My first build ever. A copy of Wayside's design.

  • Thread starter DJRichard
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Wow, what a difference with that seat! Best €20 you've ever spent, I'd reckon :lol:

Watching your build with interest... :)
 
Got a few of the intricate bits done today. I also gave it a second coat of paint. My hands are currently still covered in the stuff despite my best efforts to clean my hands!

Ive made the pieces for the dashboard and used a drill and the router to cut it down at the back for the switches. I dont have enough switches for the amount of holes Ive made, but I thought I may as well get the work done while all the tools were out as I will get more switches soon. I have to order 300R resistors anyway, so until then, the switches will not be wired up. They are just decorational at the moment.

I also drilled all the mounting points for the wheel etc, so it will be hard mounted. I also attached the monitor deck and painted it. I cut-out the wheel shape from the monitor deck and you can see that the cooling vents on the back of the wheel are perfectly clear, so there wont be any over-heating issues to resolve. This was more by luck than forward planning.

The dashboard which has the switches attached to it was screwed on upside down, so you can see its not fitting properly. I will turn that the right way around tomorrow. Im so annoyed with myself for doing that because I was struggling to screw it together in alignment and now I can see why. It makes the entire thing look awful. So it will be flush tomorrow for a fact!

Here is the monitor deck on.
sideonoftopdeckattached.jpg

I had to put some wedges in to secure it all. The wedges next to the wheel have been chopped down a bit to allow fopr switch cabling in the future.
topdeckscrewedon.jpg

Here its all been painted.
sideonwithmonitorstandpainted.jpg

Trying out the switches after drilling some holes.
switchesfixedtodashboard.jpg

Ive now painted the small part of the dashboard and you can see where Ive used the router to allow the switches to be screwed into place. I know its not all that neat, but its out of sight so isnt all the important.
routeddashboard.jpg

This is the front of it.
routeddashboardfront.jpg

Ive put all the switches onto the other side. Dashboards now attached, still to paint the screws to hide them.
dashboardattached.jpg

You can see what I meant about it being attached upside down. Schoolboy error.
dashboardswitches.jpg


So its starting to take shape. The dashboard, apart from not being lined up properly on the right hand side, is looking a lot better than I thought it would. Its nice and simple. I much prefer this to a chunky buttonbox which doesnt look integrated with the cockpit.
 
Are you absolutely sure you've never done this sort of thing before? That looks excellent! You might like to countersink the screws (and use countersunk screws if you're not already) to make them flush, that's all I can think to add at this point.
 
Thanks. Ive deffo never done anything like this. The last thing I made was a cassette holder in woodwork in school. That was when I was 13 or something, Im 35 now!

To be honest, its not that hard, just have to be really careful and take my time. A few times, when I was getting tired after being at it all day, I would find myself starting to cut the wood faster and not being so cautious. Thats when I decided Id be best to stop for the day. Ive found myself struggling to get to sleep at night because Im constantly thinking about this and what I can do to it.

This is the first time Ive used MDF in my life, I dont really like it. After all the work cutting out the bits for the switches, I split the MDF as I was screwing it together. I even had a pilot hole and screwed it REALLY slowly. If it had been normal wood, such as plywood, it wouldnt have happened. I may actually rip that MDF off the right hand dashboard and make it again with plywood. Im thinking part of the problem is that the MDF is quite old. So on some parts of it, its fluffed up a bit, its not as compact as it ought to be.

The screws are countersunk screws. I thought as I tightened them they would pull themselves into the wood, just like everywhere else in the build. The MDF didnt behave like that, I thought it might just rip through it. You can see Im not feeling this MDF stuff!

I will work on the right side tomorrow, even if it takes me a long time, because Im very unhappy with it. I feel like the time and care Ive taken over the rest of the build is being ruined by that one piece. If there is going to be any lazy corner-cutting, I sure dont want it to be right at the front where I can see it.

I was going to buy this wooden bird house a few weeks ago, they were for sale in a local shop and they got them from a local man who wanted to make a bit of extra money. Now I see how relatively easy this is, when you have the use of the tools, I could easily make one myself.
 
I went back today (after Andy Murray destroyed Federer to take the gold!) to fix that right hand piece of the dashboard. Its now all mounted properly. I also added my pedals and I secured the gear selector.

Ive painted the screws to keep it all black and I was hoping to bring it in to setup on my computer. Any further work could be done in the house.

DISASTER!!! It weighs an absolute ton. I cant move it at all.....I will have to remove the seat and I really dont want to, that thing was ridiculously difficult to attach. It wasnt a case of simply fastening with 4 bolts to the rails. The rails were not flat, they had all kinds of weird metal brackets under them that I had to cut around on the base. Also the runners are not the same length. I nearly rounded off a couple of screws while attaching it.

I have no choice though, otherwise it will be staying in the garage!

cockpitnearcompletion.jpg


Here is the drivers eye view.

fromdriversviewside.jpg


angledswitchesmonitor.jpg
 
Looking absolutely fantastic! Sucks about not being able to move it, get a couple more burly Scotsmen to help?
 
I went into my house after looking about for some kind of wheeled device to help carry the weight of the rig. Nothing. I was gutted and shut up the garage for the night. Then a EUREKA moment! I ran into the garage again and took one of the huge blue plastic pipes and cut it into 5 pieces. I was going to roll this like they did in ancient times. Except rolling it over rough ground wasnt so easy, it actually slid along the length of the plastic really easily. So thats what I did. With the light fading fast (you can see the darkness as Im just entering the kitchen) I shoved this thing all over the place and managed to get it into my computer room.

I have just had a shot of it and its fantastic. I have to put my pedals much lower though as I measured it with big walking boots on that I was wearing while doing the build. I never realised just how big they were until I tried it in my socks!

I know these are quite boring photos, but its what allowed me to single-handedly get this heavyweight rig into my house over rough ground and up 1 foot on height.

There are of course a few finishing touches to be done and I'll do them as soon as I get the pieces I need.

I have to say, Im gobsmacked at how well this has turned out. If Id been shown this at someones house Id never have believed Id have been able to make this on my own.

Id like to thank everyone who has given me advice in the thread and also a very special thanks to Wayside for so kindly providing his sketchup plans that enabled me to build this.

Extremely strong pipe cut into pieces with the jigsaw.
step1.jpg
step2.jpg

Now the akward bit of raising it up onto the decking to get it in the kitchen doors.
step3.jpg

Light is fading fast here as I prepare to slide it into the house.
step4.jpg

Sideways and Im inside at last.
step5.jpg

Entering the warmth of the kitchen.
step6.jpg

Hmmm now this isnt going to fit so easy...
step7.jpg

This should do the trick.
step8.jpg

and finally, I thought Id never see this done today, sitting ready to go!
step9.jpg


THANK YOU!
 
That's incredible, congratulations! Just don't forget there are other seats in the house though!
 
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