cycle car with moto wheel

1920 Briggs & Stratton Cycle Car

with

Motor Wheel Drive

Copyright 2006Everett Moore

Everett MooreP.O. Box 1705

Cottonwood, AZ 86326

1

I originally built the Briggs and StrattonCycle Car without the conventional motorwheel drive. This was done to create an sim-ple, easy to build car for the beginningbuilder. It required no welding or machinework other than simply cutting a few piecesof steel to length.

This little car functioned fine, but was notwithout the peculiarities of one-wheel drive. Iwas not totally satisfied and became inspiredto build a motor-wheel to power it.

Rather than build another Cycle Car fromscratch, I decided to alter the existing one toaccept the motor-wheel. I kept in mind thatmany of you have built from the originaldesign and I wanted to make it as easy aspossible to alter yours to accept the motor-wheel.

Some further modifications were madeincluding changing from a hand brake leverto a conventional, foot operated, brake. Withthe exception of moving the equalizer assem-bly, all the original brake parts were used. Idid re-design the brake band anchor bracketsto provide a better geometry for clamping thebrake band, resulting in an improvement instopping power.

The motor-wheel is a self-contained unitthat attaches to the chassis board with 2brackets that allow it to pivot up and down,thereby maintaining constant contact withthe road. The only other attachment to car isthe throttle cable. This cable terminates cen-trally below the front edge of the seat and iscontrolled by hand. We chose to simplify thedesign on the motor-wheel and only used acentrifugal clutch.

The motor-wheel was designed with theidea that the builder could adapt it to aboutanything, similar to what was done with the

original Smith Motor-Wheel. Since a cen-trifugal clutch was used, it eliminated thenecessity for a lever, linkage, etc. to lift themotor-wheel off the road for starting.

A Worksman wheel and Kevlar tire wasused on the motor-wheel. Power was provid-ed to the wheel by using a 15 inch, “V” beltsheave as used on a Whizzer Motor Bike.These sheaves and mounting brackets areavailable from Whizzer dealers or directlyfrom Whizzer.

The most difficult task in building themotor-wheel is getting the belt sheavemounted concentrically on the wheel. Sometrial and error may be necessary.

Upon completion, some adjustment wasnecessary to the jack shaft to get the propertension on the “V” belt. We managed to get bywithout using a spring-loaded idler pulley tokeep the belt tight, although that could be anoption.

The entire car was completed in time for ashake-down cruise in the Cottonwood, AZChristmas Parade. It performed flawlesslyand finished the parade with it’s two passen-gers plus dog!

These plans were done with three possibleend results in mind.

1) Modifying an existing Cycle Car builtfrom our original plans.

2) Building a completely new Cycle Car fromthe beginning.

3) Build only the motor/wheel unit for adapt-ing to a personal project.

Enjoy and email me if you have any ques-tions. [email protected]

2

Foreword

"Tattoo the above quotes on your brain" asErnest used to say. Better yet, paint them assigns to hang in your shop where you can lookat them every time the going gets rough.

It was with this incentive that the manu-al you're holding was done. With its nearly200 different parts not even a simple cyclecar is necessarily easy. However, ifapproached one part at a time, the jobbecomes much easier.

Sometimes when you buy a set of plans fora project such as this, all you get is a copy ofa magazine article or everything crowdedonto a few sheets of paper.

In this manual you will find a completedrawing of each part — nothing is left for you— no guess work! A lot of parts are simply apiece of bar stock, angle or tubing cut tolength with one or more holes drilled in it.

This is not to imply that you can't go offthe beaten trail and modify or redesign toyour own desires. To do so is encouraged.

The idea that this horseless carriage couldbe approached as a class project crossed ourmind. Since it utilizes several machine shopoperations, each student could be assigned afew parts to do according to their ability andskills. When completed, let the auto body

shop do the painting. Then drive in the home-coming parade! The Industrial Arts Deptwins, hands down!

The same could apply to friends or neigh-bors who join together to build each a carwith different ones making all of certainparts.

A few tools I consider a necessity (eitherowning or having access to) and they are: acut-off saw, a drill press, a hand grinder, anaccurate square (combination & large carpen-ter's square), a bottle of layout blue and themeans of accurately-scribing layout lines onthe stock. Always center punch all holesbefore drilling.

The motor-wheel unit does require somebasic welding on the frame. The jack shaftmount was build from individual parts boltedtogether (Erector Set style). Note that shieldplates were used for safety on this unit.

Before you start making scrap iron, studythis manual and drawings. Obtain catalogsfrom suppliers and if you have access to theinternet, look at and bookmark the supplierswe have referenced.

Plan where you are going to work on yourcar. Although desirable, a large shop isn'tnecessary. Henry Ford utilized a coal shed for

3

Introduction

“Nothing is particularly hardif you divide it into small jobs.”

— Henry Ford

“Before everything else,getting ready is the secret of success.”

— Henry Ford

his first horseless carriage, the Quadricycle.And, while Henry said “plan ahead,” he evenhad to knock out the existing door and add alarger one just to get his car outside!

Visit your local steel supplier. Dependingon your location, you may have access to awell-stocked supplier. If you live in a ruralarea, look for a welding shop that might havesome scrap or be willing to order for you.

— What Tools Will You Need? —

Tools, while making any job easier, cannotreplace skill in the hands using them. Thelist of tools that follows are what I considersufficient to build the “Red Bug.”

1. A good floor-standing drill press. Includes a drill press vice and drill bitset.

2. A quality table saw.3. A good metal chop saw.4. An electric hand drill (3/8)5. A bellhangers drill bit (1/4)6. A set of Forstner drills.7. A hand jig saw.8. A drum sander (either individual or

attachment for drill press.9. A hand, belt sander is very useful.

10. A bench grinder or hand grinder for smoothing metal parts.

11. A good tap and die set (both NC & NF)12. A box of Band Aids!13. Arc welder — or have welding done.

— Start with the wooden parts —

It is only a suggestion that you start withthe wooden parts. The chassis is not unlikethe foundation when building a house. Sincemost other components rely on it for align-ment, care must be exercised when laying outthe various locations on the chassis.

Set the frame on a couple of saw horses.Every time you enter your shop you will seeit and it will trigger your mind to the ideathat, "By golly I'm really building a car - fromscratch - by myself". "I wonder when the nextparade in town is." Also, since the chassis isbasically a 2 x 8 ft piece of 3/4 plywood, itmakes an excellent place to sit down andmake other small parts. Seeing you car takeshape is a thrill you'll never forget.

On the original Briggs & Stratton CycleCar, the chassis was constructed from six 31/2” wide boards of (I would guess) 1” thickoak or hickory. If you have such available, goahead and substitute for the plywood I used.

