CycleKarts GB
Forums => Build journals => Topic started by: uncantim on 24 Oct 22, 09:07 pm
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I’m building an ERA R6B.
I watched these things on the telly racing at the Goodwood Revival and they were incredible, they don’t hang about for cars that are nearly 100 years old.
I’m not a welder, engineer, carpenter or draftsman but I’ll have a go at anything. This should be a giggle then.
This is a pic of R6B with the ERA that Chris took as his inspiration car
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I’ve started and actually got quite far, but before I tell you any more, some thanks are in order.
First off thanks to Chris Slade for being so generous with his time, I intruded on Chris one Sunday when I was sort of in his neck of the woods. I have to say it was the best 2 ½ hours talking about Cyclekarts I’ve ever had, my thinking and understanding progressed so much because of his advice and actually seeing the Cyclekart I wanted to build. It was well worth the investment in time, fuel and Tunocks biscuits let me tell you. I also visited the Sywell show this year and spoke to Andy B, Chris and JimR, great to see so much interest
So I’ve looked at cyclekarts for years and only just got the time space and budget to start to put one together. The cyclekart I’m building is an ERA like Chris Slade’s but the R6B which is almost identical apart from being black. I’m also using Chris S’s plans as a guide, although I’m having to modify the seat, steering…well pretty much all of it so that I can get in it. I’m a slightly bigger unit than Chris and when I sat in his, I did wonder if we were going to have to call the emergency services to get me out.
So I’ve subtly redesigned it and set about building. I got the chassis welded up and then started on the tub. I have some modifications to make to the tub as some of my measurements were wrong but on the whole I’m happy with the progress so far. 1 question I do have…whats the best way to fasten the tub to the chassis? Self-tappers or bolts?
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Some more pics
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and again
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...and again
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My images are too big to put lots on one post so putting them up individually
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I’m ready for the running gear now but that requires a bit of investment and is going to have to wait until I’ve saved up. I’ll keep you posted as I go but my main objective is to have something to drive by the first event we run next year.
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Excellent progress. And very smart of you sticking with a tried and tested design, albeit tweaked to fit.
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Looks like good progress Tim, Another northern cyclekart on the way! :)
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Thank you Stefan, I'm not confident enough to build something a bit different just yet. I also need to see stuff in order to recreate it, it’s just the way I learn, hence reaching out to Chris. I think it’s because I’m not trained at any of this…I fly a desk for a living.
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Thanks Jim ;D
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Hey Tim, Great to see you've been busy, looks like a great start! 2023 we could have 'Team ERA'.
I used coach bolts for my tub, 8mm I think.
Keep up the good work.
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Thank you Chris
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Well it’s been an interesting start to the year…I’ve moved one business, resigned from another business, and then gone and started another. I’m sure you’ll understand but my ERA has taken a little bit of a back seat recently.
The build is slowly starting again, I have purchased my front springs, front axels and other bits and bobs so have plenty to be fabricating and getting on with. I’m currently re lacing and trueing my renovated wheels, which I have discovered to be more frustrating than bringing up children! For those of you who have built your wheels yourself…I salute you, you are better men than I.
Pics and more stuff to follow
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Great to hear you are back at it Tim, we will have to do a northern builders meet soon, we are pretty thinly spread at the moment but I think we have traction up north. 😁
...And yes, after truing bicycle wheels for years, and then attempting to build a reliable one for touring, I have to say it is an art as much as a science. I will leave building wheels to others, I still true them though
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A northern builders meet would be good Jim, I like the sound of that. Somewhere in the middle...Manchester?
Lacing the wheels is the easy bit to be honest, but truing them is just awful. You think you're nearly there and then too many twists here and its all over the place there...really frustrating. I have also fabricated a truing gig as buying one is too much £££ for the use it will get. I've found a pro wheel builder in Leeds so will be using him next time.
My daughter is helping me this weekend fit the springs, and hopefully front axel.
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My springs from Jones Springs
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A bit of Friday night fabrication
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Where it goes
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I've also started thinking about the dash and secured this lovely thing from eBay. It's a Smiths clock that I think is from an old Jag. Just taken it apart to clean it up.
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Monday evening shenanigans in the workshop.
Had a great time building the front end up and seeing it coming together. Me and my daughter fabricated the front brackets over the weekend from a length of square tube I found in my wife's new shop...result! I love a freebie. Now need to work out where the rear axel is going to go so that we are within the guidelines.
Now I have the challenge of fitting everything in to the rear. I already have my engine, sprocket, brake disk and rear axel so my next purchase is the Torque Converter and chain. May need some guidance on the chain from you guys.
I hope driving this thing is going to be as much fun as building it...I'm having a great time!!!
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More pics
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Great progress Tim, looking very cyclekart - like, the chain will depend on your sprocket dimensions, thickness, pitch and space between teeth. If it is a Gemini one from the cyclekart section I think they run on 420 chain from memory.
