1920 Briggs & Stratton Cycle Car with Motor Wheel Drive

Copyright 2006 Everett Moore

Everett Moore P.O. Box 1705 Cottonwood, AZ 86326

Foreword
I originally built the Briggs and Stratton Cycle Car without the conventional motor wheel drive. This was done to create an simple, easy to build car for the beginning builder. It required no welding or machine work other than simply cutting a few pieces of steel to length. This little car functioned fine, but was not without the peculiarities of one-wheel drive. I was not totally satisfied and became inspired to build a motor-wheel to power it. Rather than build another Cycle Car from scratch, I decided to alter the existing one to accept the motor-wheel. I kept in mind that many of you have built from the original design and I wanted to make it as easy as possible to alter yours to accept the motorwheel. Some further modifications were made including changing from a hand brake lever to a conventional, foot operated, brake. With the exception of moving the equalizer assembly, all the original brake parts were used. I did re-design the brake band anchor brackets to provide a better geometry for clamping the brake band, resulting in an improvement in stopping power. The motor-wheel is a self-contained unit that attaches to the chassis board with 2 brackets that allow it to pivot up and down, thereby maintaining constant contact with the road. The only other attachment to car is the throttle cable. This cable terminates centrally below the front edge of the seat and is controlled by hand. We chose to simplify the design on the motor-wheel and only used a centrifugal clutch. The motor-wheel was designed with the idea that the builder could adapt it to about anything, similar to what was done with the 2 original Smith Motor-Wheel. Since a centrifugal clutch was used, it eliminated the necessity for a lever, linkage, etc. to lift the motor-wheel off the road for starting. A Worksman wheel and Kevlar tire was used on the motor-wheel. Power was provided to the wheel by using a 15 inch, V belt sheave as used on a Whizzer Motor Bike. These sheaves and mounting brackets are available from Whizzer dealers or directly from Whizzer. The most difficult task in building the motor-wheel is getting the belt sheave mounted concentrically on the wheel. Some trial and error may be necessary. Upon completion, some adjustment was necessary to the jack shaft to get the proper tension on the V belt. We managed to get by without using a spring-loaded idler pulley to keep the belt tight, although that could be an option. The entire car was completed in time for a shake-down cruise in the Cottonwood, AZ Christmas Parade. It performed flawlessly and finished the parade with its two passengers plus dog! These plans were done with three possible end results in mind. 1) Modifying an existing Cycle Car built from our original plans. 2) Building a completely new Cycle Car from the beginning. 3) Build only the motor/wheel unit for adapting to a personal project. Enjoy and email me if you have any questions. evmoore80@msn.com

Introduction
Nothing is particularly hard if you divide it into small jobs. Henry Ford Before everything else, getting ready is the secret of success. Henry Ford

"Tattoo the above quotes on your brain" as Ernest used to say. Better yet, paint them as signs to hang in your shop where you can look at them every time the going gets rough. It was with this incentive that the manual you're holding was done. With its nearly 200 different parts not even a simple cycle car is necessarily easy. However, if approached one part at a time, the job becomes much easier. Sometimes when you buy a set of plans for a project such as this, all you get is a copy of a magazine article or everything crowded onto a few sheets of paper. In this manual you will find a complete drawing of each part nothing is left for you no guess work! A lot of parts are simply a piece of bar stock, angle or tubing cut to length with one or more holes drilled in it. This is not to imply that you can't go off the beaten trail and modify or redesign to your own desires. To do so is encouraged. The idea that this horseless carriage could be approached as a class project crossed our mind. Since it utilizes several machine shop operations, each student could be assigned a few parts to do according to their ability and skills. When completed, let the auto body 3

shop do the painting. Then drive in the homecoming parade! The Industrial Arts Dept wins, hands down! The same could apply to friends or neighbors who join together to build each a car with different ones making all of certain parts. A few tools I consider a necessity (either owning or having access to) and they are: a cut-off saw, a drill press, a hand grinder, an accurate square (combination & large carpenter's square), a bottle of layout blue and the means of accurately-scribing layout lines on the stock. Always center punch all holes before drilling. The motor-wheel unit does require some basic welding on the frame. The jack shaft mount was build from individual parts bolted together (Erector Set style). Note that shield plates were used for safety on this unit. Before you start making scrap iron, study this manual and drawings. Obtain catalogs from suppliers and if you have access to the internet, look at and bookmark the suppliers we have referenced. Plan where you are going to work on your car. Although desirable, a large shop isn't necessary. Henry Ford utilized a coal shed for

his first horseless carriage, the Quadricycle. And, while Henry said plan ahead, he even had to knock out the existing door and add a larger one just to get his car outside! Visit your local steel supplier. Depending on your location, you may have access to a well-stocked supplier. If you live in a rural area, look for a welding shop that might have some scrap or be willing to order for you. What Tools Will You Need? Tools, while making any job easier, cannot replace skill in the hands using them. The list of tools that follows are what I consider sufficient to build the Red Bug. 1. A good floor-standing drill press. Includes a drill press vice and drill bit set. 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 with the wooden parts. The chassis is not unlike the foundation when building a house. Since most other components rely on it for alignment, care must be exercised when laying out the various locations on the chassis. Set the frame on a couple of saw horses. Every time you enter your shop you will see it and it will trigger your mind to the idea that, "By golly I'm really building a car - from scratch - by myself". "I wonder when the next parade in town is." Also, since the chassis is basically a 2 x 8 ft piece of 3/4 plywood, it makes an excellent place to sit down and make other small parts. Seeing you car take shape is a thrill you'll never forget. On the original Briggs & Stratton Cycle Car, the chassis was constructed from six 3 1/2 wide boards of (I would guess) 1 thick oak or hickory. If you have such available, go ahead and substitute for the plywood I used. I used a 2 x 8 sheet of 3/4 plywood and added phony slats by gluing 3 1/2 wide strips of 1/4 plywood to the top surface. I found this arrangement to be a bit flexible with a payload of 450 lbs. Therefore, a support, made from a 2x4, was added to each on the underside. _______________