I used a 2 x 8 sheet of 3/4 plywood andadded “phony” slats by gluing 3 1/2 widestrips of 1/4 plywood to the top surface. Ifound this arrangement to be a bit “flexible”with a payload of 450 lbs. Therefore, a sup-port, made from a 2x4, was added to each onthe underside.

_______________

4

The Original 1920 Briggs and Stratton Cycle Car

5

The Finished Cycle CarFeaturing the Motor Wheel

Let’s Make Sawdust First

I would recommend that all the woodenparts be sawed out at the same time. Thiswill reduce the large sheets of plywood into,smaller, more manageable pieces. In some ofthe next pages you will find rough, cutoutdimensions.

Rip all similar width pieces at the samesaw setting. Start with the widest and pro-ceed to the smaller ones.

You might consider finishing the seat,cushion bases and seat support first and setthem aside for final painting.

You will note how the axles are made bygluing pieces of 3/4 inch plywood together toget the desired thickness. The front axle isstraight forward gluing together of 3 identi-cal pieces. Whether you cut the profile of thefront axle in the individual pieces or aftergluing, is up to you.

Note how the rear axle has a dado (1 x 1)to hold the 1” square axle tube at assembly.You can come close to this dado by sawing thefiller pieces as shown. However, because ofthe varying thickness of purchased plywood,you will most likely have to “fine tune” thedado for a good fit to the steel tube. This fitshould be close enough to allow epoxying thetube at final assembly. The tube must beflush to top surface of axle after assembly.

The foot rest is, likewise, made by gluingtogether two pieces of 3/4 inch plywood.

The fun piece is the steering shaft supportwhich, because of its shape, I call the “dogbone.” Like the front axle, you might want tosaw the 2 individual pieces before gluingtogether. A good drum sander is very usefulin the finishing of this part. Save the drillinguntil after the gluing is done.

While I didn’t specify any corner round-ing, I personally used a hand router and a1/4” round over bit to make a lot of edges“look pretty.”

I, also, spared a lot of little detail on the

wood parts because I find most people withany degree of a home workshop will usuallyhave sufficient woodworking skills to suffice.

I recommend that any finished wood partbe left without paint at this time. You shouldcompletely finish, assemble and test driveyour car and only then disassemble andpaint.

_______________

6

The Making and Assembly Processes

A city version of the Cycle Car was madelater, using electric power for use in large

estates as personal transportation.It was call the “Red Bug.” We named ours

Red Bug, likewise.

PART DESCRIPTION

SHEET - 1PLYWOOD CUTTING

PART NUMBER

007SCALE

See Notes


7

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4 Plywood - full 4 x 8 sheet.4. Saw cuts have been allowed for.

40 14

1534

front axle front axle front axle

rear axle rear axle

CHASSIS

seat support front

foot rest

foot rest

rear axle

seat support front

seat supportside

seat supportside

24

3

5 14

24 22 12 15 34 15 34

22 12

31 3/4 31 3/4 31 3/4 4 14

3 12

38 3

2 12

3 34

48

seat support botton

86

96

PART DESCRIPTION

SHEET - 2PLYWOOD CUTTING

PART NUMBER

008SCALE

See Notes


8

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 1/4 Plywood - full sheet

3 12 ( X6 )

2 12

floor slat x 6

floor slat x 6

floor slat x 6

floor slat x 6

floor slat x 6

floor slat x 6

PART DESCRIPTION

SHEET - 3, SEATPLYWOOD CUTTING

PART NUMBER

009SCALE

See Notes


9

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4 Plywood

17.00

16.00

8.00

1.75

44.00

17.00 17.00

40.00

Back

Side Side

Bottom

Seat Back Strip

48.00

48.00

PART DESCRIPTION

TOP VIEWCHASSIS —

PART NUMBER

010SCALE

See Notes


010

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4” Plywood — Imitation Slats = 1/4” Plywood.4. All hole dia’s to be 3/8” except those marked “x” which are 1/4”.5. Some hole dia’s are called out on hole patterns.6. See text for more drilling instructions.7. Break all corners and sharp edges.8. Finish: Choice of builder.

8

15 12

20 27

48 12

72

4 14 7 78

2

2 116

2 116

18 R

10 516

10 516

6 58

1 14

Center Line Rear Axle

Center Line Front Axle

10 (ref) 1

1Hole Pattern "A"

4 R

Hole Pattern "B"

xx

x x

xx

xx

Center Line of Chassis

2

20 3 Center on groove

*

*

*

*

Dims marked with ( * ) apply to both front and rear axle mounting holes.

Hole Pattern "D"

42.00

4

1 12 R

86

x

x

4

PART DESCRIPTION

SHEET 2CHASSIS - TOP VIEW

PART NUMBER

011SCALE

See Notes

Copyright 2005 - Everett Moore

011

HOLE PATTERN LAYOUTSUse dimensions given - Do not scale drawing.

38 DIA - 2 Holes

3

1 12

38 R

3 12

38 DIA - 2 Holes

1 383

2 12

5 1238 R

14 DIA - 2 Holes

1 12

Cut relief to clear 1/4" flat washer Cut thru 1/4" imitation slat - 2 places

A B

DHole patterns “C” & “E” are not used.

PART DESCRIPTION

PIVOT SHAFTMOTOR WHEEL

PART NUMBER

012SCALE

See Notes


12

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: .750 dia CRS.4. Break all corners and sharp edges.5. Finish: Choice of builder.

10 3812

12

18 DIA (2)

18 R .750 dia CRS

PART DESCRIPTION

FOOT REST

PART NUMBER

013SCALE

See Notes


013

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4 Plywood. Glue 2 pieces together.4. Break all corners and sharp edges.5. Finish: Choice of builder.

6

38 DIA - 2 Holes

36

1 12

1 R

3 R1 12

6

1

1 12

7 34

3

20 12

3 R

PART DESCRIPTION

SUB - ASSEMBLYFRONT AXLE

PART NUMBER

014SCALE

See Notes


014

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4 Plywood (3 pieces glued together)4. Break all corners and sharp edges.5. Finish: Choice of builder.

2 12

4 14

2 1478

1 18

Center Line of Chassis

10 516

2 116 2 1

16

10 516

2 14 78

38 DIA - 8 holes 2 14 (ref)

3 1316 both ends

13 1316 both ends

31 342 34 - 4 plcs

1" Dia. C'bore to depth shown - Typical 4 Places

PART DESCRIPTION

ASSEMBLYREAR AXLE

PART NUMBER

015SCALE

See Notes


015

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4 plywood (3 pieces), 1/4” plywood (1 piece) Cut to dims shown.

1” square x .120 wall steel tubing - 34.750 long4. Glue plywood pieces together as shown. When dry, epoxy steel tube in

to dimensions shown. Tube and plywood to be flush at top.5. Plywood thickness can vary. Therefore it may be necessary to touch up the

1” dado on the table saw to make a snug but loose fit between steel and wooden axle.

