Cushman based build
Re: Cushman based build
Following this build with great anticipation...
I have a 1990s 3 wheel Cushman that i would love to make into something useful to me. I have a very wide array of interests and tasks that I would like to use the Cushman for but its current setup just doesn't help me.
I have a 1990s 3 wheel Cushman that i would love to make into something useful to me. I have a very wide array of interests and tasks that I would like to use the Cushman for but its current setup just doesn't help me.
Re: Cushman based build
You know this project was preceded by the 3 wheel Cushman in the beginning of the thread. I did a down and dirty conversion to a triangulated 4-link with airbags and I loved it:




Re: Cushman based build
Finally, a month and a half waiting on the sandblaster to blast and prime it. Got it back today! Time for paint prep!




Re: Cushman based build
Painted the cart today. Had one screw up. When I got to the roof I was standing on a stool. I raised my paint gun too high and bumped the drop ceiling making it snow on the wet roof. Not a big deal. I'll get that repainted soon.
Still have to paint the side panels and a bunch of parts.

Still have to paint the side panels and a bunch of parts.

Re: Cushman based build
Really cool project!!
1000w - 48v Ebike with 48v 20ah LiFePO4 pack from sun-thing28
Re: Cushman based build
Coming along nicely. Looks Awesome.

3220 Mountain Bike http://endless-sphere.com/forums/viewto ... 17#p244317
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Re: Cushman based build
Thanks guys, spent yesterday afternoon and evening sanding. Re-painted the body area around 9pm last night but it looks a lot better:




Re: Cushman based build
The fenders and lights give it a little more character. The suspension and bed will really help.


- amberwolf 100 GW
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Re: Cushman based build
And wheels....it really gets nifty when you add wheels. 

If you found this advice helpful, supporting contributions are accepted here.
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
Re: Cushman based build
Well, I did figure wheels and tires with suspension but that is true.
- amberwolf 100 GW
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Re: Cushman based build
Sorry...couldn't help teasing.
Your trike is much nicer than mine.

If you found this advice helpful, supporting contributions are accepted here.
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
Re: Cushman based build
No problem!
Getting things together is gratifying for the work that has been done! I love the triangulated 4-link! You can see the 2-speed trans:




Getting things together is gratifying for the work that has been done! I love the triangulated 4-link! You can see the 2-speed trans:




- amberwolf 100 GW
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Re: Cushman based build
It's looking really good...but I must've missed (even after rereading the thread) the explanation of the GAS logo on the front?
(BTW, I originally started following the build when you posted the first post, but then the housefire happened and I lost track of it till recently, when you took it off for painting).
(BTW, I originally started following the build when you posted the first post, but then the housefire happened and I lost track of it till recently, when you took it off for painting).
If you found this advice helpful, supporting contributions are accepted here.
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
Re: Cushman based build
Sorry to hear about the house fire. The last two houses I have had I had a rule that the shop not be attached to the house.
The "GAS" is for a company I have "Gas Auto Solutions" where I make inertia based auto cancel turn signal and light controller. I developed them for Hot Rod's and custom cars but they have been making their way into things from golf carts to Polaris.
Plus when people see the gas sign then all the electric batteries they get confused. Have to say that's a bit fun.

The "GAS" is for a company I have "Gas Auto Solutions" where I make inertia based auto cancel turn signal and light controller. I developed them for Hot Rod's and custom cars but they have been making their way into things from golf carts to Polaris.
Plus when people see the gas sign then all the electric batteries they get confused. Have to say that's a bit fun.

Re: Cushman based build
BTW just left of the 2 speed transmission in this shot, there is a trailer hitch tube mounted vertically. Harbor Freight has a jib crane and I am going to use this as a socket to drop it in or take it out.


