"Sting"

[Ray]

The project is progressing. If I don't have time to work on the framing, I spend time working out other issues. Today I was able to complete the ignition system. I'm using the VW steering with the locking ignition switch. I designed the VW switch to work in conjunction with some relays I picked up on ebay to mimic the action of the Goldwing key, stop switch and starter button. I was able to test it out today and it worked great. I used short leads but will extend the wiring harness when I get to that stage. For now, I am satisfied that I can start the powertrain with my setup. I think I might conceal the kill switch as an additional anti-theft device.

This evening, I spent some time thinking about the linkages for shift, brakes and accelerator. I'm anxious to get the frame complete so I can work out the details.

[stretchmobileski]

Pull the arms off, grease everything well and reassemble. You won't need to grease them again in your life time. Remove the fitting and clamp over the holes (you can plug the holes with silicon if you are worried about dirt.) I've seen 100's of bugs that the owners never greased the front end with a million miles on them. Yes the front will wear out faster without being greased but that is subjective. With a very light load it should last 20-30 years of everyday driving. Its not hard to pull it apart on a vehicle like ours so even then it still can be greased.

[Ray]

May 9, 2015 19:53:41 GMT -5 stretchmobileski said:

Pull the arms off, grease everything well and reassemble. You won't need to grease them again in your life time. Remove the fitting and clamp over the holes (you can plug the holes with silicon if you are worried about dirt.) I've seen 100's of bugs that the owners never greased the front end with a million miles on them. Yes the front will wear out faster without being greased but that is subjective. With a very light load it should last 20-30 years of everyday driving. Its not hard to pull it apart on a vehicle like ours so even then it still can be greased.

Thanks. I will be taking the front end apart to grease it. I'll wait until I have the frame complete to do it but definitely will be done. 

Today, I got a chance to work on Sting a little more. I am working on the shape of the front frame. I'm seriously considering an opening hood storage compartment like the vw bug has. I'll have to make a decision shortly about that if I do it, otherwise there will be wasted space. One of my friends suggested  a ballast in the front if I have problems with the balance. Has anyone done that? 

[DaveJ98092]

May 10, 2015 1:30:13 GMT -5 Ray said:

May 9, 2015 19:53:41 GMT -5 stretchmobileski said:

Pull the arms off, grease everything well and reassemble. You won't need to grease them again in your life time. Remove the fitting and clamp over the holes (you can plug the holes with silicon if you are worried about dirt.) I've seen 100's of bugs that the owners never greased the front end with a million miles on them. Yes the front will wear out faster without being greased but that is subjective. With a very light load it should last 20-30 years of everyday driving. Its not hard to pull it apart on a vehicle like ours so even then it still can be greased.

Thanks. I will be taking the front end apart to grease it. I'll wait until I have the frame complete to do it but definitely will be done. 

Today, I got a chance to work on Sting a little more. I am working on the shape of the front frame. I'm seriously considering an opening hood storage compartment like the vw bug has. I'll have to make a decision shortly about that if I do it, otherwise there will be wasted space. One of my friends suggested  a ballast in the front if I have problems with the balance. Has anyone done that? 

What you want to do is move any other required items around to balance the cart before you add ballast. Things like a bigger radiator or fuel cell can be moved around to help.

[Ray]

May 10, 2015 20:15:43 GMT -5 DaveJ98092 said:

May 10, 2015 1:30:13 GMT -5 Ray said:

Thanks. I will be taking the front end apart to grease it. I'll wait until I have the frame complete to do it but definitely will be done. 

Today, I got a chance to work on Sting a little more. I am working on the shape of the front frame. I'm seriously considering an opening hood storage compartment like the vw bug has. I'll have to make a decision shortly about that if I do it, otherwise there will be wasted space. One of my friends suggested  a ballast in the front if I have problems with the balance. Has anyone done that? 

What you want to do is move any other required items around to balance the cart before you add ballast. Things like a bigger radiator or fuel cell can be moved around to help.

I had planned on using the original fuel tank on the GL1200 and the original radiator. I was wondering if the radiator was moved to the front of the vehicle, what would be the limitation as the fluid moves 5+ feet away from the pump etc. Or does the larger radiator go near the original location? Just wondering. I'm planning on providing ventilation via air scoops on the sides channeled over the engine and radiator. At one stage I had thought about the possibility of installing a VW type fuel tank in the front where the VW tank would go but decided that the smaller GL1200 tank should be sufficient. I'll just need to provide a door to access the tank. 