6. Break all corners and sharp edges.7. Finish: Choice of builder.

1 14 1 14 Center line

10 516

2 116 2 1

16

10 516

34 34

1 12

1 12 38 DIA - 4 holes

14 DIA - 12 holes

2 122 12

3 12

1 916 (ref - both ends)31 34

1 14 - Typical 6 places

Sq tube & plywood surfaces to be flush this entire surface34 78

PART DESCRIPTION

SUPPORTSTEERING SHAFT

PART NUMBER

016SCALE

See Notes


16

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 2 pieces of 3/4 plywood glued together.4. Round over corners as shown.5. Finish: Choice of builder.

1 14

2

11 12

58 DIA

3

4 Places

34

Typical both ends

4 Holes

1 R12 R

1 12

2

5

14

1 14

38 DIA

PART DESCRIPTION

ASSEMBLYSEAT SUPPORT

PART NUMBER

017SCALE

See Notes


17

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/4” Plywood.4. Glue & screw together.5. Finish: Choice of builder.

15 34

22 12

24

7 78

20

2 2 (REF)

38 DIA - 2 Holes

3 34

6

5 14

4 12

PART DESCRIPTION

SEAT ASSEMBLY

PART NUMBER

018SCALE

See Notes


18

NOTES:

1. Use dimensions shown. Do not scale drawing.2. Material: 3/4 in. plywood.3. Referring to this drawing and drawing XXX, cut two slots to accept corner brackets.4. Fit parts - glue - reinforce with screws and corner brackets.

15 34

40

4 R

4 R

80°

44

15

16

1 14

2

17

15

16 516

Front corner top viewTypical two places

3 12

o

1 R

8

PART DESCRIPTION

SEAT - REAR DETAIL

PART NUMBER

019SCALE

See Notes


19

NOTES:

1. Cut two slots as shown. Use router preferably. However, multiple holes can bedrilled and connected with jig saw. Slot should only be wide enough to acceptthe bracket. Prototype used 1/4 in.

2. Drill 1/4 dia holes thru seat back & arm rests and secure brackets with 1/4 - 20bolts, fender washers and nuts. Place nuts on outside.

Cut slot thru seat back to accept corner bracketboth sides

4 in corner reinforcing bracketfasten to rear of seat, extend thru slotfasten to outside of arm rest. ( 2 places )

Rear view of seat

Detail of seat back reinforcement

PART DESCRIPTION

SUPPORT - LHUNDER CHASSIS

PART NUMBER

020SCALE

See Notes


20

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Make from 2 x 4 (1 1/2 x 3 1/2)4. Mounting holes to be drilled at assembly.5. Finish: Choice of builder.

10 1811

12 38

3 12

1 14 69 58

316

1 DIA

PART DESCRIPTION

SUPPORT - RHUNDER CHASSIS

PART NUMBER

021SCALE

See Notes


21

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Make from 2 x 4 (1 1/2 x 3 1/2)4. Mounting holes to be drilled at assembly.5. Finish: Choice of builder.

1

10 1811

12 38

69 58

316

1 DIA

If you haven’t already, you might want tocut the 1” square tube to required length andfinish the rear axle per drawing No. 015.

Be sure to align your chop saw so as to cutas near to 90 degrees as possible. I nevertrust the marks provided and prefer to use asquare to do this.

I recommend cutting all bar stock, anglesand motor-wheel parts to the required lengthat one time. Next, remove any burrs andsharp edges with a hand file.

To layout the hole locations, you shouldhave a small bottle of layout blue. You needonly apply it to the approximate area wherethe holes will be. Accurately locate the holeswith a good square and scale. Scribe lineswith a scriber and center punch beforedrilling holes.

When all holes are drilled, using either abench grinder or hand grinder, form theradius’ called out on the drawings. These arenot critical and in some cases are more forappearance than anything else.

One of the more difficult parts will be thetwo hub mounting flanges, Drawing No. 034.Layout and scribe the hole locations withyour square and compass or use the card-board tool described in Drawing No. 035.

Using the appropriate tap drill, drill andthen tap holes per drawing. If you have neverused a tap before, do two things — 1) Use acutting fluid to lubricate the tap while cut -ting (I use WD-40) 2) Every couple or threeturns of the tap, stop and backup a turn tobreak the chip and free the tap again.

Don’t force the tap, back up, and go again.Nothing will make a grown man cry quickerthan breaking a tap flush with the work, usu-ally on the last hole of a nearly completedpart! Make an effort to start the tap perpen-dicular to the the part.

After completing drilling and tapping, allthat’s left to do is cutting the center hole. Insticking with my criteria established at thebeginning, I did this without using a lathe. Of

course, if you have a lathe, by all means useit!

I used a 1-5/8” dia. metal cutting hole saw,cutting half way on one side and turning thepart over and finishing from the other side.

Since the hole could be a bit smaller, if youhave a 1-9/16” dia saw or want to use a flycutter, use it.

The only tapped holes remaining are onthe chain tightener anchor blocks and thetubular nuts (use in the steering shaft sup-port AKA “Dog Bone.”)

All the techniques of tapping used on theprevious parts, apply here, also.

While into tread cutting, you might aswell cut the threads on all parts made fromround CRS. From your tap and die set chosethe appropriate die and die stock (the handlethat holds the die) and, after cutting the rodsto length, cut the threads per drawings No.038 and 039.

The remaining metal work entails modify-ing a purchased part, such as cross drillingand pressing in a roll-pin, drill and tappingor, in one case, cutting threads with a die.

One part, the brake activator guide, PartNo. 041 requires drilling and tapping pluspressing in two bearings.

Other modifications are self-explanatoryas per the drawing.

Now is a good time to examine all yourparts by comparing them to the drawing.Remove any burrs found, de-grease and setaside for the initial assembly process.

Collect all the motor-wheel parts and setup for welding or, if desired, taken, togetherwith drawing, to a welder for completing themotor-wheel frame.

Only after making sure that parts fit andfunction as intended, should they be de-greased, primed and painted with the finishof your choice.

_______________

22

The Making of Metal Parts

PART DESCRIPTION

MOUNTING BRACKETFRONT SPINDLE

PART NUMBER

023SCALE

See Notes


23

NOTES:1. Quantity required per car: 42. Use dimensions given - Do not scale drawing.3. Material: 1/4 X 1-1/2 Steel Bar Stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

.750

2.250

4.125

1 12 R

1 12

1116

5 58

.375 DIA (2)

.625 DIA

PART DESCRIPTION

BRAKE ARMINTERMEDIATE

PART NUMBER

024SCALE

See Notes


24

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 1/4 x 1” steel bar stock.4. Break all corners and sharp edges.5. Finish: Builder’s choice.