- amberwolf 100 GW
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Re: Cushman based build
Unfortunately that wouldn't have made any difference to this one.burner1 wrote:The last two houses I have had I had a rule that the shop not be attached to the house.
Interesting. I'd planned something like that for my original ebike control system idea, but the project itself never got started past the idea stage. (would've used the accelerometer in the system's MCU module to determine direction and velocity change and turn signals and brake lights on and off if the rider didn't do it manually).The "GAS" is for a company I have "Gas Auto Solutions" where I make inertia based auto cancel turn signal and light controller. I developed them for Hot Rod's and custom cars but they have been making their way into things from golf carts to Polaris.
That's true.Plus when people see the gas sign then all the electric batteries they get confused. Have to say that's a bit fun.

With the motorcycle lighting on my bicycle builds, people sometimes get confused and stare...even turn around and go back and pass me again to check it out again.

If you found this advice helpful, supporting contributions are accepted here.
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
"if it ain't broke, improve it till it is"----Dog-Hauler Cargo eTrike SB Cruiser----The HI-Lebowski: a Lebowski SMD brain running a zombified Honda IMA Inverter: a HOW-TO guide----Cargo eBike CrazyBike2----General Blog
Re: Cushman based build
A lot more work left then it appears but at least I can see what it looks like now; except for the bed.


Re: Cushman based build
I am slow with these things. I only get a chance to work on it here and there. It always seems like I need to order something.
I got the motor drive system wired up and working. Power relay, reverse relays, motor controller, gas pedal, all hooked up and working well:

The gas pedal is off a larger commercial truck. It is a new pedal I got at a swap meet for $10. I needed to adapt a POT so I 3D printed an adapter and it works great.

I put in a 10k pot but I probably should have put in a 5K. However, when I moved the 10k pot on the pedal I checked the resistance within the range of movement and it ended up being 0-1.2k when it was on the floor. I turned on the controller, checked the rpm and it was good but not as fast as it should be. I plugged the computer and reset the controller for a 1k range and it worked great. I also used the exponential setting which is good for smoothing the throttle.
Now looking to the rest of the car. I made a geometry error in the front suspension (something really stupid). Basically I need to remake the a-arms which is next. So here is what I have left:
Charging plugs/cavity
A-arms
Brake Lines
Windshield
Bumper
Aluminum Diamond plate Stake bed
Light/electrical system.
I got the motor drive system wired up and working. Power relay, reverse relays, motor controller, gas pedal, all hooked up and working well:

The gas pedal is off a larger commercial truck. It is a new pedal I got at a swap meet for $10. I needed to adapt a POT so I 3D printed an adapter and it works great.

I put in a 10k pot but I probably should have put in a 5K. However, when I moved the 10k pot on the pedal I checked the resistance within the range of movement and it ended up being 0-1.2k when it was on the floor. I turned on the controller, checked the rpm and it was good but not as fast as it should be. I plugged the computer and reset the controller for a 1k range and it worked great. I also used the exponential setting which is good for smoothing the throttle.
Now looking to the rest of the car. I made a geometry error in the front suspension (something really stupid). Basically I need to remake the a-arms which is next. So here is what I have left:
Charging plugs/cavity
A-arms
Brake Lines
Windshield
Bumper
Aluminum Diamond plate Stake bed
Light/electrical system.
Re: Cushman based build
After doing something stupid with the front suspension set up it was time to drop back and do it again right.
I used rod-ends to mount the uprights to the a-arms. One thing I did not like was on my first a-arm build I welded to the rod ends. There was no way to take them off or repair them. The second time I did it a little different.
First I straightened the outside of the rod end:

Then I threaded them:

I used cut down the outside of coupling nuts and welded them to the tubes. This made the rod ends removable:

Cardboard templates to locate mounting points for lower and upper a-arms:



I used rod-ends to mount the uprights to the a-arms. One thing I did not like was on my first a-arm build I welded to the rod ends. There was no way to take them off or repair them. The second time I did it a little different.
First I straightened the outside of the rod end:

Then I threaded them:

I used cut down the outside of coupling nuts and welded them to the tubes. This made the rod ends removable:

Cardboard templates to locate mounting points for lower and upper a-arms:



Re: Cushman based build
That is Awesome!

