get real world practical dimension for this project.

Seat-to-pedal dimensions are about the sum total of what gets re-used ... well actually not, as these dimensions are now amended to Maritx's current size.


And then there are a host of features that I will be adding to this "Monster Truck" .... :cooldude: :lmao: :twisted:


Sneak pre-view of some of the dimensions that have been resolved to date ....
Monster trapkar.JPG


As this vehicle will be used in a small erf I need to optimize all dimensions. Out on a farm it would make a lot of sense to make it wider and longer, and plan to just swop out the crank as the kid grows up


while I wait for the bushes I can start on the "front suspension" and steering - though the total width can only be confirmed once I have the bushes ....


Maybe I should just go to Addendorf and get that 1ph lathe/milling machine ..... :siffler: :surrender:
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Re: Pedal car ...

Post by ChrisF »

Bearings ....

Friction can both rob pedal energy and even result in a noisy pedal car.

The rear shaft will run on SKF pressed steel bearings .... Pillow block may well have been the better option ...

Front wheels will get Vesconite bushes - https://www.google.co.za/search?q=vesco ... PgodOVQKbA

Nice and cheap .. except it must be machined .... thus not practical for DIY; if you dont have friends with tools ...

Initially I wanted bearings for the crank, but I just cant get the ends of the shaft 100% true ... so I will be using vesconite bushes here as well.
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Re: Pedal car ...

Post by Stef »

Back in our day friends of mine had very simple yet effective pedal cars...

No bodies and no sprockets/chains; just a simple sq tube chassis with lawnmower wheels and v-belts. Worked like a charm :thumbup:
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Re: Pedal car ...

Post by chopper »

Chris
Thank you - I'm following your progress with great interest :thumbup:
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Re: Pedal car ...

Post by ChrisF »

bushes en collars is nog nie klaar nie ... :naah: :crazy:


Toe skenk ek so bietjie aandag aan die elektriese goedjies .... :mocking: :cooldude: :yahoo:


Gaan maar sukkel om n "dash board" te maak .... tot kry ek n idee .... :siffler: :surrender:

DSCN2879 (Small).JPG
Ligte skakelaar .... hooter knop ..... skakelaar vir die volt meter
DSCN2881 (Small).JPG
bracket om die stuurwiel aan die rod te koppel en vir die Volt meter
DSCN2883 (Small).JPG

nou om blou verf te kry ... Hammerite .... selfde kleur as die blou van die stuurwiel .... :thumbup:
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Re: Pedal car ...

Post by ChrisF »

Had a year-end function today .... so not much play time.


Finished a few bits and pieces, then marked out the frame dimensions. Next step to start cutting the lengths ....



sommer so lus maak foto -
DSCN2887 (Small).JPG
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Re: Pedal car ...

Post by chopper »

Still impressed!
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Re: Pedal car ...

Post by The Legend »

Hier is n mooi produk op pad.Kan nie wag om die end resultaat te sien nie :subscribed:
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Re: Pedal car ...

Post by ChrisF »

uhm ja ....

danksy stakings wag ek nou al meer as n week vir die parte wat gemasjineer moet word .... vandag gehoor dit sal waarskynlik eers volgende week gedoen word.

Weet die as kom eers mid volgende week.

en volgende naweek is n kamp naweek .....



so ja .... die projek rek nou so bietjie uit .....



sal maar probeer om n paar verwante goed reg te kry die naweek, maar ek kan nie veel vorder sonder die parte waarvoor ek wag nie.
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Re: Pedal car ...

Post by ChrisF »

we plan .. then life happens .... :naah:

My friend that would have helped me with the bushes and collars was locked out by strikers for more than three weeks !! :thumbdown: :frustrated:

Another friend stepped in and helped out :thumbup:


But the last two weeks have just been an insane blur with the rush to get our projects done before the builders holiday ... so just too tired at night to still work on the pedal car. So more than a month this is what I saw in the garage -
DSCN2895 (Small).JPG

This morning I picked up the bits and .... went back to the the bearing shop as I had enough time to partially re-design the project .....


Pedals are now fixed - the bracket I had previously made to adjust the crank had too much play in it ..... So now I use pillow block bearings at the back .... heavier than the pressed steel bearings, but just so much easier to adjust the chain tension.