3.50

.50 R

.312 DIA

.50

.250 DIA4 holes

7.00

8.00

9.00

10.00 (ref)

PART DESCRIPTION

MOUNTING BRACKETBRAKE PEDAL

PART NUMBER

025SCALE

See Notes


25

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Make from purchased part per drawing callout.4. Break all corners and sharp edges.5. Finish: Builders choice.

1116 1 12

58

516 DIA

.625 Dia (ref)

PP 242

PART DESCRIPTION

WASHER PLATE

PART NUMBER

026SCALE

See Notes


26

NOTES:1. Quantity required per car = (4)2. Use dimensions given - Do not scale drawing.3. Material: 1/8 x 1 Bar stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

38 1 14

2

932 DIA

12

1

PART DESCRIPTION

ASSEMBLYBRAKE PEDAL

PART NUMBER

027SCALE

See Notes


27

NOTES:1. Quantity required per car: 12. Weld components as shown.3. Material: 1/4 X 1 Steel bar stock & .625 dia CRS.4. Finish: Choice of builder.

3.75

18

316.50

1.00

1.00

1.00

1 58

414 R

34

7 78

3 316

.125 dia

.625 dia CRS

Weld all around

.250 DIA

.625 DIA

3 holes

PART DESCRIPTION

PULLEY MTG. BKT.CENTER BRAKE

PART NUMBER

028SCALE

See Notes


28

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 1/8 X 1- 1/2 steel bar stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

7

4.001 12

.250 DIA2 Holes

34

1 12

PART DESCRIPTION

PULLEY MTG. BKT.OUTBOARD BRAKE

PART NUMBER

029SCALE

See Notes


29

NOTES:1. Quantity required per car: 1 Left Hand & 1 Right Hand.2. Use dimensions given - Do not scale drawing.3. Material: 1/8 X 1- 1/2 Steel Bar Stock4. Twist bend as shown to allow brake cable to go under chassis board.4. Break all corners and sharp edges.5. Finish: Choice of builder.

1 12 4.50 6.00

13

11 12

12°

34

1 12

.250 DIA

.375 DIA2 Holes

Twisting bend to be within this area

LH as shown (Qty 1)

18 R

RH to be mirrow image (Qty 1)

A =

B =

PART DESCRIPTION

ATTACHMENT BRACKETMOTOR WHEEL

PART NUMBER

030SCALE

See Notes


30

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 3/16 X 2 X 3 Angle.4. Break all corners and sharp edges.5. Finish: Choice of builder.

.375 DIA

.25 R, typical.25

1.50

3.00

2.003.00

2.00

.75

.750 DIA

PART DESCRIPTION

MOUNTING BKT - LHBRAKE ANCHOR

PART NUMBER

031SCALE

See Notes


31

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/16 X 2 X 2 Angle.4. Break all corners and sharp edges.5. Finish: Choice of builder.

.375 DIA

1 12

1

22

3 HOLES 5

5 34

78

12

14 R

12 R

PART DESCRIPTION

MOUNTING BKT - RHBRAKE ANCHOR

PART NUMBER

032SCALE

See Notes


32

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/16 X 2 X 2 angle4. Break all corners and sharp edges.5. Finish: Choice of builder.

.375 DIA

3 HOLES

1 12

121

2

2

78

5

5 34

14 R 1

2 R

PART DESCRIPTION

LEVER MTG BKTINTERMEDIATE BRAKE

PART NUMBER

033SCALE

See Notes


33

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 3/16 - 2 x 3 Angle & 3/16 x 1 1/2 bar stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

4

1 12

3

1434

1 12

412 (ref)

516 DIA Weld

1

2

12

3

38 DIA

14 R (typical)

2 Holes

PART DESCRIPTION

FLANGE - ALTERNATIVEHUB MOUNTING

PART NUMBER

034SCALE

See Notes


34

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: See drawing callout.4. Break all corners and sharp edges.5. Finish: Choice of builder.

Make from 3 1/2" Dia. Aluminum discMcMaster-Carr No. 9035K17 - PP 248

5/16 x 24 UNF4 holes

2.812 DIA

2.000 DIA

1/4 x 28 UNF4 holes

1-5/8 DIA

3-1/2 DIA (ref)

.50 (REF)

PART DESCRIPTION

WHEEL/FLANGE DRILLCARDBOARD TOOL

PART NUMBER

035SCALE

See Notes


35

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Cardboard such as on back of writing tablets, poster board, etc.4. Cut stack of small disks to be snug fit in wheel bearing hole. (approx 1.375).5. Glue stack of small disks concentrically on large disk. This stack must be

sufficient to firmly locate tool in wheel hub.6. Make small pin hole at intersection of all 8 hole locations.

3 12 DIA

2 1316 DIA

1 1332 R

2 DIA

1 R

1 1132 DIA

*

Location of pin holesTypical 8 places

PART DESCRIPTION

COMP0NENT PIECESWHEEL SUPPORT

PART NUMBER

036SCALE

See Notes


36

NOTES:1. Quantity required per car = 2 each2. Use dimensions given - Do not scale drawing.3. Material: 3/16 x 2 bar stock.4. Break all corners and sharp edges.5. Finish: Finished after final weldment.

1.00 R

.750 DIA

.50 R

.50 R

8 12 (ref)

Mat'l = 3/16 bar stock

C B A

5 126 12

7 12

22

2

PART DESCRIPTION

TUBULAR NUT

PART NUMBER

037SCALE

See Notes


37

NOTES:1. Quantity required per car: 42. Use dimensions given - Do not scale drawing.3. Material: 5/8 Dia CRS4. Break all corners and sharp edges.5. Finish: Choice of builder.

58 DIA

5/16 - 24 UNF

34

1 12

PART DESCRIPTION

SHAFTSBRAKE ACTIVATOR

PART NUMBER

038SCALE

See Notes


38

NOTES:1. Quantity required per car = 1 each2. Use dimensions given - Do not scale drawing.3. Material: .250 Dia. Cold Rolled Steel (CRS).4. Break all corners and sharp edges.5. Finish: None.

1/4 - 28 UNF - Both ends - Min. full thread as shown

See Length Table Below

Lengths

A = 8 inchesB = 10 1/2 inchesC = 7 inches

1 141 14

PART DESCRIPTION

TIE RODS - A & B

PART NUMBER

039SCALE

See Notes


39

NOTES:1. Quantity required per car: 1 “A” & 1 “B”2. Use dimensions given - Do not scale drawing.3. Material: Per drawing callout.4. Break all corners and sharp edges.5. Finish: Choice of builder.6. Assemble each Tie Rod with lock nut and ball end on each end. Screw on

far enough to keep together as a unit. Do not tighten until final assembly.

