www.recumbents.com - Carbon mold/tool for lower&upper enclosed velo
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 Carbon mold/tool for lower&upper enclosed velo
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carolina
human power supergeek

USA
1373 Posts

Posted - 10/19/2019 :  11:42:58  Show Profile  Visit carolina's Homepage  Reply with Quote
Amateur hand tools for plug making working the bondo and matching left & right sides.


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carolina
human power supergeek

USA
1373 Posts

Posted - 10/19/2019 :  11:46:08  Show Profile  Visit carolina's Homepage  Reply with Quote
EBAY BIDDING:


Another ROHLOFF here now from ebay, this was bid that included nice wheel laced up (26”).



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Edited by - carolina on 10/19/2019 12:00:26
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carolina
human power supergeek

USA
1373 Posts

Posted - 10/20/2019 :  16:27:41  Show Profile  Visit carolina's Homepage  Reply with Quote
Deplorable history being made in bondo:

Pull two lines left and right of flat avionics wire tie string. Then color coded above an below that. Bondo below yellow line on both sides. (Lower photo).

Grey primer i brush on and sand to find faults. Grey shows blemishes. This side getting closer.


Red primer for guide coat.
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Edited by - carolina on 12/21/2019 07:55:41
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carolina
human power supergeek

USA
1373 Posts

Posted - 10/20/2019 :  16:29:56  Show Profile  Visit carolina's Homepage  Reply with Quote
At your fastenal store: i use the color coded paint markers, paint dry in few minutes.


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carolina
human power supergeek

USA
1373 Posts

Posted - 10/21/2019 :  11:46:51  Show Profile  Visit carolina's Homepage  Reply with Quote
THINNING BONDO FOR THIN SKIM COATS FOR FINISHING SANDING READY FOR EPOXY PRIMER:



1) bondo and it’s matchin glaze/photo above. I did bout 60/40 ,, 60% bondo.
2) regular bondo hardner.
3) for best i add micro ballons too. (Free aircraftspruce catalog)..
4) spraying primer helps fill too.
5) little blemishes i use kombi putty before spraying.
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Edited by - carolina on 10/21/2019 11:48:03
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carolina
human power supergeek

USA
1373 Posts

Posted - 10/29/2019 :  15:10:59  Show Profile  Visit carolina's Homepage  Reply with Quote


Pulled 2 piece mold from steel red primer part. Now you see part in carbon. The carbon base for different kinds of pinion mounts for recumbents.
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carolina
human power supergeek

USA
1373 Posts

Posted - 10/30/2019 :  10:11:09  Show Profile  Visit carolina's Homepage  Reply with Quote
THE SECOND ACTIVE MID-DRIVE PROJECT WITH HILGO OF NETHERLANDS.

1)chain fence on 11 tooth
2)chain fence on 34 tooth.
3) pic of hilgo floor shifter in post above.
4) next project on hilgo will be indexing gear cogs with rohloff twist grip using the spring loaded pins from Fastenal store. Drill & tap and put dimple under that hole for pin to seat in.





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Edited by - carolina on 10/30/2019 10:16:15
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/02/2019 :  11:25:47  Show Profile  Visit carolina's Homepage  Reply with Quote
Making a new rear chain wheel house under seat. Below pic is one iam using now. I am just making it wider is all.



Heres the plug below: l will pull a carbon part directly from the plug to use now. Later l will pull 2 part mold from this plug in photo.



Couple days on this plug and iam getting close. Wet sanding next, then polishing and release agent.

New rear chain wheel house behind seat curing, hardware going in tomorrow.




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Edited by - carolina on 11/08/2019 11:45:41
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/18/2019 :  22:05:19  Show Profile  Visit carolina's Homepage  Reply with Quote
New 3” rear chain wheel house.


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carolina
human power supergeek

USA
1373 Posts

Posted - 11/18/2019 :  22:08:05  Show Profile  Visit carolina's Homepage  Reply with Quote
Disc brake are now gone and the great STURMEY ARCHER drum brakes going into rear of 4 wheeler. Right side complete, left will be easy.


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https://youtu.be/_B204SJUPTw
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Edited by - carolina on 12/06/2019 06:32:36
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/20/2019 :  16:44:05  Show Profile  Visit carolina's Homepage  Reply with Quote
Work back from the machine shop: u see the gates belt cog on the Pinion 18 speed mid-drive project moving forward.

1)Crank cut off, the base of crank arm reshaped and 7 four mm bolts sit in place.
2) You see the gates belt cog.
3) other chain cog going forward on velomobiels not bolted on yet.
4) middrive behind seat on floor.


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Brevity&misspelling rampant
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Edited by - carolina on 11/28/2019 12:41:16
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/20/2019 :  16:49:02  Show Profile  Visit carolina's Homepage  Reply with Quote
Quattrovelo differential.



11/23 cassette 9 sp/Schlumpf drive up front.
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Edited by - carolina on 11/23/2019 16:35:33
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/23/2019 :  16:38:50  Show Profile  Visit carolina's Homepage  Reply with Quote
Still having fun with 1)hilgo floor shifter that belongs in 3 wheeler, but its pretty good in the 4 wheeler. This one is 9 sp 11/23. 2) schlumpf mountain drive up front.

https://youtu.be/bc--Qi6RAZ8
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Edited by - carolina on 11/28/2019 12:38:25
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/28/2019 :  12:27:01  Show Profile  Visit carolina's Homepage  Reply with Quote
Amature build here:
1) a useable plug to test ride.
2) covered over all the foam/bondo work with fglass.
3) pedal clearance now close to wet sanding.
4) also rear cowling plug is getting ready to be sprayed with primer.



