Z Wheelz, LLC . . . San Antonio, TX, USA . . . info.zwheelz@gmail.com
The smallest vehicle is the ZW1-E (ZWheelz 1-seat Efficiency). It is a simple recumbent trike (based on bicycle parts) with a 1900 watt electric hub motor installed in the rear. It will have a full enclosure with lights and mirrors suitable for the most efficient commuting and touring. It will have removable battery packs for remote recharge and be capable of solar panel recharge.
See below for Riley XR3 build.
Side project - Building the XR3 (see http://www.rqriley.com/xr3.htm for info)
Tools - get some good drill bits. A bunch of small split-tips for pilot holes and an expensive set for thick steel. Cheap drills are good for wood and plastic, and maybe aluminum. When you're drilling thick steel they get dull as soon as you tighten the chuck. This may be the best money spent on a project like this - dull bits will make every hole a dreadful experience and sharp ones will go thru like butter.
Steel rules - 6" x 1/2", 12" x 1" and 24" x 3/4". Small square, spring-loaded punch and lots of fine tip sharpie pens.
Use a small square to measure in from the sides. The mantra is " measure twice, cut once". Measure in from the other side to double check. Drill a small pilot hole for better accuracy - drill bits "drift" quite a bit. Use split-tip drill bits which will stay centered on the punch mark.
Some metal cutting tools - a compound miter saw with a carbide blade - or at least a chop saw - comes in really handy. A hand-held band saw is not as good as a larger horizontal/vertical unit but it's nice to have. The angle grinders have cutoff and grinding discs and are very handy along with a bench grinder and large bench disc sander.
The hole saw is slow-going but gets the job done. There is still a lot of grinding to do to get a good fit. Drill once and cut across the middle to get two pieces.
The fit doesn't have to be very close if it's going to be welded, but an old craftsman once said "treat every piece like a work of art". Conversely, when things start getting sloppy, it tends to set the level of quality for the rest of the project. You may as well relax and enjoy the ride - it's gonna be a long one.
Here are the main pieces for the front subframe. There are still holes to drill and a few more cuts on the round tubes before it will be welded together. Then there are a lot of small brackets to be cut and welded.
A die grinder with a rotary file was used to enlarge the holes after drilling with the hole saw. It sure would have been easier if the 2" tube fit in the 2" hole drilled with the 2" hole saw.
The main frame of the front assembly is done. The spring perches, transmission plate and lots of brackets are next. The beer is for size reference. A poor choice - it's already gone. More size references will be purchased.
TIG was used for all of the front weldment.
A The first side weldment was used as a jig for the second.
A pile of waterjet cut parts. Upper and lower control arms, spring perches, transmission mount and battery boxes.
Spring perches tacked on.
Upper control arm parts to the right and lower control arms on the left.
"Jig" for lower control arm sway bar bushing.
Lower control arms about half welded.
Lower control arm ball joint.