Make from 3/8 dia CRS

3/8 - 24 UNF - Min 1-1/2" full thd - both ends

3/8 - 24 Nut (4 req"d)

Tie Rod "A" = 7 in. Long

Tie Rod "B" = 23 3/8 long

3/8 - 24 Ball end - No. PP 203 (4 req'd)

PART DESCRIPTION

DIAGONAL BRACE

PART NUMBER

040SCALE

See Notes


40

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 1/8 X 3/4 bar stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

8 2132

38

38

34

9 1332

.250 dia - 2 holes38 R

PART DESCRIPTION

GUIDEBRAKE ACTIVATOR

PART NUMBER

041SCALE

See Notes


41

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Per drawing callout. The builder has lattitude to utilize what ever

is on hand to build this guide. 4. Break all corners and sharp edges.5. Press bearings in flush with flange (both ends). The .250 hole thru bearings

must be aligned and free for movement of activator shaft. This may require running drill through holes after assembly.

6. Finish: Choice of builder.

58

34 1 12

3" (ref)

1 14 (ref) 12

14 (ref)

1/4 - 28 UNF - 2 holes

.375 DIA - thru both ends

1 (ref)

PP 242

PP 243 (2)

14 DIA

See notes

PART DESCRIPTION

LINKBRAKE ACTIVATOR

PART NUMBER

042SCALE

See Notes


42

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Make from PP 244 - No. 6065K131 (McMaster - Carr)4. Break all corners and sharp edges.5. Finish: Choice of builder.

.250 DIA 1/4 -28 UNF

1 12Min full thd

3 (ref)

PP 244

Make from Rod End Blank, McMaster Carr No. 6065K131

PART DESCRIPTION

ANCHOR BOLTBRAKE BAND

PART NUMBER

043SCALE

See Notes


43

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: Make from 3/8 x 24 UNF bolt.4. Cross drill .125 dia as shown.5. Break all corners and sharp edges.6. Press roll pin thru bolt flush with opposite side.7. Finish: Choice of builder.

2 14

12

1/8 x 3/4 Roll pin1

1 in. before threads

PART DESCRIPTION

ANCHOR PINBRAKE BAND

PART NUMBER

044SCALE

See Notes


44

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: .375 dia. Cold rolled steel (CRS) or make from Cable Pins,

Part. No. 13663 (Northern Tool)4. Break all corners and sharp edges.5. Press roll pin thru until flush with with opposite side.6. Finish: Choice of builder.

12

1/8 x 3/4 Roll pin1

.375 DIA - CRS

38 (ref)

.125 Dia.

PART DESCRIPTION

MODIFICATIONREAR HUB

PART NUMBER

045SCALE

See Notes


45

NOTES:1. Quantity required per car: 22. Material: Per callout on drawing.3. Carefully remove bearing from one side.4. Use dimensions given - Do not scale drawing.5. Remove burrs after drilling.6. Finish: Paint metal exposed by drilling. Color: Choice of builder.

on 2.000 dia BC4 holes, evenly spaced

Only hub is shown for clarity.

17/64 Dia.

Rear Wheel (Purchased Part No. 206)

PART DESCRIPTION

PLATEPIVOT SUPPORT

PART NUMBER

046SCALE

See Notes


46

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 3/16 x 3 bar stock.4. Break all corners and sharp edges.5. Finish: Finished at welded assembly.

1

4 12

1

3

12 R

PART DESCRIPTION

THROTTLE MTG BKT

PART NUMBER

047SCALE

See Notes


47

NOTES:1. Quantity required per car = 12. Use dimensions given - Do not scale drawing.3. Material: 1 x 1/8 Aluminum bar stock.4. Finish: Natural

38 2 14

1 12

3

12

1

38 DIA

316 DIA 2 holes

PART DESCRIPTION

A & BSTEERING SHAFT

PART NUMBER

048SCALE

See Notes


48

NOTES:1. Quantity required per car: 1 each.2. Use dimensions given - Do not scale drawing.3. Material: Make from purchased parts per drawing callout.4. Break all corners and sharp edges.5. Finish: Choice of builder.

SHAFT "A" (1 Req'd)

SHAFT "B" (1 Req'd)

PP 232

Make from PP 233

15 12

24 (REF)

You will find that there are some partsthat can best be assembled as a sub-assemblyand then, be attached to the final assembly asa unit.

Starting at the front of the car: the frontaxle can be done as a sub-assembly per draw-ing No. 054.

The brake mechanism as depicted ondrawing No. 050 can be partially assembledas a sub- assembly.

The motor wheel itself is a sub-assemblywith some of its components put together assub-assemblies.

The next two sub-assemblies are a bitmore difficult. Referring to drawing No. 052,you will see how the adapter, Part No. 034 isattached to a rear wheel. While we do notpower either wheel, both wheels have brakedrums and require both rear wheels to havethis adapter attached.

Originally, we fastened the adapter andwheel with 1/4-28 socket-head cap screwsand split lockwasher. However, this tended toloosened up..

Therefore, we now recommend that, inaddition to the lockwasher, the threads becoated with LocTite (Red), making a semi-

permanent assembly.The inner bearing of the wheel had to be

removed for the drilling of the four holes asshown in drawing No. 045. The bearing is notreplaced until after the mounting flange hasbeen attached.

Doing the above described assemblyrequires working in very tight quarters. Along, ball end allen wrench is used to insertand turn the Allen Head screws from theopening in the opposite bearing.

After applying LocTite, tighten all fourscrews as tight as you can get them — justshort of breaking the ball end off yourwrench. Hopefully, this is the last time youhave to do this.

With the two rear wheels thus done, youmight as well proceed to finishing up the rearwheels by attaching the discs and brakedrums per drawing No. 053.

The purpose of these discs is to help keepthe brake bands in place.

The front axle can either be sub-assem-bled separately or after it is attached to thechassis board. I prefer the latter. In eithercase it is depicted on drawing No. 054.

49

The Sub-Assembly Process

PART DESCRIPTION

ASSEMBLYBRAKE ACTIVATOR

PART NUMBER

050SCALE

See Notes


50

NOTES:1. Quantity required per car: 13. Material: Per drawing callout4. Finish: Choice of builder.5. Add a compression spring to area indicated to achieve desired

brake return.6. Adjust so that when lever No. 024 is upright (as shown)

there’s sufficient release of brake bands.7. Adjust brake pedal No. 027 to suit operator.

