radio flyer wagon build

delray

delray

Well-Known Member
#1
#1
this summer i will be drag racing a minibike that i built for clay tracking racing at 125ft and i would like to have something to tow my minibike and carry my equipment. making it alot easyer get everything move from the parking area to the track. i know the two places that i will be racing have some distance between the track and parking.
for most of my project i will be using alot of recycled parts from just about everthing i can salvage from.
wagon i will be building off of will be the woody model(ATW). this model looks to be the biggest model they build and will work perfect for hauling my equipment.
i guess i won't be using these directions.....:laugh:
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delray

delray

Well-Known Member
#2
#2
first thing was to bed coat the woody box.
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some off the stuff i will be using for my project.
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made a quick jeg out of wood for the outer frame.
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delray

delray

Well-Known Member
#4
#4
moch up the motor and the rear suspenions.
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before doing that i had to make two grooves in the 3/4 keyway shaft to hold my rear sprocket in place with snap rings and drill and tap the ends of the shaft for 1/4 thread bolts.
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delray

delray

Well-Known Member
#5
#5
main frame and the rearend & motor in place.
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rearend sprocket and locker is out of a snowblower. works pretty slick. just pull the lever and it moves a fork and assembly back away from the pin's and it is unlock. this too work's great if the battery's are dead,motor....etc. now the wagon can also roll on it's own if need to be.
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delray

delray

Well-Known Member
#7
#7
ok little behind on posting pictures. try to catch up.
had to fab a drive sprocket for the 24v electric motor shaft. it has a 15mm keyway setup...:doah:
so i found a 15mm love joy and turn it down on my lathe and made it into a hub so i could weld a standard sprocket on to it...:thumbsup:
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turn down
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bore out the standard sprocket
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hub fits and now i am going to weld it up and then chuck up the new 15mm hub and cut off the old hub thats on the
sprocket(5/8 keyway)
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also decided to make a small grove the last minute before welded it.
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cut off and welded

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delray

delray

Well-Known Member
#8
#8
fab up a roller tensioner out of a skate board wheel. chuck it it up in the lathe and turn it down some and then use a cut off tool to make a groove in the roller for the chain.
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mounted the wheel in place. also made the bracket adjustable up and down.
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delray

delray

Well-Known Member
#11
#11
i pulled the factory disc brake lock off. i could see this being a problem down the road. the way it work was to run 24v to the brake and that would unlock it. if for some reason i lost voltage this until would automatically lock up. not good at all.....:doah:




after disconnecting it. i reinstalled the round cover. i will be installing a new disc brake setup on the rear axle 3/4 keyway shaft...:thumbsup:
 
massacre

massacre

#12
#12
This is really cool! I didn't know they offered a kit like this.
I have a vintage wooden Wagon I think it's a radio flyer or similar. It's all apart and in primer has been for 20 years.
I love the electric motor idea!
 
delray

delray

Well-Known Member
#15
#15
fab up up a small tow dolly for the drag bike.



i will still have to make a loop bar that will go around the tire on the minibike to lock it into place when tow it. for now i will make it a fix/stationary position. may change it to a pivot mount.
 
delray

delray

Well-Known Member
#16
#16
found these nice blank thick steel door hinges that i want to use to pin the wagon to the frame.
i cut two of the loops/hinges off first and then mount three loop on the back of the wagon also purchase the long stlye trailer pins.
to make them fit in the door hinge loop. i had to drill out the loops little to make the pin fit snug.then took the remaining two loop hinge and
use them on the front with a shorter trailer pin.


this will make it real easy to access the batterys by lifting one end up.(pull the pins)or pull all the pins and remove the woody wagon and you have a steel frame to haul on.














then took the remaining two loop hinge and
use them on the front with a shorter trailer pin.

 
delray

delray

Well-Known Member
#17
#17
mounted the battery box off to one side and forward has much as possible to help even the weight out. battery was just moch up at first to see how the box would look in it's place...:rolleyes:

 
Mark G

Mark G

#19
#19
Looking good so far Brian:thumbsup:

If I were you I'd make sure that hitch for the tow dolly pivots. The bike will be too top heavy and the parking lot at Symco ain't exactly flat, if it's only allowed side to side motion it won't tow very well and could possibly tip.
 
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