I sanded out inside of clearance humps with 3 different tools:
1) now l can ride and see if alls well on clearance.


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Jeroen s
Starting Member

Netherlands
34 Posts

Posted - 11/29/2019 :  09:38:35  Show Profile  Reply with Quote
OK i am losing track of all the gearing options going on here. A Pinion in front, a Hilgo middrive, a rohloff and then the cassette on the rear axle?

Next to the drumbrake i think i see a delrin spacer. Would that cope with a hot drum?

Greetings, Jeroen
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/29/2019 :  20:42:41  Show Profile  Visit carolina's Homepage  Reply with Quote
Just different options. You’ll haf to read all the post.

No delrin and not near any heat. They say not to use rear brakes that much just the other day. I installed sturmey archer, i love em and on all 4 wheels.

1) you saw the stock pics of quattrovelo with mid-drive ROHLOFF up above.
2) hilgo floor shifter is for 3 wheeler, but i had a trial with it. Pretty good!
3) the Pinion middrive with short gates belt is my project. A take-off on rohloff’s middrive.
4) read about the quattrovelo with straight axle, can jump cogs over humps.
5) last year was 3 wheeler with bafang up front and rohloff at rear in waw linear supension.
6) oh, dont forget the schlumpf mountain drive up front now.
7) everyone wants something different.
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Edited by - carolina on 12/06/2019 06:10:51
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carolina
human power supergeek

USA
1373 Posts

Posted - 11/30/2019 :  23:31:15  Show Profile  Visit carolina's Homepage  Reply with Quote
Mod’ed shop vac.

https://youtu.be/ZwPQBCGQkrE
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Channel “pushyhog”
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Edited by - carolina on 11/30/2019 23:33:18
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carolina
human power supergeek

USA
1373 Posts

Posted - 12/06/2019 :  06:23:33  Show Profile  Visit carolina's Homepage  Reply with Quote
Nothing going on but slow bondo sanding every day. These are all plugs below to pull molds from:

Grey is the plug/master that the mold will be made from , ready for wet sanding soon:

The lower of this rear cowling is already a mold, the grey area will be 1 of 3 piece mold.

jan 5/ wet sanded, sprayed 3 more coats, now last wet sand and polish.



Also as said before: fiber glassed over toe clearance humps with 40 ounce fglass/2 layers. Honed out inside and put it on velomobiel for test ride/all good. Now iam adding bondo over fglass to sand and ready the two humps & whole part for grey epoxy primer.
Plug=Mold=Part


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Edited by - carolina on 01/05/2020 20:17:57
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carolina
human power supergeek

USA
1373 Posts

Posted - 12/23/2019 :  11:44:24  Show Profile  Visit carolina's Homepage  Reply with Quote
PHOTOBUCKET is down right now but pics can come later.

I have finished pinion and rohloff middrives finally as a display. Either gearboxes go behind seat on floor low down in the wide chain valley for next year.

I am still using the hilgo floor shifter and 9 sp cassette in the 4 wheeler with F. Schlumpf mountain drive 2 sp crank up front.
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carolina
human power supergeek

USA
1373 Posts

Posted - 01/05/2020 :  14:08:14  Show Profile  Visit carolina's Homepage  Reply with Quote
harbor freight milling a two piece mold:



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carolina
human power supergeek

USA
1373 Posts

Posted - 01/05/2020 :  14:34:25  Show Profile  Visit carolina's Homepage  Reply with Quote
these from harborfreight are really usefull in shop big time: trim micro, bondo, wood,& more.


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carolina
human power supergeek

USA
1373 Posts

Posted - 01/05/2020 :  17:39:47  Show Profile  Visit carolina's Homepage  Reply with Quote


2 piece mold for pinion gearbox mount.
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carolina
human power supergeek

USA
1373 Posts

Posted - 01/05/2020 :  20:13:50  Show Profile  Visit carolina's Homepage  Reply with Quote


PINION GEARBOX:base mount in carbon.
worked last night up til now on this pinion 18 speed mount mold. Black custom fitted pinion plug u see got me here. The center part between two orange pieces l poured down in between two orange parts (cotton flox and poly resin) for the 3rd part of this mold. lt is tight & fits incredible. Never tried that before.

l have L & R trim fixtures after part comes out. All six holes of finished part are pre-drilled before relief from mold. Then trimmed and 6 aluminum rivnuts installed.
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Edited by - carolina on 01/06/2020 11:19:27
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carolina
human power supergeek

USA
1373 Posts

Posted - 01/06/2020 :  20:28:51  Show Profile  Visit carolina's Homepage  Reply with Quote
More milling tonight:
Machine last part for left side sturmey archer drum brake on rear of 4 wheeler. Like to have a harbor freight lil’ laithe.


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Edited by - carolina on 01/08/2020 22:55:34
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carolina
human power supergeek

USA
1373 Posts

Posted - 01/07/2020 :  22:40:09  Show Profile  Visit carolina's Homepage  Reply with Quote
Took quattrovelo rear end out again to install left sturmey archer drum brake. Alot of work.



Now L&R drum brakes are complete, installing will take some more work. i love this setup for alot of reasons. The quattrovelo rearend is a great design. rides like a dream.

beautiful photo below:


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Edited by - carolina on 01/08/2020 22:52:44
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