042

1/4 - 28 Hex Nut (4)

PP 214 )ref)

On final assembly, useLoctite (blue) on coupling nut

033 038A

038B

024

025

027038C

PP 214 (5)PP 240 (5)PP 241 (5)

PP 214 (ref)PP 240 (ref)PP 241 (ref)

041

See Notes

Note: It may be necessaryto file clevis in this areafor free turning of pulley

PP 235 (1)

On final assembly, useLoctite (blue) on these 2 capscrews

PP 231

PART DESCRIPTION

JACKSHAFTMOTOR WHEEL

PART NUMBER

051SCALE

See Notes


51

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: .750 Dia CRS with full keyway4. Break all corners and sharp edges.5. Finish: None

11 34

.750 DIA (ref)

.050 R (typical)

PART DESCRIPTION

SUB-ASSEMBLYREAR WHEEL - FLANGE

PART NUMBER

052SCALE

See Notes


52

NOTES:1. Quantity required per car: 22. Material: Per drawing callout. 3. Apply LocTite (Red) to threads.4. Re-install bearing removed when modifying hub. Use new bearing if

original was damaged.5. Finish: Finished prior to assembly.

1/4 X 28 - 5/8 Long Socket Hd Capscrew (4 req'd)

Only hub is shown for clarity.Part No. 045

Part No. 034

1/4 Lock Washer (4 req'd) - Apply LocTite (Red) to threads.

PART DESCRIPTION

GUIDE DISC & DRUM REAR WHEEL ASS’Y -

PART NUMBER

053SCALE

See Notes


53

NOTES:1. Quantity required per car: 22. Material: Per callout on drawing.3. Finish: Parts are pre-finished at assembly

5/16 x 24 UNF - 7/8 Long Socket Head C'Screw

4 each req'd

Wheel Sub-Assembly Part No. 052Brake Drum - PP No. 223

5/16 Lock Washer Plus use LocTite (red)

075

PART DESCRIPTION

ASSEMBLYFRONT AXLE

PART NUMBER

054SCALE

See Notes


54

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Per drawing callout.4. Break all corners and sharp edges.5. Finish: Parts to be finished before assembly.6. Add 3/8 fender washers to lower spindle brackets as necessary to obtain

proper fit of spindle.

PP 202 PP 228 (2)

PP 201 PP 228 (2)

023 (4) 014

Adjust spacing between brackets, if needed, by placing large, fender washers between lower brackets and wood.

PART DESCRIPTION

BASE ANGLEJACKSHAFT

PART NUMBER

055SCALE

See Notes


55

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 1/8 x 1 angle.4. Break all corners and sharp edges.5. Finish: Choice of builder.

2 34 6 1212

1 6

9 34

58

12

.250 Dia - 2 holes

.312 dia - 2 holes

12 R

A = Left side as shown

B = Right side mirrow image of left

PART DESCRIPTION

UPRIGHT ANGLESJACKSHAFT

PART NUMBER

056SCALE

See Notes


56

NOTES:1. Quantity required per car: 2 of A & 2 of B2. Use dimensions given - Do not scale drawing.3. Material: 1/8 x 1 angle.4. Break all corners and sharp edges.5. Finish: Choice of builder.

12 2

7 3438 (ref)

12

.250 Dia

Dimensions are same for both parts

12 R

B = Left (2)

A = Right (2)

PART DESCRIPTION

MOUNTING PLATEBEARING

PART NUMBER

057SCALE

See Notes


57

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 1/8 x 3 bar stock.4. Break all corners and sharp edges.5. Finish: Choice of builder.

12

3 141 25

32 1 2532

6 12

7 12

12

34

2

3

.250 Dia - 4 holes

7/16 Dia - 2 holes

1 DiaBearing Mounting Plate (2)

PART DESCRIPTION

BOTTOM VIEWCHASSIS ASSEMBLY -

PART NUMBER

058SCALE

See Notes


58

NOTES:1. Quantity required per car: 12. Parts locate per previously drilled holes.3. Material: Per drawing callout.4. Assemble per intructions in text.

PP 236

054

039A

039B

010

020

021

029A PP 235

029B PP 235

015

050 028

PP 235 (2)

026

026

PART DESCRIPTION

TOP VIEWCHASSIS ASSEMBLY -

PART NUMBER

059SCALE

See Notes


59

NOTES:1. Quantity required per car: 12. Parts locate per previously drilled holes.3. Material: Per drawing callout.4. Assemble per intructions in text.5. ** Throttle cable exit location determined by engine used.

030 (2)

065 013

For brake detail see drawing 050

017

Attach brake actuator ass'y (below) with 1.4-28 x 1" caoscrews & washers Bolt heads must not interfer with Seat support (017). Secure with LocTite (Blue).

**

PP 251 (ref)

PART DESCRIPTION

SIDE VIEWCHASSIS ASSEMBLY

PART NUMBER

060SCALE

See Notes


60

NOTES:1. Dis-assemble pillow blocks No. PP 204 and re-assemble with oil cup out

side instead of top hole. This will allow extreme movement of bearingnecessary to match angle of steering shaft.

2. Position the steering shaft to clear front axle by 1/4” and secure in placewith Collars PP 212 and Bearings PP 229.

3. Attach seat to support with 2-1/2” removable pin hinges (2)4. Throttle cable to be mounted 1” below top edge of seat support.

016 037 (4)

068

018

PP 226 PP227

Mtg. flange included with 048B

048B

PP 204 (2)

PP 212 (2) PP 229 (2)

PP 234

048A

For brake detail see drawing 050

For detail see drawing 061

See notes

067

030 (2) (ref)

14

PP 251

047

Length of throttle cable extending and wire end bendingto be determined when engine wheel is mounted

PART DESCRIPTION

SHAFT ASS’Y DETAILSTIE ROD - STEERING

PART NUMBER

061SCALE

See Notes


61

NOTES:1. Assemble as shown.2. End of steering shaft to be 1/4” from front axle.2. Use shim washers as shown to premit maximum tie rod travel.3. Secure nuts with LocTite (blue)

PP XXX (typical)

PP XXX (typical)

Apply LocTite (Blue) 2 places

PP 210 (typical)

PP 211 (typical)

Apply LocTite (Blue) 2 places

1/4

PART DESCRIPTION

FINAL WELDMENTMAIN FRAME

PART NUMBER

062SCALE

See Notes


62

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Per drawing callout.4. Engine mounting plate is P/N AZ8190 from Manufacturers Supply5. Break all corners and sharp edges.5. Finish: Choice of builder.

5 1217

125 38

1 1/2 x 1 1/2 x .120 Sq Tube 2 pieces - 5 3/8 Lg.

5 (ref)

1" x 1" x .120 Sq Tube - 8 3/8 Lg.

Weld according to accepted welding practices

063 RH

063 LH

046 (2)

PP 250

PART DESCRIPTION

SIDE WELDMENTMAIN FRAME

PART NUMBER

063SCALE

See Notes


63

NOTES:1. Quantity required per car: 2, 1 RH & 1LH2. Use dimensions given - Do not scale drawing.3. Material: Per drawing callouts.4. Break all corners and sharp edges.5. Finish: Finished at final welded assembly.