The crank has custom high-tech bushes, inside a make shift bracket ... :thumbup:
DSCN2909 (Small).JPG
DSCN2910 (Small).JPG

The collars will be used to mount the sprockets for the drive train. The front sprocket will be interchangable, to be swopped out as Maritz's pedal power increases.
DSCN2904 (Small).JPG
DSCN2900 (Small).JPG
DSCN2912 (Small).JPG
The front suspension - some more hi-tech bushes between the wheel studs and the rims.

Then 3 degrees camber, and about 12 degrees castor. The Ackerman angle will be done "by feel" .... :laugh2:

Toe-angle will be fully adjustable, via a set of end rod steering components.

YES, I am having fun introducing Maritz to these angles, but NO, it has virtually no relevance in a pedal car of this shape and speed.


As promised, I DID ad a "bit" of suspension travel :yahoo: :celebrate: :laugh2: :lmao:

Will monitor this and add stoppers later ....
DSCN2914 (Small).JPG
DSCN2916 (Small).JPG
DSCN2917 (Small).JPG
NOW the work starts !!!!!
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Re: Pedal car ...

Post by Family_Dog »

Looking good, Chris! Now where were you when I was a laaitie??


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Re: Pedal car ...

Post by Dowe Koos »

Baie netjies, Chris. As jy so aangaan, gaan jou kleinseun nog wil 4X4 ry,
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Re: Pedal car ...

Post by Froll »

Looking good Chris. :thumbup: :thumbup:
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Re: Pedal car ...

Post by The Legend »

Baie netjies werk Chris-Ek wonder wie kan nie meer wag om die eind produk te sien nie.EK of jou laatjie
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Re: Pedal car ...

Post by ChrisF »

hehehehe ..... :lmao: :lmao:

been in and out of the garage non-stop .... :mocking:

now to do the seat - height and distance from the pedal must be RIGHT. :thumbup:

After this I can get started on the position of the steering wheel


jokes aside - biggest challange now - to get the welding done, so that Maritz can take part in the building process. THIS is the most important part for me !! Maritz already spends a LOT of time in the garage. He will rather be in the garage than be in front of the tv or playing with his LEGO. Nurturing an appreciation for building stuff .... :thumbup:



Koos this little laaitjie was 6 months old when he did his first trip from Cape Town to the very North of Namibia. His parents wedding car was a Range Rover, which has since been replaced by a Prado.
Weskus-22 (Small).jpg
here he is helping his dad - getting rocks to pack in the tent poles in loose sand ...
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Re: Pedal car ...

Post by Dowe Koos »

Hallo Chris, ek bedoel 4X4 trapkar
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Re: Pedal car ...

Post by JohanW »

Baie netjie Chris. Net so 'n nota. Dit saal mos besonders kwaai lyk as jy 'n paar "shocks" op daardie voorste suspension sit. Twee ou gas lifts of 'n stel met 'n lae newton rating gaan mos mooi kan werk. Die ball joints op hulle behoort nie met die stuur meganisme te bots nie. Sal ook bump steer beter maak. Weld 'n T bar voor regop en maak die gas lifts aan die ore van die T vas.
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Re: Pedal car ...

Post by ChrisF »

Johan I like the way you think .... :twisted: :twisted:



JIP, dit sal beslis GOED lyk ....



so paar goed gesweis vanoggend, wag nou vir Maritz vir sy eerste "tes-fit", om die sitplek hoogte en afstand REG te kry.
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Re: Pedal car ...

Post by ChrisF »

Temporary piece of wood just to check the seat height and position, and his first view of his "monster truck" -
DSCN2919 (Small).JPG
This photo does not show it properly, but there is a flat plate at the back for a "number plate" ....

"MARITZ - WP" is an option .... but certainly there must be a more catching phrase ......

He LOVES his PRADO, but actually handed the PRADO's keys to the current owner of their previous Range Rover ... but NO, that is asking TOO much to put some Brit name on the fruits of my labour ! :naah:


WOULD LOVE TO HEAR YOUR SUGGESTIONS FOR A NAME


Pedaling away, with no chain or sprockets fitted as yet .... but then the lack of steering rods certainly did not stop him from TURNING that steering wheel ... :yahoo: :celebrate: :lmao:
DSCN2925 (Small).JPG

You should have seen his face when he realised this monster truck CAN go off road .....
DSCN2930 (Small).JPG

For the seat we are considering going RETRO - meranti slats, similar to a garden bench seat. (the wood does not get as hot as metal when the truck is parked in the sun) With the back of the seat having the shape of a "sissy-bar" on a motorcycle. Behind this a load-bed made out of meranti .....
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Re: Pedal car ...