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Hey Jim, I'm assuming those details are on the sprocket somewhere? I didn't buy it new so don't know if it came from Gemini or not. Can't remember what tooth it is from memory either. I'm playing out at the workshop tonight so I'll have a look.
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It is littered with ads but the link below has some reasonable information about the different types of kart chain. Of course it might not be a kart or motorcycle sprocket, if you buy a TAV, the sprockets that come with it are for 35series chain and 40 series chain. I use the 10T 40 series with a 420 chain on mine to a 420 rear sprocket... Hope it helps. https://www.gokartguide.com/go-kart-chain-size-chart/
Jim
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Thank you Jim, that's brilliant
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I sneaked off to the workshop last night.
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looking good Tim and I like your Mag Base. :) An Ideal tool for that application.
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Hi Tim, Jim - Picking up on the sprocket thread how many teeth is you axle sprocket. I have the same Torque converter issue and will need to switch to 420 chain or find a small 219 ? sprocket. Thanks. Ian
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Apologies to all you new builders out there, I haven't posted for a while as I forgot how important the Build Journals are when you are just starting out. As it's been so long, this may come across as a bit "all over the place"...soz!
To be honest there was a massive push to get things ready for Brooklands, I managed to get the kart built to be a rolling chassis, albeit a non-runner.
Building up the chassis went reasonably smoothly, mounting all the front suspension and axels was really easy. The rear setup took some brain power though to make sure everything was lined up and stayed that way. I’ve mounted the engine and engine plate on a sliding bed so I can adjust for chain tension using a bolt at the rear of the chassis. Not my idea, one I pinched from Chris S.
Following some advice on the forum I have a brake caliper from a Suzuki GSF 650, a Gemini brake disc and a Wilwood 0.70 Brake cylinder. The challenge here was that all the fittings are different sizes from metric to imperial and thread size, very confusing for a simple fella like me. I have used copper brake pipes (for now) to get it running but would like to change over to braided pipes in the future. The brakes are all set up and seem to work static. I do get a little movement in the caliper mount but nothing that can’t be strengthened later on. It could also be my really terrible welding!
The body slid into the chassis like it was made to fit…oh, wait a minute, it was! I still can’t believe it fits like a glove as it did keep me awake on a couple of nights.
The steering is just standard gokart stuff, I’ll upload some pics of this soon.
Wheels…these have been the most frustrating part of the build so far. I bought some Honda C90 originals that were in a proper state and to be honest, would probably have been better scrapped rather than renovated. But I thought “No, I’m going to bring those back to life”… foooool! So I bought 7 wheels, 5 of which were 17x 1.20 for £60, a deal not to be ignored by a Yorkshire man. I stripped them, wire wheeled and sanded the hubs and rims, painted them a lovely black with topcoat and then some new spokes. I spoked the rims but then spent about a week trying to true them, and this is where the problems started. It’s an art and I’m no artist…in fact, it's awful. The thing is, getting this done commercially is nearly impossible, nobody seems to do it anymore. After a lot of research, I found a place in Leeds that managed to do the front wheels for me but damaged them in the process. They tried to do the rears but lost them! 4 weeks later I eventually got them back untrued and the paint job I spent so long on was wrecked. I eventually found a really lovely fella down the road who restores bikes and he did a brilliant job.
All this work got the kart on 4 wheels and rolling at Brooklands but since then not a lot has happened other than me building a new steering wheel and starting the front grill (pics to follow).
At the moment my business is taking all my time and a sizable chunk of my budget to get it off the ground but it won't be long before I'm back at it
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Looking like great progress Tim, can't wait to see it track side :-)
JimR
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Me too Jim, but it will be next year now
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...and the grill
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Pics of the wheel I made. Quite pleased with how it turned out
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All good stuff, bet you cant wait to glue it all together. Hope to see it soon.
Cheers Nick
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So the post on FB about what everybody is building and the first Northern Builders Meet has really got me fired up to work on my ERA again.
I've stripped the whole thing down to individual components ready for painting. Once this is done I can then focus on getting it running properly and the body.
I had a very pleasant Sunday drilling drain holes and putting the end caps on my chassis in preparation for painting. Lots of welding and grinding...well, more grinding than welding actually.
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Finished the build of the grill yesterday. It has been more of a challenge than I thought it would be with all the angles. I did spend a lot of time on it though as quite often this is the first thing people look at and I wanted to make a good impression. Still to be painted but I'm chuffed with the result so far.
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Very nice, really looks the part.
Cheers Nick
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Cheers Nick
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Hours of fun
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Nice work Tim, looking good!
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Thanks Chris, this is the most enjoyable bit so far!
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I've had a couple of cracking days in the workshop, really enjoyed myself and pleased with the results so far. I've never done anything like this before and it's an absolute hoot!
My missus asked me what my advice would be to someone just about to start this stage...take your time and get yourself an extra fine Sharpie.
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Looking sweet Tim 😁
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Thanks Jim