Long time no post. My spare time for stuff like this is almost nonexistent.
I’ve been beating this poor chair like it was a rental for months. Short video of how it gets abused. Turn down your volume. You’re not drunk. This was recorded by an 11 year old.
https://www.willsjunk.com/WillChair-3/n ... -Zh4JDN3/AThe only issues I’ve really had was I managed to twist the motor mounts. Normal use would never do this. Snatching on trees and towing stuff way too heavy twisted them from the torque. So, I completely redid the rear suspension while at it. She had nearly 5 inches of suspension travel. Great for bouncing down rough trails but got annoying in day to day use. It worked perfect but too sensitive. Sitting cocked to one side or the other caused it to favor that side too much.
Shock mounts (ended up not being used). Started as plate welded onto to 1/2" scrap plate to hold it.
Video
https://www.willsjunk.com/WillChair-3/n ... -9bf46c3/AMotor mounts. Screwed onto wood to hold it. Forgot to take a pic until one was cut out.
The right piece will look just like the left in 15ish minutes...
Main suspension base. Yes, that's 3/8" plate.
Good tap swarf....
Most of the pieces before welding.
Each piece machined to snap together. Easier to ft up and makes the final product much more accurate. The pivot bores aren't finished here. They were done after welding.
The aluminum piece is to keep the tops from warping together.
I'm no pro welder and have crap quad hands but this ain't going anywhere.
These box the gearboxes to distribute the twisting force farther across the rear suspension plates.
Tappy....
https://www.willsjunk.com/WillChair-3/n ... -qKnQHqC/AHow do you hold multiple parts at a near perfect 12 degree angle so the bolts align and don't bind? 3d print jigs!
Worked perfect. Yes, I repainted everything.... I think. Not like it'll stay pretty long anyway.
Custom lock nuts for the rod ends.
Sawed off then into the lathe to be faced and tapped.
Note the seats at an angle.
Upper rear shock mount
Added notches to clear the shocks.
I faced it with a fly cutter and overlapped the paths to create a checkerboard pattern. You can only see it from certain angles.
Video of the first one I made. I slightly redesigned the second one in the above pics. Same process minus the tapping.
https://www.willsjunk.com/WillChair-3/n ... -QbqHrGc/AThe tapping swarf from the above video. Never buy cheap taps.
Shock pins. 304 stainless.
Different project but same piece of material and same process. Parting is not for the faint of heart, especially stainless.
https://www.willsjunk.com/WillChair-3/n ... -7RGBCpd/AThreading that part. I made that die holder because my crap hands can't hold normal ones.
https://www.willsjunk.com/WillChair-3/n ... -nCf4VSz/AI gave up on the touchscreen. I don't have the patience to get it to work correctly. Pretty sure it would get busted quickly anyway. I made a housing similar to W2 but got it shrunk even smaller, about 75% size. It's much smaller than it looks in these crap pictures. It was almost dark when I took them.
Yes, I made a joystick knob from 304 stainless. The red/black buttons are master kill. Touch the red and battery is disconnected from the controller for storage or charging. That's the "OH CRAP!!!" as well button. The amber turns the headlights on/off. The blue turns the volt meter on/off. The rear tiny toggle switches are: right - Roboteq on/off. Left - 12v system on/off.
Rear view. No, I didn't take any pics before getting it filthy. Yes, the tow hitch is already bent.
Ground clearance
Video of the updated rear suspension. Not as cushy on huge bumps as before but much better for daily use. It will spoil you. I have to remember W2 has no rear suspension when I get into it before hopping off of curbs or hitting sharp edges, even with the same fat low pressure tires. Turn your volume down.
https://www.willsjunk.com/WillChair-3/n ... -HWVdBXg/AI let the kids play in it. Fun for them and free durability testing for me.
I'll try to get good pictures soon. I plan to completely redo the front swingarms as soon as time allows. Already made the parts, just have to weld and mount them. As they are now, empty they're perfect. With me in it and suspension loaded the caster barrels are slightly tilted back, which makes the front end rise as the casters revolve.