The Original 1920 Briggs and Stratton Cycle Car 4

The Finished Cycle Car Featuring the Motor Wheel

The Making and Assembly Processes

Lets Make Sawdust First I would recommend that all the wooden parts be sawed out at the same time. This will reduce the large sheets of plywood into, smaller, more manageable pieces. In some of the next pages you will find rough, cutout dimensions. Rip all similar width pieces at the same saw setting. Start with the widest and proceed to the smaller ones. You might consider finishing the seat, cushion bases and seat support first and set them aside for final painting. You will note how the axles are made by gluing pieces of 3/4 inch plywood together to get the desired thickness. The front axle is straight forward gluing together of 3 identical pieces. Whether you cut the profile of the front axle in the individual pieces or after gluing, 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 the filler pieces as shown. However, because of the varying thickness of purchased plywood, you will most likely have to fine tune the dado for a good fit to the steel tube. This fit should be close enough to allow epoxying the tube at final assembly. The tube must be flush to top surface of axle after assembly. The foot rest is, likewise, made by gluing together two pieces of 3/4 inch plywood. The fun piece is the steering shaft support which, because of its shape, I call the dog bone. Like the front axle, you might want to saw the 2 individual pieces before gluing together. A good drum sander is very useful in the finishing of this part. Save the drilling until after the gluing is done. While I didnt specify any corner round ing, I personally used a hand router and a 1/4 round over bit to make a lot of edges look pretty. I, also, spared a lot of little detail on the 6 wood parts because I find most people with any degree of a home workshop will usually have sufficient woodworking skills to suffice. I recommend that any finished wood part be left without paint at this time. You should completely finish, assemble and test drive your car and only then disassemble and paint. _______________

A city version of the Cycle Car was made later, using electric power for use in large estates as personal transportation. It was call the Red Bug. We named ours Red Bug, likewise.

1 4

31 3/4

31 3/4

31 3/4

1 2

front axle rear axle seat support botton foot rest

front axle rear axle

front axle rear axle seat support front

1 2

3 3 15 4 1 5 4

foot rest

38
seat support front seat support side

22 3
seat support side

1 2

3 4

24

22

1 2

15

3 4

15

3 4

40

1 4 48

7
24
CHASSIS

86 96

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 3/4 Plywood - full 4 x 8 sheet. 4. Saw cuts have been allowed for.

Copyright 2006 Everett Moore

PART DESCRIPTION

PLYWOOD CUTTING SHEET - 1

SCALE PART NUMBER

See Notes

007

1 ( X6 ) 2

floor slat x 6 floor slat x 6 floor slat x 6 floor slat x 6

1 2

floor slat x 6 floor slat x 6

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 1/4 Plywood - full sheet

Copyright 2004 Everett Moore

PART DESCRIPTION

PLYWOOD CUTTING SHEET - 2

SCALE PART NUMBER

See Notes

008

48.00 44.00

Back 16.00 17.00 17.00

8.00

Side

Side 48.00

1.75

Seat Back Strip

9
17.00 Bottom 40.00

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 3/4 Plywood

Copyright 2004 Everett Moore

PART DESCRIPTION

PLYWOOD CUTTING SHEET - 3, SEAT

SCALE PART NUMBER

See Notes

009

86 1 10 (ref) 42.00 Hole Pattern "D" 6 2 2 x 10 5 16 * 2 1 16 * 4 x x x x 4R 18 R Hole Pattern "A" 8 1 15 2 20 27 Center Line Front Axle 1 2 72 3 Center on groove Hole Pattern "B" 20 4 1 4 Center Line Rear Axle 48 1 7 7 8 4 x 1 R 2 x x x 1 1 4

5 8

10

5 * 16

* 1 2 16

x Center Line of Chassis

010

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

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 3/4 Plywood Imitation Slats = 1/4 Plywood. 4. All hole dias to be 3/8 except those marked x which are 1/4. 5. Some hole dias 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

CHASSIS TOP VIEW

SCALE PART NUMBER

See Notes

010

A
3 R 8

3 DIA - 2 Holes 8

B
1 22
3

3 DIA - 2 Holes 8

3 18

1 2

1 2

51 2

3 8R

011

1 DIA - 2 Holes 4

Hole patterns C & E are not used.

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

Copyright 2005 - Everett Moore

PART DESCRIPTION

HOLE PATTERN LAYOUTS

Use dimensions given - Do not scale drawing.

CHASSIS - TOP VIEW SHEET 2

SCALE PART NUMBER

See Notes

011

10 1 2

3 8 1 2

12

1 R 8

.750 dia CRS

1 DIA (2) 8

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: .750 dia CRS. 4. Break all corners and sharp edges. 5. Finish: Choice of builder.