Post by Family_Dog »

Going to be a very nice off-roader once you have finished, Chris!


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Re: Pedal car ...

Post by Dowe Koos »

Wat van Maritz 4X4
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Re: Pedal car ...

Post by Froll »

Looking realy neat Chris, thats one very lucky kid to have you to spoil him.
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Re: Pedal car ...

Post by ChrisF »

Guys you should have been a fly on the wall last night !! :clap:


He was handing me tools, and helping as much as a 4 1/2 year old can.

As you can imagine I am measuring and cutting .... so he takes the measuring tape and start measuring ....

Then he takes the broom and cleans a bit.

All the while giving HIS input into how the seat should be finished off, and the spacing of the wooden slats, and, and ....


Absolutely PRICELESS !!!!!!! :thumbup: :cooldude:



PS - seat "structure" is done. Then I got stuck into the steering system .... Just after midnight I thought it best to call it a day.
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Re: Pedal car ...

Post by ChrisF »

Oooopppssss ..... :shock2: :o:

With the mechanism for the front axle articulation I cant run the standard "straight steering rod".


Not a problem, use a universal joint, and turn the axis of the steering mechanism ..... and what easier than a "universal joint" from a socket set ..... :naah:


NO !!! The universal of a socket set has a floating mid section !!!!!!!!!!!!!! You need the solid (single plain) cross member in the middle !!


So my steering rod assembly is (possibly) heading to the scrap heap ..... :slap:





ooooo, the joy of custom projects ..... :siffler:



EDIT - had another look at it .... at some angles the rotation is taken up by the mid section deflecting, BUT at other angles the rotation is transfered perfectly ..... bear in mind I need about 45 degrees either way ... seems I may just get away with this one ..... time to get some sleep, and will check again in the morning. HOPING I can still make this work :beg:
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Re: Pedal car ...

Post by ChrisF »

Another two late nights, and some progress ....

Some pics of the steering system -

Rod, through the pressed steel bearing, then the universal joint to change the axis of the steering system, then a horizontal axis, with a 70mm turning radius and bolt for the rod-ends. The steering rods end in another set of rod-ends at steering linkage at each wheel.
DSCN2938 (Small).JPG
the construction and dimensions are such that I can alter/adjust all the major angles and leaverages ...
DSCN2941 (Small).JPG
Every effort was made to limit bump steer
DSCN2940 (Small).JPG

I need to finish the "hood" section, to created an upper point where I can attach the steering rod. So time for a detour .... thanks to a number of vice-grips I can test and SEE the different options and effects .....


But first time for some custom jigs to bend the hollow tubes -
DSCN2935 (Small).JPG
DSCN2942 (Small).JPG
DSCN2943 (Small).JPG
This jig is for a 40mm radius bend, then another jig for the 65mm radius for the larger frame .... and so you can play to create the small details ..... just time, and more time ..... :siffler:


And this is what the mock-up looks like now - :celebrate: :yahoo:
DSCN2946 (Small).JPG

Next challenge - to try and bend galv plate with a 50mm radius .... THIS "minor" detail will be the most visible cosmetic finish, and create the ultimate look of the final product.



And then it will be time to finally complete the drive train. :thumbup:




en DAN is dit tyd om die wa te strip, al die welds the check, en dan begin die verf proses ....
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Re: Pedal car ...

Post by Dowe Koos »

Hallo Chris, bou jy dit rêrig vir Maritz. Lyk vir my meer vir jouself, maar dis rêrig "cool"
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Re: Pedal car ...

Post by ChrisF »

hehehehe .....


Die sitplek het "bucket seat side supports", juis om seker te maak net die klein man kan agter daai stuur in kom.
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Re: Pedal car ...

Post by Dowe Koos »

Gaan niks meer sê, sal maar wag vir die eind produk.
Ecc 1:9 Wat gewees het, dit sal daar weer wees; en wat gebeur het, dit sal weer gebeur, en daar is glad niks nuuts onder die son nie.
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Re: Pedal car ...

Post by Family_Dog »

Chris,

You got those pipe bends Absolutely Perfect! I would have expected the pipes to crinkle at the bends. Did you fill them with sand whilst bending?


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Re: Pedal car ...

