Determine which details of the future of the moped will be purchased and some homemade. With the exception of the engine in unit with the gearbox, the power supply system and ignition, front forks, wheels, gas tank and lighting all can be done independently.
Please follow the sketch of the future design on paper or cardboard. Then transfer it to a sheet of plywood and make a Plaz – accurate drawing in full size. This will help to link all the elements of a moped and clarify its layout. The binding of the elements of the design start by placing the wheels.
Define the distance between them (database). The silhouette of the front wheel attach the front fork to the wheel. Between the wheels, place the silhouette of the motor in the most optimal location from the standpoint of convenience and reliability of fastening to the frame. Then combine all the nodes of the frame. At the same time avoid unnecessary details, observe the simplicity of form and maximum workability.
Start the construction from the frame. It must be welded from pipes of different diameter. Material take unnecessary other frames of motorcycles and mopeds. They have the proper stiffness, I wouldn't say the water pipe. If no welding equipment or skills, contact a workshop for assistance. Rear fork, follow either from pipes or from steel strips. Sheet steel with a minimum thickness of 3 mm cut out plate engine mounts.
Before manufacture of the frame store all its components. For bending the tubes in cold tamp them sifted dry sand, plug the holes with wooden plugs and bend with simple bending. It can be made from a car Jack and piece of rail. To the rail, attach the billet thick wire (with a minimum thickness of 5 mm), move the workpiece under the Jack and bend the pipe, pushing the lever rod of the Jack. Continually monitor work using template, cut wire, curved along the contour depicted on the Plaza part.
Rear fork run of the steel strip, of a thickness less than 5 mm. In feathers of fork make grooves with a width of 10 mm to the axis of the rear wheels. Turnkey elements of the frame to fasten the soft wire and check the manufacturing and Assembly. Carefully tack weld 2-3 points at each intersection, check again and cook completely. Install the frame brackets motor mounts, slightly taking welding. Check the engine mounts to the brackets and weld completely.
If necessary, attach to the rear wheel sprocket from any moped or leading from the front of the bike. Mount follow these three M8 bolts with nuts. Install the wheel into the fork, secure the engine, the power supply system and ignition, tank, seat, headlight and taillights, ignition coil, kick starter, steering wheel and controls (throttle, clutch lever, hand or foot switch gears).
Don't forget about the brakes and footrests. Brake install simplified, drum type on the rear wheel. It would be enough for a light moped. Foot pegs are made of pipe sections and secure with welding. Pour the fuel in the gas tank, motor oil in the gearbox. The ignition is set in accordance with the instructions. Speeding up to 15 km/h, check the reliability of the brakes.
If this is your first experience in building an improvised vehicle, use the maximum number of purchased parts and not overly complicate the design of a future bike. Otherwise the project may take many months or years
Advice 2: How to make a homemade motor
Motor is a device that converts any form of energy into mechanical energy. The first electric motor was invented in 1834 by the Russian scientist B. S. Jacobi. Since there are many varieties of electric motors, but today many people want to do it yourself and improve the design of the engine.
You will need
- - vibration alert of the mobile phone;
- - drill;
- - copper wire;
- - fluorine;
- - microchip Allegro А1442.
To not buy magnet specially for the stator, use a vibrator old mobile phone. Hold the eccentric in a Vice and carefully, with the awl squeeze the shaft. The next step will be the release of the brush unit. Pry the same pain bruising on the body and clear the site. You can see the magnet. To it out again, use the drill bit that fits the diameter.
Lay the case on a hard surface and slightly tap on the drill the magnet itself will fall. In the same way to get rid of the glued sleeve, which is not needed.
The role of the shaft, use a drill, because they are more durable and resistant to bending. If the inner diameter of the magnet is larger, and the shaft it's loose, wrap it in copper wire of the required thickness. Thus you increase the diameter of the shaft itself in place of its contact with the rotor.
That the design was not scrolled, the method of resistance welding weld the wire to the part. Now connect the shaft with the rotor and fill the space between it and the magnet special super-glue.
For the manufacture of bushings, use the PTFE. Drill through the sheet hole diameter of 0.3 mm and bring the bushing to the similarity of the tube. To the shaft to move freely through it, grind it to the desired diameter. Thus you will get rid of friction.
Now wind the coil. For convenience make on a lathe frame of required size on which the wrap 60 turns. For this you will need about 90 cm of wire.
Soak the coil with glue without removing it from the frame and gluing it to the latter. It is easy to perform only by using a microscope. Make 2 such windings and glue them, causing a minimal amount of glue between winding and bushing.
Solder one end of each of the windings to get one, but with two conclusions, which at the end of the solder to microchip Allegro А1442.
When welding the main thing is to correctly adjust the device. After all, if the voltage or the capacitance of the capacitor will be very high, the wire will not stick and will start to evaporate, leaving microcrater reducing the strength of the shaft.
To fill the space between the magnet and the shaft, use a special transparent adhesive which does not leave a white residue after drying.