Author Topic: Morgan F build (Read 14359 times)

Chris Brown · « **Reply #15 on:** 19 April 2019, 04:59:17 pm »

Not much obvious progress, but all the wiring is now labelled, the kill switch, fuel gauge, start button, and ignition key connected (in order starting from red button, top left), what's more it all works! The fuel gauge needs "calibrating" as it reads half full when it's actually only 1/4 quarter full, remove sensor and bend arm type "calibration".

As promised landscape photos replacing the portrait ones from yesterday that wouldn't rotate.

With most of the expense covered, and none of the scooter parts sold, I'm currently 31p over my £500 budget target.

Chris Brown · « **Reply #16 on:** 22 April 2019, 03:55:08 pm »

Well that's the front suspension assembled, took 3 attempts to get it right way up and pointing the right way.

Seat sorted, with temporary cover on it, just need to cut the legs off the base, and weld a couple of lengths of angle iron to it for mounting brackets.

Next job this afternoon is shifting the redundant bits of scooter to the shed. Then I can sort out the detail of attaching the front chassis to the scooter back end.

Chris Brown · « **Reply #17 on:** 22 April 2019, 06:47:14 pm »

Cleared out the bits of scooter, set up the front chassis to set the overall length. I did consider going back up to cut the scooter frame, but then the equation came to mind: glass of home made wine + 9" angle grinder = NOT a good idea. So the photos give some idea of the final result, with the front end of the scooter still attached!

ChrisS · « **Reply #18 on:** 22 April 2019, 07:47:26 pm »

Nice work chris, now I see how it fits together.

Chris Brown · « **Reply #19 on:** 24 April 2019, 05:19:16 pm »

A bit more progress, back end welded to the front, some bracing done, seat mounted (a bit skewed, but it'll do for now). So pedals, steering, floor, and the beginnings of bodywork to do before Stretton a week Sunday, shouldn't be a problem.

ChrisS · « **Reply #20 on:** 24 April 2019, 08:50:05 pm »

It's looking good Chris, are you getting any sleep?

Chris Brown · « **Reply #21 on:** 25 April 2019, 11:45:47 am »

Actually, I'd estimate the actual build has taken less than 40 hours so far. Day off today though, just got back from taking the van in for repair (under warranty), and it's Mam's 96th birthday, so the rest of the day is for her.

Steve Cole · « **Reply #22 on:** 25 April 2019, 06:11:19 pm »

Happy birthday to your Nan. is her birthday present a ride in the new mini Morgan ?

Chris Brown · « **Reply #23 on:** 26 April 2019, 08:25:52 am »

Mam, not Nan, a generation difference there, I've passed on your birthday wishes. No she's had various presents and treats, but a ride in the Morgan isn't on the cards, she might get in but getting out would need a hoist.

I've been keeping my build quiet from Wyn next door, as I wanted to do everything myself. Let the cat out of the bag Tuesday as I wanted to buy a stacking chair off him to make a seat. A group of us were discussing it after a meeting at Bethlehem Hall, and he commented "we all need to build one, then we can race them". I had a feeling Wyn would want to build one, the bonus is he's a farmer with some fields, including one that's flat (in Welsh terms), and level (again in Welsh terms), possibly a future venue (when it hasn't got sheep in it).

Chris Brown · « **Reply #24 on:** 28 April 2019, 10:40:03 pm »

The weekend's progress means the steering is sorted, just the pedal set to do, and handbrake to fit, then it's time for a test drive.

Chris Brown · « **Reply #25 on:** 03 May 2019, 08:17:05 pm »

Well after a couple of mods I took it round the paddock for a test, it does NOT like uphill on long wet grass, hopefully not too much damage done to the drive belt. I think there'll be some tweaks at Stretton, probably alterations to the steering ratio for starters.

It does fit in the van with the front wheels off, JUST!!

Chris Brown · « **Reply #26 on:** 09 May 2019, 12:25:19 pm »

Right, conclusions from Stretton:

The front end is too soft, resulting in the springs both taking a set, and coil binding under cornering.Cure, change to 30mm diameter springs, and cut them 1 inch longer than neded. Hopefully the pre load will negate any set they may take in use, I can always shorten them if needs be.

The steering was binding, wheel is off centre, and bearings too long. So I'll realign the shaft, counterbore the bottom bearing to reduce the bearing width to about 10mm, and use a conecut from the back of the top bearing to achive the same result.

The pedals are too far back. Now that I can see the geometry I can move them further apart to miss the pitman, and extend them horizontally to move them forward, without obstructing the steering.

Not enough lock. Having freed off the steering, the avaiable lock has increased quite a bit, if it's still not enough I've got two holes in the steering arms closer to the slider.

So all I need to do when I get home is find a bit of privately owned tarmac I can use for testing.

Chris Brown · « **Reply #27 on:** 09 May 2019, 02:04:15 pm »

Should have posted a bit about performance, a bit limited due to the handling problems, but still got 22mph on less than half throttle.

No need for any extra power, though I'll still change the exhaust, for practical reasons, I can then get rid of the bulky monster that's fitted at the moment. That'll make fitting the bodywork easier, and hopefully allow me to keep the back end minus body under 550mm. If I can it means the kart will go in the van even after the camper conversion is complete.

So I'll still be able to tow the caravan, or attend events without towing a trailer. Of course that also means when the double deck trailer is finished I'll have the capacity for 3 karts!

RhysN · « **Reply #28 on:** 10 May 2019, 08:09:26 am »

I think it's really great that you are giving feedback from what you have found Chris.

Chris Brown · « **Reply #29 on:** 10 May 2019, 08:39:10 am »

As far as I'm concerned Rhys, analysing what didn't work properly is an important part of the build journal, along with the solutions. That way anyone else who decides to take the same route as me can avoid the pitfalls. I've decided to reduce the camber on both sides, so as to reduce the tuck under shown in Bill's photo, should also reduce the likelihood of getting up on two wheels again.

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Author Topic: Morgan F build (Read 14359 times)

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