Copyright 2005 Everett Moore

PART DESCRIPTION

MOTOR WHEEL PIVOT SHAFT

SCALE PART NUMBER

See Notes

012

36

1 1 2

1R

3 DIA - 2 Holes 8 3 3R 1 2

3 4

1
3R

013

1 2

1
6 20

1 2

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

FOOT REST
SCALE PART NUMBER

See Notes

013

10 7 8 2 1 4

5 16 2

10 1 16 2 1 16

5 16 2

1 4

7 8

1 8

3 DIA - 8 holes 8 3 2 - 4 plcs 4 31 3 4

1 (ref) 4 2 1 2 1 4

014

4 13 both ends 16

13 13 both ends 16

Center Line of Chassis 1" Dia. C'bore to depth shown - Typical 4 Places

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

FRONT AXLE SUB - ASSEMBLY

SCALE PART NUMBER

See Notes

014

10

5 16 2 1 16 2 1 16

10

5 16

1 DIA - 12 holes 4 2 1 2 2 1 2

3 4 34 1 1 2 7 8

1 - Typical 6 places 4

3 4

1 2

Sq tube & plywood surfaces to be flush this entire surface

1 2

015

1 4

3 DIA - 4 holes 8 31 3 4

Center line

1 4 1 9 (ref - both ends) 16

NOTES: 1. Quantity required per car: 1 2. 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 long 4. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

REAR AXLE ASSEMBLY

SCALE PART NUMBER

See Notes

015

1 14

14

1 2

1R

1 2R

5 8 DIA 4 Holes 1 1 4

16
11 2

3 DIA 8 4 Places

3 4 Typical both ends

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

STEERING SHAFT SUPPORT

SCALE PART NUMBER

See Notes

016

6 1 5 4 22

1 2

20 3 4

15
17

3 DIA - 2 Holes 8

7 8

3 4 1 2

3 4

2 24

2 (REF)

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 3/4 Plywood. 4. Glue & screw together. 5. Finish: Choice of builder.

Copyright 2004 Everett Moore

PART DESCRIPTION

SEAT SUPPORT ASSEMBLY

SCALE PART NUMBER

See Notes

017

44 4R 15
o

16

5 16

3 15 4

15 4R 80 16

40 3 1 2

1 4

18

2 17 1R Front corner top view Typical two places

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

Copyright 2004 Everett Moore

PART DESCRIPTION

SEAT ASSEMBLY
SCALE PART NUMBER

See Notes

018

Cut slot thru seat back to accept corner bracket both sides

4 in corner reinforcing bracket fasten to rear of seat, extend thru slot fasten to outside of arm rest. ( 2 places )

19

Rear view of seat

Detail of seat back reinforcement

NOTES:
1. Cut two slots as shown. Use router preferably. However, multiple holes can be drilled and connected with jig saw. Slot should only be wide enough to accept the bracket. Prototype used 1/4 in. 2. Drill 1/4 dia holes thru seat back & arm rests and secure brackets with 1/4 - 20 bolts, fender washers and nuts. Place nuts on outside.

Copyright 2004 Everett Moore

PART DESCRIPTION

SEAT - REAR DETAIL

SCALE PART NUMBER

See Notes

019

1 DIA

10 11

1 8 3 8

12
20

1 4

69

5 8 3 16

1 2

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

UNDER CHASSIS SUPPORT - LH

SCALE PART NUMBER

See Notes

020

1 DIA

10 11

1 8 3 8

12
21

69

5 8 3 16

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

UNDER CHASSIS SUPPORT - RH

SCALE PART NUMBER

See Notes

021

The Making of Metal Parts

If you havent already, you might want to cut the 1 square tube to required length and finish the rear axle per drawing No. 015. Be sure to align your chop saw so as to cut as near to 90 degrees as possible. I never trust the marks provided and prefer to use a square to do this. I recommend cutting all bar stock, angles and motor-wheel parts to the required length at one time. Next, remove any burrs and sharp edges with a hand file. To layout the hole locations, you should have a small bottle of layout blue. You need only apply it to the approximate area where the holes will be. Accurately locate the holes with a good square and scale. Scribe lines with a scriber and center punch before drilling holes. When all holes are drilled, using either a bench grinder or hand grinder, form the radius called out on the drawings. These are not critical and in some cases are more for appearance than anything else. One of the more difficult parts will be the two hub mounting flanges, Drawing No. 034. Layout and scribe the hole locations with your square and compass or use the cardboard tool described in Drawing No. 035. Using the appropriate tap drill, drill and then tap holes per drawing. If you have never used a tap before, do two things 1) Use a cutting fluid to lubricate the tap while cut ting (I use WD-40) 2) Every couple or three turns of the tap, stop and backup a turn to break the chip and free the tap again. Dont force the tap, back up, and go again. Nothing will make a grown man cry quicker than breaking a tap flush with the work, usually on the last hole of a nearly completed part! Make an effort to start the tap perpendicular to the the part. After completing drilling and tapping, all thats left to do is cutting the center hole. In sticking with my criteria established at the beginning, I did this without using a lathe. Of 22 course, if you have a lathe, by all means use it! I used a 1-5/8 dia. metal cutting hole saw, cutting half way on one side and turning the part over and finishing from the other side. Since the hole could be a bit smaller, if you have a 1-9/16 dia saw or want to use a fly cutter, use it. The only tapped holes remaining are on the chain tightener anchor blocks and the tubular nuts (use in the steering shaft support AKA Dog Bone.) All the techniques of tapping used on the previous parts, apply here, also. While into tread cutting, you might as well cut the threads on all parts made from round CRS. From your tap and die set chose the appropriate die and die stock (the handle that holds the die) and, after cutting the rods to length, cut the threads per drawings No. 038 and 039. The remaining metal work entails modifying a purchased part, such as cross drilling and pressing in a roll-pin, drill and tapping or, in one case, cutting threads with a die. One part, the brake activator guide, Part No. 041 requires drilling and tapping plus pressing in two bearings. Other modifications are self-explanatory as per the drawing. Now is a good time to examine all your parts by comparing them to the drawing. Remove any burrs found, de-grease and set aside for the initial assembly process. Collect all the motor-wheel parts and set up for welding or, if desired, taken, together with drawing, to a welder for completing the motor-wheel frame. Only after making sure that parts fit and function as intended, should they be degreased, primed and painted with the finish of your choice. _______________