1 1/2 x 1 1/2 x .120 Sq Tubing

Weld

Right side shownLeft side is mirrow image

32 12

036-C

036-B

036-A

046 (2)

073

PART DESCRIPTION

INSTALLATIONBRAKE BAND

PART NUMBER

064SCALE

See Notes


64

NOTES:1. Quantity required per car: 2 (left and right)2. Loosely assemble anchor bolt (043) at this stage. Final adjustment are

made to it and brake cable after rear wheels are mounted.3. Secure brake cable with standard clamp from hardware store.4. Roll-pins of parts 043 and 044 are positioned approximately as shown.

PP 224 (2)

031 (Left ) 032 (Right )

043

044

PART DESCRIPTION

DETAILSAXLE - HUBCAP

PART NUMBER

065SCALE

See Notes


65

NOTES:

1. Use dimensions shown. Do not scale drawing.2. Axle = 3/4 dia CRS cut oversize (48”) - Push axle thru axle tube on frame - Install shim

washers and 1 wheel as show above - Install 1 hub cap, cross drill, install cotterpin - Install shim washers and 2nd wheel - Allowing extra length for hub cap,cut off - Install hub cap - cross drill - Install 2nd cotter pin.

3. Add or remove 1/32 shim washers to allow wheels to turn freely without excess-sive end play.

1/8 shim washer

1/32 shim washer (as needed)

Make from 1/2 in pipe capDrill out to 3/4 dia. - cross drill 5/32 dia.

Attach entire assembly to axle with 5/32 cotter pin

See notes about axle length

053 (2) (wheel)

PART DESCRIPTION

ASSEMBLYDRIVE WHEEL

PART NUMBER

066SCALE

See Notes


66

NOTES:1. Quantity required per car: 12. Material: Worksman Wheel, Tire, Tube & Strip. Whizzer Motorbike Sheave.

Callouts refer to purchased part list.3. Finish: Parts are plated.4. Using Clips (PP 239), mount Sheave (PP 238) to spokes of wheel. Use care

to get sheave concentric with axle/hub.

A

ASection A - A

PP 207 PP 216 PP 220 PP 221

PP 238 PP 239 (9)

PART DESCRIPTION

SEAT CUSHION BASE

PART NUMBER

067SCALE

See Notes


67

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 1/2 inch plywood - 1/4 - 20 x 5/16 “T” nuts (4) - PP 2494. Break all corners and sharp edges.5. Finish: None.6. Suggest using 2 in. of foam covered with appropriate upholstery material

stretched tight and stapled in back. Be sure and not cover up the mountingholes. Alternate: Take to an upholstery shop and let them cover it.

Section A - A 4:1

7 14 21

35 12

AA

11

14

1 12

5/16 dia C'bore 1" dia 1/16 deep

Press 1/4 - 20 "T" nut flushTypical 4 places

PART DESCRIPTION

CUSHION BASESEAT BACK

PART NUMBER

068SCALE

See Notes


68

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: 1/2 inch plywood - 1/4 - 20 x 5/16 “T” nuts (3) - PP 2494. Break all corners and sharp edges.5. Finish: None.6. Suggest using 2 in. of foam covered with appropriate upholstery material

stretched tight and stapled in back. Be sure and not cover up the mountingholes. Alternate: Take to an upholstery shop and let them cover it.

Section A - A 4:1

Press 1/4 - 20 "T" nut flush

AA

Typical 3 places

7 12

3 34

32

16

5 12

43

4 R

1 R

5/16 dia C'bore 3/4" dia 1/16 deep

PART DESCRIPTION

ASSEMBLYJACKSHAFT

PART NUMBER

069SCALE

See Notes


69

NOTES:1. Quantity required per car: 12. Material: Per drawing call out.3. After alignment of sprockets and pulleys, secure all setscrews. At final

assembly, secure all setscrews with LocTite (blue).4. Finish: n/a

070 B

070 A

051

PP 245

076

PART DESCRIPTION

SUPPORT ASSY, A & BJACKSHAFT

PART NUMBER

070SCALE

See Notes


70

NOTES:1. Quantity required per car: 2, 1 LH (A) & 1 RH (B)2. Material: Per drawing callout.3. Use 1/4 hardware except mounting bearing, which is 7/16.4. Use Nylon insert locknuts on all hardware.5. Finish: Parts are individually finished before assembly.

A = Left hand as shownB = Right hand to be mirrow image

074

040

055 A

056 A056 B057 PP 205

PART DESCRIPTION

FINAL ASSEMBLYMOTOR WHEEL

PART NUMBER

071SCALE

See Notes


71

NOTES:1. Quantity required per car: 12. Material: Per drawing callout.

060

Sprocket & Pulley not shown on Jackshaft for clarity

066062

Final jackshaft - belt - chain alignmentand tension adjustment per drawing No. 072

PP 215

PP 237

PP 252

PP 222 PP 230

For wheel and Axle assembly see Drawing No. 077

PART DESCRIPTION

ADJUSTMENTJACKSHAFT SUPPORT

PART NUMBER

072SCALE

See Notes


72

NOTES:1. Loosely mount to dimensions shown.2. Use dimensions given - Do not scale drawing.3. Material: Per drawing callout.

12 Initial Adjustment

2

5/16 x 24 All thread rod (2" lgth) 4 reqd.5/16 x 24 Nylon insert lock nut - 4 reqd.5/16 x 24 hex jam hut - 8 reqd.5/16 x 24 hex nut - 4 reqd.

See text foradjustment instructions

063 (ref)

070A (left side)070B (right side)(ref)

PART DESCRIPTION

MOUNTING ANGLEJACKSHAFT

PART NUMBER

073SCALE

See Notes


73

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: 1/8 x 1 angle.4. Break all corners and sharp edges.5. Finish: Finished after welded assembly.

1 6

8

12

.312 Dia

PART DESCRIPTION

SHIELD PLATE

PART NUMBER

074SCALE

See Notes


74

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: Any 18 to 20 gauge sheet metal4. Break all corners and sharp edges.5. Finish: Choice of builder.

5 34

386 12 5

16

6 12

7 18

78

3 916

1 12 R

516 DIA (4)

PART DESCRIPTION

GUIDE DISCBRAKE BAND

PART NUMBER

075SCALE

See Notes


75

NOTES:1. Quantity required per car: 22. Use dimensions given - Do not scale drawing.3. Material: Make from Northern sprocket p/s 1361 (PP 217)4. Break all corners and sharp edges.5. Finish: Choice of builder.

6.75 DIA

2.813 DIA

.281 DIA4 holes on a 2.813 dia BC

2.00 DIA

Make from 1/8 steel plate or machine teeth off a 60 tooth - #35 sprocket (Northern #1361)

PART DESCRIPTION

WELDED ASSEMBLYDRIVEN SPROCKET

PART NUMBER

076SCALE

See Notes


76

NOTES:1. Quantity required per car: 12. Use dimensions given - Do not scale drawing.3. Material: Per parts callout.4. Break all corners and sharp edges.5. Finish: Choice of builder.