3220 Mountain Bike http://endless-sphere.com/forums/viewto ... 17#p244317
Suzuki Lipo Upgrade http://endless-sphere.com/forums/viewto ... 86#p335986
Race Bike http://endless-sphere.com/forums/viewto ... =3&t=32486
Re: Cushman based build
No brakes but I took it for a short drive. Soon vibration showed I must have not gotten the clips in the U-joint. Low gear is a little weak on start on one set of batteries. When I bring in both it's better. Speed is no issue around the property in low gear. It will go faster on property then I need to go. Once it starts going it winds out pretty quickly.
Suspension is real good. Steering is good. A-arms worked out well. On the 3-wheel Cushman I had I made this 4-link suspension but it needed a sway bar. This 4-wheel cart does not.
Back to the list of things to do. Started on bumper. Still have a dozen things to do. Putting a bed on it is really going to change the look.


Suspension is real good. Steering is good. A-arms worked out well. On the 3-wheel Cushman I had I made this 4-link suspension but it needed a sway bar. This 4-wheel cart does not.
Back to the list of things to do. Started on bumper. Still have a dozen things to do. Putting a bed on it is really going to change the look.


Re: Cushman based build
BTW it has a nose only a mother could love!!
Re: Cushman based build
Nice work. Wish I had your mechanical skills!
dh
2013 Chevy Volt
2009 Prius with Hymotion L5 PCM
2008 Prius with Hymotion L5 PCM (passed on to daughter)
2011 Rose Xing Fu 48V 500 Watt commuter scooter (now departed)
1984 Honda Interceptor 48V electric conversion motorcycle
Under construction: 2008 Miles ZX40ST truck with altered DC drivetrain
Departed: 2002 VW Jetta TDI which was run for a time partly on WVO.
Amateur radio station run entirely on solar/battery power.
"You can tell I'm a troublemaker, because I plug in my car."
2013 Chevy Volt
2009 Prius with Hymotion L5 PCM
2008 Prius with Hymotion L5 PCM (passed on to daughter)
2011 Rose Xing Fu 48V 500 Watt commuter scooter (now departed)
1984 Honda Interceptor 48V electric conversion motorcycle
Under construction: 2008 Miles ZX40ST truck with altered DC drivetrain
Departed: 2002 VW Jetta TDI which was run for a time partly on WVO.
Amateur radio station run entirely on solar/battery power.
"You can tell I'm a troublemaker, because I plug in my car."
Re: Cushman based build
Most people are quite capable of more then they know!
Re: Cushman based build
Agreed, but being a novice, my welding and structural work (see the Miles thread in this forum) doesn't look like yours.burner1 wrote:Most people are quite capable of more then they know!

dh
2013 Chevy Volt
2009 Prius with Hymotion L5 PCM
2008 Prius with Hymotion L5 PCM (passed on to daughter)
2011 Rose Xing Fu 48V 500 Watt commuter scooter (now departed)
1984 Honda Interceptor 48V electric conversion motorcycle
Under construction: 2008 Miles ZX40ST truck with altered DC drivetrain
Departed: 2002 VW Jetta TDI which was run for a time partly on WVO.
Amateur radio station run entirely on solar/battery power.
"You can tell I'm a troublemaker, because I plug in my car."
2013 Chevy Volt
2009 Prius with Hymotion L5 PCM
2008 Prius with Hymotion L5 PCM (passed on to daughter)
2011 Rose Xing Fu 48V 500 Watt commuter scooter (now departed)
1984 Honda Interceptor 48V electric conversion motorcycle
Under construction: 2008 Miles ZX40ST truck with altered DC drivetrain
Departed: 2002 VW Jetta TDI which was run for a time partly on WVO.
Amateur radio station run entirely on solar/battery power.
"You can tell I'm a troublemaker, because I plug in my car."