5 8 4.125 2.250 11 16

1 R 2 1 1 2

23

.375 DIA (2) .625 DIA

.750

NOTES: 1. Quantity required per car: 4 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

FRONT SPINDLE MOUNTING BRACKET

SCALE PART NUMBER

See Notes

023

9.00 8.00 7.00 3.50 .50

24

.50 R .250 DIA 4 holes 10.00 (ref) .312 DIA

NOTES: 1. Quantity required per car: 1 2. 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: Builders choice.

Copyright 2005 Everett Moore

PART DESCRIPTION

INTERMEDIATE BRAKE ARM

SCALE PART NUMBER

See Notes

024

PP 242

.625 Dia (ref) 5 DIA 16

25

11 16

1 2

5 8
Copyright 2006 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car: 1 2. 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.

BRAKE PEDAL MOUNTING BRACKET

SCALE PART NUMBER

See Notes

025

3 8

1 4

9 DIA 32 1

26

1 2

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.

Copyright 2005 Everett Moore

PART DESCRIPTION

WASHER PLATE
SCALE PART NUMBER

See Notes

026

1 R 4

.250 DIA 3 holes

7
27

7 8

1.00 1.00 5 8 Weld all around 3 3 4 3 16 .125 dia

.625 DIA

.50 1.00

1 8

3 16 3.75

.625 dia CRS

Copyright 2005 Everett Moore NOTES: 1. Quantity required per car: 1 2. Weld components as shown. 3. Material: 1/4 X 1 Steel bar stock & .625 dia CRS. 4. Finish: Choice of builder.
PART DESCRIPTION

BRAKE PEDAL ASSEMBLY

SCALE PART NUMBER

See Notes

027

7 1 1 2 4.00

3 4 .250 DIA 2 Holes

1 2

28

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

CENTER BRAKE PULLEY MTG. BKT.

SCALE PART NUMBER

See Notes

028

.250 DIA 13 12 1 1 2 4.50 6.00

3 4 1 1 2 1

1 2

1 R 8

.375 DIA 2 Holes

29

Twisting bend to be within this area

A= B=

LH as shown (Qty 1) RH to be mirrow image (Qty 1)

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 Stock 4. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

OUTBOARD BRAKE PULLEY MTG. BKT.

SCALE PART NUMBER

See Notes

029

.75 .375 DIA 1.50 .25 3.00 .25 R, typical

30

3.00

2.00

.750 DIA

2.00
NOTES: 1. Quantity required per car: 2 2. 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. Copyright 2005 Everett Moore
PART DESCRIPTION

MOTOR WHEEL ATTACHMENT BRACKET

SCALE PART NUMBER

See Notes

030

1 R 4

1 R 2

7 8

5 .375 DIA 3 HOLES

3 4

31

1 2

1 2

1 2

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

BRAKE ANCHOR MOUNTING BKT - LH

SCALE PART NUMBER

See Notes

031

1 R 4

7 8 1 R 2

5 .375 DIA 3 HOLES

3 4 5

32

1 2

1 2

1 2

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

BRAKE ANCHOR MOUNTING BKT - RH

SCALE PART NUMBER

See Notes

032

2 1 1 R (typical) 4

4 3 3

1 2 5 DIA 16 1 4 1 2 1 4

1 2

33

3 4

Weld

3 DIA 8 2 Holes

1 (ref) 2

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

INTERMEDIATE BRAKE LEVER MTG BKT

SCALE PART NUMBER

See Notes

033

2.812 DIA

2.000 DIA

5/16 x 24 UNF 4 holes

1/4 x 28 UNF 4 holes

34

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

1-5/8 DIA 3-1/2 DIA (ref)

.50 (REF)

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

Copyright 2004 Everett Moore

PART DESCRIPTION

HUB MOUNTING FLANGE - ALTERNATIVE

SCALE PART NUMBER

See Notes

034

1 DIA 2 2 13 DIA 16 1 13 R 32

2 DIA 1R

35

11 * 1 DIA 32 Location of pin holes Typical 8 places

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

CARDBOARD TOOL WHEEL/FLANGE DRILL

SCALE PART NUMBER

See Notes

035

.750 DIA 1.00 R .50 R .50 R 7 Mat'l = 3/16 bar stock 5 1 2 1 (ref) 2

36

1 2 6

C
2

B
2

1 2

2
Copyright 2005 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car = 2 each 2. 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.