Post by ChrisF »

Eric the rule of thumb : the radius of the bend to be at least 5 times the diameter of the pipe.

Thus for the 12mm diameter pipe the bend should be at least radius 60mm.



I mas "nipping" with that tight radius bend !!!

Glad it came out good.

Filling with sand would have been the next step ....
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Re: Pedal car ...

Post by ChrisF »

ALMOST ready for three days of road testing before painting and finishing touches ....

On the topic of "bending steel" -

And so I took great care to measure the compounded radia of the bonnet - 42mm in the front, and 65mm in the back, with different off-sets .... I had a piece of 0,5mm galv plate and marked out the exploded view of the bonnet and used my home-made clamp and cutter ,,,, :laugh2: :o:
DSCN2951 (Small).JPG
Then off to the local hard ware store to get wood with a 69x69 profile. With great care I marked out the compounded radia, turned the garage into a pile of wood shavings and ended with the perfect mold to bend the galv sheet .....
DSCN2948 (Small).JPG
DSCN2947 (Small).JPG
NO !!! Epic fail !!!! :shock2: :shh:

YES, the radia was correct. The concept was almost right .... EXCEPT - thin steel sheet does not stay in the form you bend it .... it kicks back "a bit" ..... so you must bend it further, then let it kick back to where you actually want it.


So I did the next best thing .... took the nearest steel pipe, and bent the sheet around it - TO TIGHT, then rolled it back to the form I wanted

My apprentice helped me, holding the hood in place while I riveted the sheet into place
DSCN2953 (Small).JPG

JIP, the hood actually opens and closes. :lmao: :thumbup:

Actually the FIRST thing he asked me when he saw the hood: "Hoe gaan ek dit oop maak?" ..... can see his first 4x4 was a Range Rover .....

Next step was to introduce side sections for the hood, following the curve of the wheel arches ...
DSCN2956 (Small).JPG
DSCN2957 (Small).JPG
DSCN2959 (Small).JPG

Today I finished the "bak", and the drive train ....
DSCN2964 (Small).JPG
DSCN2965 (Small).JPG

Maritz did a 10 minute test drive :thumbup: :yahoo: :celebrate: :clap:

gear ratio is a winner !!!!!!!!!!!!!! Will admit that I had more than a second thought about the ration !! Actually had another gear in my hand today, then decided to stick to my previous calcs ..... He "spins" at a good walking pace, which is GOOD, no he cant race ahead like he does with his bicycle. And he HAS enough torque to climb obstacles and ride over thick grass :thumbup:


one big ticket item remaining - HAND BRAKE

should the chain come off there is NO way of slowing down the "Bakkie" .... so the hand brake must be added before any more driving.



The electrics will be added after the painting. Also another party piece thanks to 4x4Direct .... :siffler: :subscribed:



How to teach a 4 year old about "gedult" (patience). As you can so well imagine the last two weeks he greats me by asking: "Is die Bakkie klaar?" So I had a nice chat with him about the virtue of patience and waiting for good things to come to be, and working towards a goal. Not once has he sulked or complained about the long wait !! This morning I am cleaning the pool before he takes a swim, and he says: "Ek wag geduldig tot die swembad skoon is voor ek swem". PRICELESS.
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Re: Pedal car ...

Post by Family_Dog »

Chris wrote: " Not once has he sulked or complained about the long wait !!"

No....But we are!! :mrgreen:

Can't wait to see the final product, Chris. But you're getting there - that bonnet looks GOOD!


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Re: Pedal car ...

Post by ChrisF »

Okay, handbrake DONE.


Now he needs to DRIVE the Bakkie for the next three days. Proper shake down to show up any build issues ....



From the 25th they are gone for 5 days - then I can do the painting and electrics.
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Re: Pedal car ...

Post by JohanW »

Bitter netjies. Welgedaan!
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Re: Pedal car ...

Post by Rusti »

Hi Chris,

Looks amazing..

Just be carefull... A friend of mine bought his kid a plastic bakkie and the dude accidentily drove into his friend with it and broke his leg... That steel bull bar of your looks great but could be quite dangerous.
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Re: Pedal car ...

Post by Thunder02 »

Stunning Chris, I take my hat off to the young man for waiting so long, as Eric said, we can't wait to see the end product.
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Re: Pedal car ...

Post by ChrisF »

Rusti wrote:Hi Chris,

Looks amazing..