[Ray]

I am finally back at my project. I have a running engine. The rolling chassis is almost complete. I am working on the brackets for the lighting. Next will be the controls. I need to get some paint on the chassis as some of the raw materials are rusting some. I'll post some pictures shortly. I was stumped on a opening hood but I think I have a solution for that. I am exited about the progress.

[Ray]

[Ray]

As you can see from the above pictures, I have created a swoop to the top bars. I have also modified the front some. I watched a video yesterday that has influenced my hood design so that will change soon. I finished the brackets for the taillight and blinkers. I think it turned out well. I might try to figure out the headlight position. I bought spotlight headlights. I was going to mouth them low but I read somewhere about minimum distance from the ground. I will need to get a kit to lower my VW front suspension. I am leery of that phase so I will probably leave that until later.

[Ray]

[mtntech]

Good to see that you are back at it. Was wondering how you were progressing.

[Ray]

Today I worked on hooking the clutch master cylinder to the clutch pedal. It is not elegant but I think it will do the trick. Since everything needs to come apart to paint, I will not hook the clutch lines up yet, nor the brake lines. I will work on the accelerator and the choke next. I will need to work out the linkage. I've seen some ideas here I like so I will work on modifying one of the designs to suit my needs. I have an idea for the shifter I will work on soon. Right now, I need to concentrate on getting all the welding done so that I can paint the frame. 

[Ray]

Today's accomplishment was the choke. I connected the cable to the VW vent lever. 

[Ray]

This last couple of weeks I have been able to get the accelerator working and the shift mechanism. I have drilled the location for the seats and I received the 4 point seat belts today. I will create the ties for them in the next couple of days. The headlights are mounted for licensing purposes. They will be incorporated into the hood eventually. For now, they will do the trick.

 

[Ray]

I have taken Sting apart to paint the frame. I have the primer on. I will be painting it black. I have also installed the adjusters on the beam. I'll be painting it this week and reassembling it next week. I am pleased with the progress. 

[Ray]

The front end is coming together well. I have it mostly together. The paint is done with the exception of a few little parts. 

[Ray]

I have been able to put some good time into Sting. I am in the process of putting it back together after the frame paint. I have connected the brakes but I haven't added fluid or bled them yet. I decided to do some fiberglass at this stage so I started to cut out my molds yesterday and today. Also, I've ordered the line for the clutch and a few additional fittings. The accelerator and the shifter are hooked up. 

[Ray]

I decided to finish putting together the steering column today. I got it finished with the exception of the horn assembly. I even adjusted the slack in the steering. The driver's seat is mounted and I tried to bleed the brakes this eve. The rear and left front bled fine but the right front did not. I must have a blockage somewhere. The front calipers had been sitting a long time. The left was "sealed" by a crimp in the line but the right was not. There may be some rust or something keeping the fluid from flowing. I will not have time to work on it for a few days. The clutch line will be here in a day or two so hooking it up will complete the controls assuming I can get the right front brake working.

[Ray]

[Ray]

Today I worked on my first fiberglass endeavor. I had built a mold for the fender from a Goldwing fender but cutting it in half and adding a piece of metal to widen it by 50mm then used Bondo to smooth it out. I coated the fender with paraffin wax and made my first fender. I got a little over confident and tried to make the second and it did not turn out very well. I'll need to try again. Here is the rough, good fender. I haven't made the brackets yet but I set it in place to see what it will look like. 

[2rike]

Aug 28, 2016 2:39:24 GMT -5 Ray said:

Today I worked on my first fiberglass endeavor. I had built a mold for the fender from a Goldwing fender but cutting it in half and adding a piece of metal to widen it by 50mm then used Bondo to smooth it out. I coated the fender with paraffin wax and made my first fender. I got a little over confident and tried to make the second and it did not turn out very well. I'll need to try again. Here is the rough, good fender. I haven't made the brackets yet but I set it in place to see what it will look like. 

Now you have got stared with fiberglass there will be no stopping you !