WHEEL SUPPORT COMP0NENT PIECES

SCALE PART NUMBER

See Notes

036

5/16 - 24 UNF 5 DIA 8

3 4 1 1 2

37

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

Copyright 2004 Everett Moore

PART DESCRIPTION

TUBULAR NUT
SCALE PART NUMBER

See Notes

037

See Length Table Below 1 1 4 1 1 4

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

38

Lengths A = 8 inches B = 10 1/2 inches C = 7 inches

NOTES: 1. Quantity required per car = 1 each 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

BRAKE ACTIVATOR SHAFTS

SCALE PART NUMBER

See Notes

038

Tie Rod "A" = 7 in. Long Tie Rod "B" = 23 3/8 long

3/8 - 24 UNF - Min 1-1/2" full thd - both ends Make from 3/8 dia CRS
39

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

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.

Copyright 2004 Everett Moore

PART DESCRIPTION

TIE RODS - A & B

SCALE PART NUMBER

See Notes

039

9 3 8 8 21 32

13 32 3 8 3 4

40

.250 dia - 2 holes

3 R 8

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

DIAGONAL BRACE
SCALE PART NUMBER

See Notes

040

PP 243 (2)

1 (ref) 4

.375 DIA - thru both ends

1 (ref) 1 DIA 4 See notes

1 2 1/4 - 28 UNF - 2 holes

1 (ref) 4

PP 242

41
3 4 1 1 2 5 8 3" (ref)

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

BRAKE ACTIVATOR GUIDE

SCALE PART NUMBER

See Notes

041

3 (ref) 1 2 Min full thd 1

.250 DIA

1/4 -28 UNF

42

Make from Rod End Blank, McMaster Carr No. 6065K131 PP 244

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

BRAKE ACTIVATOR LINK

SCALE PART NUMBER

See Notes

042

1 in. before threads 1 1/8 x 3/4 Roll pin

1 2 2 1 4

43

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

BRAKE BAND ANCHOR BOLT

SCALE PART NUMBER

See Notes

043

1/8 x 3/4 Roll pin .125 Dia.

3 (ref) 8

1 2

.375 DIA - CRS

44

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

BRAKE BAND ANCHOR PIN

SCALE PART NUMBER

See Notes

044

17/64 Dia. 4 holes, evenly spaced on 2.000 dia BC

45

Rear Wheel (Purchased Part No. 206) Only hub is shown for clarity.

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

REAR HUB MODIFICATION

SCALE PART NUMBER

See Notes

045

1 2

46

1 3

1 R 2

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

PIVOT SUPPORT PLATE

SCALE PART NUMBER

See Notes

046

3 3 8 2 1 4 1 2

47

1 2 3 DIA 8

3 DIA 2 holes 16

NOTES: 1. Quantity required per car = 1 2. Use dimensions given - Do not scale drawing. 3. Material: 1 x 1/8 Aluminum bar stock. 4. Finish: Natural

Copyright 2004 Everett Moore

PART DESCRIPTION

THROTTLE MTG BKT

SCALE PART NUMBER

See Notes

047

1 2

15

SHAFT "A" (1 Req'd)

Make from PP 233

48

24 (REF)

SHAFT "B" (1 Req'd)

PP 232

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.

Copyright 2004 Everett Moore

PART DESCRIPTION

STEERING SHAFT A&B

SCALE PART NUMBER

See Notes

048

The Sub-Assembly Process

You will find that there are some parts that can best be assembled as a sub-assembly and then, be attached to the final assembly as a unit. Starting at the front of the car: the front axle can be done as a sub-assembly per drawing No. 054. The brake mechanism as depicted on drawing No. 050 can be partially assembled as a sub- assembly. The motor wheel itself is a sub-assembly with some of its components put together as sub-assemblies. The next two sub-assemblies are a bit more difficult. Referring to drawing No. 052, you will see how the adapter, Part No. 034 is attached to a rear wheel. While we do not power either wheel, both wheels have brake drums and require both rear wheels to have this adapter attached. Originally, we fastened the adapter and wheel with 1/4-28 socket-head cap screws and split lockwasher. However, this tended to loosened up.. Therefore, we now recommend that, in addition to the lockwasher, the threads be coated with LocTite (Red), making a semipermanent assembly. The inner bearing of the wheel had to be removed for the drilling of the four holes as shown in drawing No. 045. The bearing is not replaced until after the mounting flange has been attached. Doing the above described assembly requires working in very tight quarters. A long, ball end allen wrench is used to insert and turn the Allen Head screws from the opening in the opposite bearing. After applying LocTite, tighten all four screws as tight as you can get them just short of breaking the ball end off your wrench. Hopefully, this is the last time you have to do this. With the two rear wheels thus done, you might as well proceed to finishing up the rear wheels by attaching the discs and brake drums per drawing No. 053. The purpose of these discs is to help keep the brake bands in place. The front axle can either be sub-assembled separately or after it is attached to the chassis board. I prefer the latter. In either case it is depicted on drawing No. 054.

49

027 038C PP 214 (ref) PP 240 (ref) PP 241 (ref) On final assembly, use Loctite (blue) on these 2 capscrews

024

025 1/4 - 28 Hex Nut (4) PP 235 (1)

042 033 038B PP 214 )ref)

038A PP 214 (5) PP 240 (5) PP 241 (5)

041

50

Note: It may be necessary to file clevis in this area for free turning of pulley

PP 231 See Notes On final assembly, use Loctite (blue) on coupling nut

NOTES: 1. Quantity required per car: 1 3. Material: Per drawing callout 4. 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) theres sufficient release of brake bands. 7. Adjust brake pedal No. 027 to suit operator.