Just be carefull... A friend of mine bought his kid a plastic bakkie and the dude accidentily drove into his friend with it and broke his leg... That steel bull bar of your looks great but could be quite dangerous.
you worry about the bumper, and THUNDER wants me to install a V8 ... and Eric wants me to install a BLOWN V8 :shock2: :twisted: :shock2: :twisted:


Fortunately he HAS been driving since the ripe old age of 18 months !! Three years later that first car is still PRISTINE ! :thumbup:


jokes aside - the current gear ratio limits him to no more than a walking pace, and he KNOWS not to drive into people and objects ...
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Re: Pedal car ...

Post by Rusti »

Ha ha..

He sounds like a better driver than most people on the road these day..

Awesome truck for the little guy!
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Re: Pedal car ...

Post by ChrisF »

Andy DID warn me. :mocking:

WOW !! Serious amount of work involved in building such a small toy from scratch ..... Here is a summary of the project, including some thoughts on alternative options ....


It took some time to get to this plan -
DSCN2969 (Small).JPG
Key to this approach is a rectangular frame and a crank. The other approach is to have a centre shaft and a bicycle "bottom bracket and crank" assembly ..... The second option may well have been a lot easier to build .....

This approach requires bushes for the crank, and custom "collars" for the sprockets. A friend was going to turn these for me, but due to some strike action at his place of work he got locked out of the machining room .... Finally got another friend to turn the bits. {with the centre shaft layout only one collar would have been needed}

And so the parts lay on the bench for nearly two months -
DSCN2895 (Small) - Copy.JPG
Once I got the sprocket I drilled and tapped three threads, that co-incide with the placement of the locating holes of the set of gears in the back sprocket of a bicycle -
DSCN2896 (Small).JPG
Thus I can just undo these three bolts and replace the front sprocket at any time, thus adjusting the gear ratio as Maritz grows -
DSCN2996 (Small).JPG
The same approach was followed to locate and centre the rear sprocket. Here I also welded "studs" onto the collar, to transfer the drive to the one rear wheel -
DSCN3004 (Small).JPG
Sadly these pedal cars only have a single drive wheel, as it just cant turn with locked rear wheels. But when driving on sand, this single drive often leads to loss of traction. Thus I made another spider. This one is locked to the drive shaft by means of a "R-clip". Typically the spider would be held in the "open" position, but when going onto sand the R-clip is taken out and the spider slipped into place, now the R-clip becomes a diff-lock :thumbup:
DSCN3003 (Small).JPG

back to the crank and the bush -
DSCN2908 (Small) - Copy.JPG
completed bush and bracket -
DSCN2999 (Small).JPG

With the crank fixed in position I had to find a way to make the rear axle adjustable, to manage the chain tension.
{I did initially make an adjustable bracket for the front crank .... managing the "free play" became mission impossible}
I finally settled on using pillow block bearings for the back axle. It would provide the adjustability I needed, but sadly these are pretty heavy .... As it turns out the slot in the pillow block bearing does NOT provide enough adjustability !! I had to slot the frame rail to get enough adjustability ..... -
DSCN3001 (Small).JPG

Okay, so the "drive" is sorted. Well sort off ..... the other problem with typical pedal cars are the rigid frames, combined with a single drive wheel. Negotiating the smallest "cross-axle" or pavement means the drive wheel gets air borne at some stage and the car must be pushed until all the wheels are on the ground again. Simple enough, just add some suspension travel ... yeah right .... I welded the front solid axle to a centre shaft, which pivots inside another shaft ..... As it turns out I had to add bump-stops to limit the amount of travel ....
DSCN2983 (Small).JPG
DSCN2984 (Small).JPG

This moving front axle seemed a breeze .................... And then I set about manufacturing the bits for the steering - which now also needed to cope with the moving axle .... The standard rod approach just would not do the trick. I opted for a pressed steel bearing to provide a proper turning point for the steering system, using a "universal joint" to change the direction of the steering system. Then some "rod-ends" to provide the flex and adjustability I wanted.
DSCN2977 (Small).JPG
DSCN2981 (Small).JPG
DSCN2982 (Small).JPG
At the front wheels I used two off M16 bolts, welded at 90 degrees. At the base I welded in a M10 extention nut. Now a M8 bolt was used as a steering arm, with another M8 extension nut welded to the end where the rod-ends are to be connected. This system allows for complete adjustabiltity. :thumbup:
DSCN2994 (Small).JPG
And thus basics were in place .... one more item to think about - seat placement. I made rails for the seat to slide on. As Maritz grows the seat can be moved back.