PP 219

PP 218

Weld all around

#41 - 54 teeth - 8 3/4 Dia (ref)

PART DESCRIPTION

MOUNTING DETAILSDRIVE WHEEL

PART NUMBER

077SCALE

See Notes


77

NOTES:1. Quantity required per car: 12. Use shim washers (PP 246 & pp 247) to center wheel in frame.3. When axle bolt (PP 253) is tightened, the proper amount of shim washer willprovide a slight pre-loading on wheel bearings. ( Just enough to remove anyside play of wheel.

PP 253

PP 246 PP 247

062 (ref)

066 (ref)

5/8 - 11 Nylon stop nut

79

Photo shows 3/4 dia hole 1 inch down &centered in seat support front (017). Whenrouting throttle cable, keep sharp bend to aminimum.

This photo shows push-pull throttle (PP251) and Throttle mounting plate (047) fas-tened to front of seat support (017).

Photo above shows throttle cable exitingthe seat support box. This hole is drilled 1inch down from top edge and inward tomatch engine used.

The centrifigal clutch (PP 237) is shownabove. Note how it is retained to enginecrankshaft by a large fender washer and 5/16capscrew.

Thus, it is imparative that your enginehave the end of crankshaft drilled andtapped. This is common with most engines.

Vendor Code = FB Foley-BelsawP.O. Box 419593Kansas City, Mo 641411-800-821-3452

Vendor Code = G * W. W. Grainger, Inc.Website: www.grainger.com

Vendor Code = McC ** McMaster-CarrWebsite: www.mcmaster.com

Vendor Code = MS Manufacturer’s SupplyP.O. Box 167Dorchester, WI 544251-800-826-8563Website: www.mfgsupply.com

Vendor Code = NT Northern Tool & Equipment1-800-556-7885Website: www.NorthernTool.com

Vendor Code = SEW Small Engine Warehouse765-768-6725Website: www.smallenginewarehouse.com

Vendor Code = GKG Go-Kart Galaxy1-903-340-1965Website: www.gokartgalaxy.com

Vendor Code = AS Aircraft Spruce & Specialty Co.1-877-477-7823Website: http://www.aircraftspruce.com

Vendor Code = W Worksman1-888-394-3353

Vendor Code = WZ Whizzer U.S.A., Inc.1-972-484-9555Website: http://www.whizzermotorbike.com

* W. W. Grainger has outlets in most larger cities. You need to contact the one closest to you.Look in a phone book for a larger city near you.

** McMaster-Carr has several locations. They have such a user friendly website that theeasiest way to order from them is on the internet.

Always check our website: www.smallcarplans.com for links to the latest in suppliers.

80

PP No. Qty Description Vendor Code Catalog No.

201 1 Spindle, RH MS AZ2518

202 1 Spindle, LH MS AZ2519

203 4 Ball Joint, 3/8 - 24 MS 10-2214

204 2 Pillow Block, 5/8” Bronze G 2X529

205 2 Flange Mt. Pillow Block, 3/4” Ball Bearing NT 1805

206 4 Pneumatic Spoked Wheel, 26” NT 145123

207 1 Heavy Duty Wheel 26” W 329A

208 10 Shim Washer, 5/8 X 1 OD X .031 McC 3088A433

209 10 Shim Washer, 5/8 X 1 OD X .125 McC 3088A513

210 10 Shim Washer, 3/8 ID X 5/8 OD X .062 McC 3088A466

211 10 Shim Washer, 3/8 ID X 5/8 OD X .125 McC 3088A511

212 2 Collar, 5/8 ID MS AZ8554

213 (left blank)

214 5 Clevis, 1/4 - 28 MS AZ8354

215 1 Engine, B&S - 5.5 hp Intek or Equiv. SEW 126312

216 1 Tire, Kevlar Belted 26” W 4922AKV

217 2 Sprocket, #35 - 60 Tooth NT 1361

218 1 Sprocket, #41 - 54 Tooth NT 1363

219 1 Sprocket Hub SC 1-2343-E

220 1 Heavy Duty Tube 26” W 6023A

221 1 Rim Strip W 1017

222 10 ft. #41 Roller Chain NT 136510

223 2 4” Brake Drum MS 4-485

224 2 4” Brake Band w/pin MS 4-486

225 1 Steel shaft with Keyway 3/4” OD x 12” McC 1497K161

226 1 12” Steering Wheel MS 4-9396

227 1 Steering Wheel Cap Assembly GKG 1877

228 4 King Pin Bushing (nylon) MS AZ8215

81

PP No. Qty Description Vendor Code Catalog No.

229 2 Bronze Bushing - 5/8 ID - 3/4 OD x 1 Lg McC 6391K243

230 1 Connect Link - #41 Chain McC 6261K192

231 1 Coupling Nut - 1/4 x 28 McC 90977A140

232 1 24” Steering Shaft w/o pitman arms welded MS AZ1868-24

233 1 22” Steering Shaft w/ pitman arms welded MS AZ1867-22

234 1 5/8 x 5/8 Coupling SC 1320-0016

235 5 Control Cable Pulley AS A-124

236 15 ft Control Cable - 3/32 x 7x19 AS 05-04000

237 1 Centrifigal Clutch, Hilliard Ex Duty MS H3441

238 1 Sheave WZ 2973

239 9 Sheave Mounting Bkt/w screws WZ N-3018

240 5 Clevis Pin MS AZ8355

241 5 Cotter Pin MS AZ8419

242 2 Spindle Bracket MS AZ8171

243 2 Bronze Bearing - 1/4 ID - 3/8 OD Flanged McC 6338K413

244 1 Rod End Blank McC 6065K131

245 1 V Pulley - 1/2 w x 3.00 OD - 3/4 bore SC 1-2721

246 10 Shim Washer, 3/4 ID x 1 1/8 OD x 1/32 McC 3088A434

247 10 Shim Washer, 3/4 ID x 1 1/8 OD x 1/8 McC 3088A514

248 2 Aluminum Disc, 3 1/2 OD x 1/2 thick McC 9035K17

249 7 Tee Nut, 1/4 - 20 x 5/16 High McC 90975A025

250 1 Engine Mounting Plate MS AZ8190

251 1 Push-Pull Throttle Control FB EGR5960237

252 1 V belt - 4 L 620 (62”) **

253 1 Shoulder Bolt - .750 x 5.50 Socket Head McC 91259A857

** It is recommended that V Belt be purchased locally should a different size be required.

82

Building The 1920Briggs & Stratton CycleCar With Motor Wheel

cycle car with moto wheel

Documents

cold rolled steel

lhscale part number

rhscale part number

assemblyscale part number

bscale part number

1 32 shim washer

install shim washers

press roll pin