Copyright 2006 Everett Moore

PART DESCRIPTION

BRAKE ACTIVATOR ASSEMBLY

SCALE PART NUMBER

See Notes

050

11

3 4

51

.050 R (typical) .750 DIA (ref)

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: .750 Dia CRS with full keyway 4. Break all corners and sharp edges. 5. Finish: None

Copyright 2006 Everett Moore

PART DESCRIPTION

MOTOR WHEEL JACKSHAFT

SCALE PART NUMBER

See Notes

051

1/4 X 28 - 5/8 Long Socket Hd Capscrew (4 req'd) 1/4 Lock Washer (4 req'd) - Apply LocTite (Red) to threads.

52
Part No. 034 Part No. 045 Only hub is shown for clarity.

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

REAR WHEEL - FLANGE SUB-ASSEMBLY

SCALE PART NUMBER

See Notes

052

5/16 x 24 UNF - 7/8 Long Socket Head C'Screw 5/16 Lock Washer Plus use LocTite (red) 4 each req'd

075

53

Brake Drum - PP No. 223

Wheel Sub-Assembly Part No. 052

Copyright 2006 Everett Moore NOTES: 1. Quantity required per car: 2 2. Material: Per callout on drawing. 3. Finish: Parts are pre-finished at assembly
PART DESCRIPTION

REAR WHEEL ASSY GUIDE DISC & DRUM

SCALE PART NUMBER

See Notes

053

023 (4)

014

PP 202 PP 228 (2)

PP 201 PP 228 (2)

54
Adjust spacing between brackets, if needed, by placing large, fender washers between lower brackets and wood.

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2004 Everett Moore

PART DESCRIPTION

FRONT AXLE ASSEMBLY

SCALE PART NUMBER

See Notes

054

.312 dia - 2 holes

1 2 1 6 9 3 4 1 2 1 2

1 R 2

3 4

55

.250 Dia - 2 holes

5 8

A = Left side as shown B = Right side mirrow image of left

Copyright 2005 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car: 2 2. 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.

JACKSHAFT BASE ANGLE

SCALE PART NUMBER

See Notes

055

1 R 2 A = Right (2)

7
56

1 2 B = Left (2) 1 2

3 4

3 (ref) 8

.250 Dia Dimensions are same for both parts

Copyright 2005 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car: 2 of A & 2 of B 2. 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.

JACKSHAFT UPRIGHT ANGLES

SCALE PART NUMBER

See Notes

056

3 1 2

1 4 1 25 32 1

6 25 32

1 2 1 2

3 4
57

2 3

1 2 1 Dia

.250 Dia - 4 holes 7/16 Dia - 2 holes

Bearing Mounting Plate (2)

NOTES: 1. Quantity required per car: 2 2. 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. Copyright 2005 Everett Moore
PART DESCRIPTION

BEARING MOUNTING PLATE

SCALE PART NUMBER

See Notes

057

039A 054 020

050

028 PP 235 (2)

029A PP 235 026 015

58
010 021 029B PP 235 039B 026 PP 236

NOTES: 1. Quantity required per car: 1 2. Parts locate per previously drilled holes. 3. Material: Per drawing callout. 4. Assemble per intructions in text.

Copyright 2006 Everett Moore

PART DESCRIPTION

CHASSIS ASSEMBLY BOTTOM VIEW

SCALE PART NUMBER

See Notes

058

013

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) 017

065 030 (2)

**

59
For brake detail see drawing 050

NOTES: 1. Quantity required per car: 1 2. 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.

Copyright 2006 Everett Moore

PART DESCRIPTION

CHASSIS ASSEMBLY TOP VIEW

SCALE PART NUMBER

See Notes

059

Mtg. flange included with 048B 048B PP 212 (2) PP 229 (2) PP 204 (2) PP 234 048A 016 037 (4) 067 See notes PP 251 047 030 (2) (ref) Length of throttle cable extending and wire end bending to be determined when engine wheel is mounted PP 226 PP227 018 068

60
1 4 For brake detail see drawing 050 For detail see drawing 061

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 bearing necessary to match angle of steering shaft. 2. Position the steering shaft to clear front axle by 1/4 and secure in place with 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.

Copyright 2006 Everett Moore

PART DESCRIPTION

CHASSIS ASSEMBLY SIDE VIEW

SCALE PART NUMBER

See Notes

060

1/4 PP 210 (typical) PP XXX (typical)

XXX (typical) PP 211 (typical) Apply LocTite (Blue) 2 places (Blue) 2 places
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)

Copyright 2004 Everett Moore

PART DESCRIPTION

TIE ROD - STEERING SHAFT ASSY DETAILS

SCALE PART NUMBER

See Notes

061

PP 250 063 RH

3 8

1 2 063 LH

1 2 17

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

62
1" x 1" x .120 Sq Tube - 8 3/8 Lg.

046 (2)

5 (ref)

Weld according to accepted welding practices

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: Per drawing callout. 4. Engine mounting plate is P/N AZ8190 from Manufacturers Supply 5. Break all corners and sharp edges. 5. Finish: Choice of builder.