Planning done, all that remained was cutting, grinding, welding, grinding, some more welding and final grinding. Then on to the next part, and the next and the next ....

Putting in 12 hour days to manage year-end rush; then another couple of hours each night making parts ..... Andy DID warn me this was going to be a LOT of work :mocking:

Every so often Maritz would join me in the garage .... seeing him taking an interest and learning about the basics and safety in a garage made it all worth while ! :thumbup: :cooldude:
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Re: Pedal car ...

Post by ChrisF »

A journey of a thousand miles start with the first step .....

and many many steps later you can reach the destination ...


And so, one component at a time, I got from here -
DSCN2969 (Small).JPG
to here -
DSCN2895 (Small) - Copy.JPG
and then I had a painted chassis -
DSCN2972 (Small).JPG
and another angle -
DSCN2973 (Small).JPG

For kicks I added a bonnet, complete with hinges, and a rod to hold open the bonnet, even clips to keep the rod in place while driving -
DSCN2979 (Small).JPG
Also note the PV-panel in the pic above :cooldude:

And thus I added a 7A.h battery in the engine bay, to power the lights and hooter. BUT, an engine bay really deserves an engine ..... :twisted: :siffler:
DSCN3010 (Small).JPG
I got the motor from - http://www.lawnmowercentre.co.za/about.htm

Old Still weed-eater motor. Bits were painted multi-colour for Maritz. :cooldude: :celebrate: :yahoo:

Have a close look at the pic above - I made a battery pan out of galv-sheet metal. As this will be a car for a todler I used "flexible rubber edging" to protect the sharp edges - thanks 4x4Direct - http://www.4x4direct.co.za/canopy-hardw ... -p-777.htm


Between the solar panel and the battery I used a TES solar regulator - thanks 4x4Direct :thumbup:
DSCN2993 (Small).JPG

Having power means you need switches .... not wanting to build a dash board I opted for a sporty steering wheel, and drilled some holes ....
DSCN3020 (Small).JPG
One button to switch the volt meter on/off .... yes, you all recognize this volt meter from 4x4Direct.
The centre emblem is also the hooter button. For the hooter I used a 12V buzzer, the type that you would normally use for a lights-on-alarm. I do have a mini-air-horn ..... thought his parents might object to the joyful sounds of an air-horn on a Sunday afternoon .... :twisted: :twisted:
The other button is for the lights.

On the front two off 3-LED "light bars" are mounted inside the bumper -
DSCN2985 (Small).JPG
DSCN2986 (Small).JPG
WOW - with these spot lights he CAN drive at night !! :siffler: :lmao:


At the back two flashing RED LED's were mounted inside the main frame, even the wires are run inside the frame. {my neighbour gave me thin steel cables to place inside the frame at the start of the build, then at the end this was used to pull the wires through the frame}
As an extra party trick these LED's have different flashing patterns ... :laugh2:
DSCN3015 (Small).JPG
DSCN3015 (Small).JPG (28.44 KiB) Viewed 4501 times

And then I saw this at 4x4Direct - http://www.4x4direct.co.za/fender-flare ... -p-930.htm

What a nice way to finish off a labour of love -
DSCN3026 (Small).JPG
DSCN3027 (Small).JPG
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Re: Pedal car ...

Post by ChrisF »

And finally the great reveal ....

Here is the final product -
DSCN3006 (Small).JPG
even has a "bak" for his "bakkie" :lmao:
DSCN3013 (Small).JPG
DSCN3021 (Small).JPG

All it now needs are some nice stickers ..... :subscribed: :siffler:
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Re: Pedal car ...

Post by pietpetoors »

WOW Chris, your car is fantastic.
That is something to be really proud of.
Well done!
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Re: Pedal car ...

Post by Family_Dog »

Really looks great Chris, a job very well done! Maritz must be getting a big kick from driving this vehicle, especially with the hooter, front LED & flashing rear lights!

Now you need to start on a trailer for him.... :siffler:


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Re: Pedal car ...

Post by ChrisF »

Dankie Pieter.

Thanks Eric. I actually built a trailer for the red-trapkar .... need to add a tow hook to the "Bakkie" .... :lmao:

but then again, it IS a bakkie, and HAS a bak .... so no need for the trailer, not just yet ....
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