Copyright 2005 Everett Moore

PART DESCRIPTION

MAIN FRAME FINAL WELDMENT

SCALE PART NUMBER

See Notes

062

073

32

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

Weld 046 (2)

63
036-C Right side shown Left side is mirrow image 036-B 036-A

NOTES: 1. Quantity required per car: 2, 1 RH & 1LH 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

MAIN FRAME SIDE WELDMENT

SCALE PART NUMBER

See Notes

063

PP 224 (2)

044

64

043 031 (Left ) 032 (Right )

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. Copyright 2005 Everett Moore
PART DESCRIPTION

BRAKE BAND INSTALLATION

SCALE PART NUMBER

See Notes

064

Attach entire assembly to axle with 5/32 cotter pin

1/32 shim washer (as needed) See notes about axle length

1/8 shim washer 053 (2) (wheel) Make from 1/2 in pipe cap Drill out to 3/4 dia. - cross drill 5/32 dia.

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 cotter pin - 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 excesssive end play.

Copyright 2004 Everett Moore

PART DESCRIPTION

AXLE - HUBCAP DETAILS

SCALE PART NUMBER

See Notes

065

A
PP 238 PP 239 (9)

PP 207 PP 216 PP 220 PP 221

66

Section A - A

A
Copyright 2006 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car: 1 2. 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.

DRIVE WHEEL ASSEMBLY

SCALE PART NUMBER

See Notes

066

1 35 2
71 4

21

5/16 dia C'bore 1" dia 1/16 deep Press 1/4 - 20 "T" nut flush Typical 4 places 11

14

67

Section A - A

4:1

A 1 1 2

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 1/2 inch plywood - 1/4 - 20 x 5/16 T nuts (4) - PP 249 4. 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 mounting holes. Alternate: Take to an upholstery shop and let them cover it.

Copyright 2004 Everett Moore

PART DESCRIPTION

SEAT CUSHION BASE

SCALE PART NUMBER

See Notes

067

5 5/16 dia C'bore 3/4" dia 1/16 deep Press 1/4 - 20 "T" nut flush Typical 3 places

1 2 16

32

4R

1 2

Section A - A

4:1 43 1R

3 4

68

NOTES: 1. Quantity required per car: 1 2. Use dimensions given - Do not scale drawing. 3. Material: 1/2 inch plywood - 1/4 - 20 x 5/16 T nuts (3) - PP 249 4. 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 mounting holes. Alternate: Take to an upholstery shop and let them cover it.

Copyright 2004 Everett Moore

PART DESCRIPTION

SEAT BACK CUSHION BASE

SCALE PART NUMBER

See Notes

068

051 070 B

69

PP 245

076 070 A
Copyright 2006 Everett Moore
PART DESCRIPTION

NOTES: 1. Quantity required per car: 1 2. 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

JACKSHAFT ASSEMBLY
SCALE PART NUMBER

See Notes

069

056 B

057

PP 205 056 A

A = Left hand as shown B = Right hand to be mirrow image

70

074

040

055 A

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.

Copyright 2006 Everett Moore

PART DESCRIPTION

JACKSHAFT SUPPORT ASSY, A & B

SCALE PART NUMBER

See Notes

070

PP 237

PP 222 PP 230

Sprocket & Pulley not shown on Jackshaft for clarity

060 PP 215 PP 252 066

062

71

Final jackshaft - belt - chain alignment and tension adjustment per drawing No. 072 For wheel and Axle assembly see Drawing No. 077

NOTES: 1. Quantity required per car: 1 2. Material: Per drawing callout.

Copyright 2006 Everett Moore

PART DESCRIPTION

MOTOR WHEEL FINAL ASSEMBLY

SCALE PART NUMBER

See Notes

071

See text for adjustment instructions

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

72
063 (ref)

1 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.

Copyright 2005 Everett Moore NOTES: 1. Loosely mount to dimensions shown. 2. Use dimensions given - Do not scale drawing. 3. Material: Per drawing callout.
PART DESCRIPTION

JACKSHAFT SUPPORT ADJUSTMENT

SCALE PART NUMBER

See Notes

072

.312 Dia

1 2

6 8

73

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

JACKSHAFT MOUNTING ANGLE

SCALE PART NUMBER

See Notes

073

3 5 DIA (4) 16 1 1 R 2

9 16

7 8

6 3 4

1 2

74
6 7 1 8 1 2 3 8 5 16

NOTES: 1. Quantity required per car: 2 2. Use dimensions given - Do not scale drawing. 3. Material: Any 18 to 20 gauge sheet metal 4. Break all corners and sharp edges. 5. Finish: Choice of builder.

Copyright 2005 Everett Moore

PART DESCRIPTION

SHIELD PLATE
SCALE PART NUMBER

See Notes

074

6.75 DIA

.281 DIA 4 holes on a 2.813 dia BC 2.00 DIA

75

2.813 DIA

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

NOTES: 1. Quantity required per car: 2 2. 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.

Copyright 2005 Everett Moore

PART DESCRIPTION

BRAKE BAND GUIDE DISC

SCALE PART NUMBER

See Notes

075

PP 218

Weld all around PP 219

76

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

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

Copyright 2006 Everett Moore

PART DESCRIPTION

DRIVEN SPROCKET WELDED ASSEMBLY

SCALE PART NUMBER

See Notes

076

062 (ref)

PP 253 PP 246 PP 247

5/8 - 11 Nylon stop nut

77

066 (ref)

NOTES: 1. Quantity required per car: 1 2. 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 will provide a slight pre-loading on wheel bearings. ( Just enough to remove any side play of wheel.

Copyright 2005 Everett Moore

PART DESCRIPTION

DRIVE WHEEL MOUNTING DETAILS

SCALE PART NUMBER

See Notes

077

78

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

This photo shows push-pull throttle (PP 251) and Throttle mounting plate (047) fastened to front of seat support (017).

Photo above shows throttle cable exiting the seat support box. This hole is drilled 1 inch down from top edge and inward to match engine used.

The centrifigal clutch (PP 237) is shown above. Note how it is retained to engine crankshaft by a large fender washer and 5/16 capscrew. Thus, it is imparative that your engine have the end of crankshaft drilled and tapped. This is common with most engines.

79

Vendor Code =

FB

Foley-Belsaw P.O. Box 419593 Kansas City, Mo 64141 1-800-821-3452 W. W. Grainger, Inc. Website: www.grainger.com McMaster-Carr Website: www.mcmaster.com Manufacturers Supply P.O. Box 167 Dorchester, WI 54425 1-800-826-8563 Website: www.mfgsupply.com Northern Tool & Equipment 1-800-556-7885 Website: www.NorthernTool.com Small Engine Warehouse 765-768-6725 Website: www.smallenginewarehouse.com Go-Kart Galaxy 1-903-340-1965 Website: www.gokartgalaxy.com Aircraft Spruce & Specialty Co. 1-877-477-7823 Website: http://www.aircraftspruce.com Worksman 1-888-394-3353 Whizzer U.S.A., Inc. 1-972-484-9555 Website: http://www.whizzermotorbike.com

Vendor Code = Vendor Code = Vendor Code =

G * McC ** MS

Vendor Code =

NT

Vendor Code =

SEW

Vendor Code =

GKG

Vendor Code =

AS

Vendor Code = Vendor Code =

W WZ

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 the easiest 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. 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228

Qty 1 1 4 2 2 4 1 10 10 10 10 2

Description Spindle, RH Spindle, LH Ball Joint, 3/8 - 24 Pillow Block, 5/8 Bronze

Vendor Code MS MS MS G NT NT W McC McC McC McC MS

Catalog No. AZ2518 AZ2519 10-2214 2X529 1805 145123 329A 3088A433 3088A513 3088A466 3088A511 AZ8554

Flange Mt. Pillow Block, 3/4 Ball Bearing Pneumatic Spoked Wheel, 26 Heavy Duty Wheel 26 Shim Washer, 5/8 X 1 OD X .031 Shim Washer, 5/8 X 1 OD X .125 Shim Washer, 3/8 ID X 5/8 OD X .062 Shim Washer, 3/8 ID X 5/8 OD X .125 Collar, 5/8 ID (left blank)

5 1 1 2 1 1 1 1 10 ft. 2 2 1 1 1 4

Clevis, 1/4 - 28 Engine, B&S - 5.5 hp Intek or Equiv. Tire, Kevlar Belted 26 Sprocket, #35 - 60 Tooth Sprocket, #41 - 54 Tooth Sprocket Hub Heavy Duty Tube 26 Rim Strip #41 Roller Chain 4 Brake Drum 4 Brake Band w/pin Steel shaft with Keyway 3/4 OD x 12 12 Steering Wheel Steering Wheel Cap Assembly King Pin Bushing (nylon) 81

MS SEW W NT NT SC W W NT MS MS McC MS GKG MS

AZ8354 126312 4922AKV 1361 1363 1-2343-E 6023A 1017 136510 4-485 4-486 1497K161 4-9396 1877 AZ8215

PP No. 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253

Qty 2 1 1 1 1 1 5 15 ft 1 1 9 5 5 2 2 1 1 10 10 2 7 1 1 1 1

Description Bronze Bushing - 5/8 ID - 3/4 OD x 1 Lg Connect Link - #41 Chain Coupling Nut - 1/4 x 28

Vendor Code McC McC McC

Catalog No. 6391K243 6261K192 90977A140 AZ1868-24 AZ1867-22 1320-0016 A-124 05-04000 H3441 2973 N-3018 AZ8355 AZ8419 AZ8171 6338K413 6065K131 1-2721 3088A434 3088A514 9035K17 90975A025 AZ8190 EGR5960237

24 Steering Shaft w/o pitman arms welded MS 22 Steering Shaft w/ pitman arms welded 5/8 x 5/8 Coupling Control Cable Pulley Control Cable - 3/32 x 7x19 Centrifigal Clutch, Hilliard Ex Duty Sheave Sheave Mounting Bkt/w screws Clevis Pin Cotter Pin Spindle Bracket Bronze Bearing - 1/4 ID - 3/8 OD Flanged Rod End Blank V Pulley - 1/2 w x 3.00 OD - 3/4 bore Shim Washer, 3/4 ID x 1 1/8 OD x 1/32 Shim Washer, 3/4 ID x 1 1/8 OD x 1/8 Aluminum Disc, 3 1/2 OD x 1/2 thick Tee Nut, 1/4 - 20 x 5/16 High Engine Mounting Plate Push-Pull Throttle Control V belt - 4 L 620 (62) Shoulder Bolt - .750 x 5.50 Socket Head MS SC AS AS MS WZ WZ MS MS MS McC McC SC McC McC McC McC MS FB ** McC

91259A857

** It is recommended that V Belt be purchased locally should a different size be required. 82

Building The 1920 Briggs & Stratton Cycle Car With Motor Wheel