Rubber Tyres Before There Were Tyres

December 8, 2021 by Jenny List 24 Comments

Sometimes there is pleasure in watching an expert demonstrating his craft, particularly so when the craft is unusual or disappearing. A video came our way of just such a thing, and it’s of a craft so rare that it’s possible few of us will have considered it. We’re used to buying tyres for our motor vehicles that come pre-made in a mould for the size of our wheels, but how many of us have considered where the origins of the rubber tyre lie? How did a 19th-century horse-drawn buggy get its tyres? [EngelsCoachShop] take us through the process, putting rubber on a set of wooden carriage wheels.

These wheels would originally have had iron rims, that must have provided a jarring ride on cobbled roads of the day. English coach-builders of the mid 19th century were the first to fit solid rubber tyres, and it’s this type of tyre that’s being fitted in the video. Instead of the rubber ring we might expect the tyre is cut from a length of vulcanised rubber extrusion with a significant overlap, then a pair of high-tensile wires are fed through holes in the extrusion. The impressive part is the jig for creating the tyre, in which the rubber is compressed to a tight fit on the wheel before the wires are cut and their ends brazed together. Once the wheel is released from the jig the compressed tyre expands to the point at which its ends meet, making a perfect circular tyre held tightly on the rim. Few of us will ever see this for real, but we’re privileged to see it on the screen.

We may not deal with wooden wheels very often, but this isn’t the first set we’ve seen.

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Abandoned Airplane Takes Off Again As Luxury RV

December 4, 2021 by Kristina Panos 30 Comments

You remember how you wanted to combine everything as a kid? Like lions and tigers into ligers and so on? Well, some kids dream of transportation hybrids. For eighty-year-old [Gino Lucci], now an Air Force retiree, that dream involved a recreational vehicle that combined an airplane fuselage and a delivery truck.

There it was, rusting in a field outside Rolla, Missouri — the vintage plane that would start [Gino Lucci] on the path to fulfilling this dream. This project began when [Gino]’s son spotted the body of a 1943 Douglas R4D military transport aircraft.

Over the next year, [Gino] and his sons painstakingly fused the fuselage to the chassis of an International DuraStar 4400 medium-duty truck. We love how they went about it. [Gino] and the boys just kept putting the two together and cutting away the fuselage in stages until they got it right. After making it roadworthy, it took another two years to work out the kinks.

The Fabulous Flamingo is 38 feet (11.6 meters) long and stands 12.5 feet (3.81 meters) tall. But the best metric is the width. It’s unspecified, but is apparently half an inch (1.27 cm) under the definition of what is street legal in Michigan. They used the plane’s engine cowlings as fenders and got the mirrors off of a ’70s Ford pickup. Floor it past the break and check it out.

This build cost about $20,000 USD all told. If you’ve got that kind of money, you could instead stuff a powerful engine into a tiny plane to get your kicks.

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Surfboard Gets Jet Upgrades

November 25, 2021 by Bryan Cockfield 6 Comments

Surfing is a fun and exciting sport but a lot of beginners can get discouraged with how little time is spent actually riding waves while learning. Not only are balance and wave selection critical skills that take time to learn, but a majority of time in the water is spent battling crashing waves to get out past the breakers. Many people have attempted to solve this problem through other means than willpower alone, and one of the latest attempts is [Andrew W] with a completely DIY surfboard with custom impeller jet drives.

The surfboard is hand-made by [Andrew W] himself using a few blocks of styrofoam glued together and then cut into a generic surfboard shape. After the rough shaping is done, he cuts out a huge hole in the back of the board for the jet drive. This drive is almost completely built by [Andrew] as well including the impeller pumps themselves which he designed and 3D printed. The pair of impellers are driven by some beefy motors and a robust speed controller that connects wirelessly to a handheld waterproof throttle to hold while surfing. Once everything was secured in the motor box the surfboard was given a final shaping and then glassed. The final touch was an emergency disconnect attached to a leash so that if he falls off the board it doesn’t speed away without him.

The build is impressive not only for [Andrew]’s shaping skills but for his dedication to a custom jet drive for the surfboard. He spent over a year refining the build and actually encourages people not to do this as he thinks it took too much time and effort, but we’re going to have to disagree with him there. Even if you want to try to build something a lot simpler, builds like these look like a lot of fun once they’re finished. The build seems flawless and while he only tested it in a lake we’re excited to see if it holds up surfing real waves in an ocean.

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E-MonoWheel

November 24, 2021 by Matthew Carlson 16 Comments

Generally, monowheels are that wacky, wildly futuristic transport that we lump in the same category as hoverbikes and jetpacks: strange, currently impractical, but very cool. Not content with waiting for the distant future, [Sam Barker] made his own electric monowheel. (Video, embedded below.)

The hardest part of any monowheel is that the outside rim needs to stand enormous abuse. It supports the weight of the vehicle and provides most of the structural integrity, but also is the means of propulsion. [Sam]’s first thought was to use a trampoline frame as it is a round and reasonably sturdy tube steel. He 3D printed the rollers that connected the subframe to the trampoline frame. Flat bar stock was used to make the angles inside the subframe and straight tube steel connected the inner frame into a trapezoid. The trampoline frame was welded together and on the first test spin, it broke apart from the stress. It simply wasn’t strong enough.

Not to be dissuaded, he found a company that bends steel into custom shapes. He stole the e-bike kit from another bike he had converted earlier, and the wheel was turning. Some handles and foot-pedal later, it was time for a proper test drive. Overall, the result is pretty impressive and the double-takes [Sam] gets while riding down streets in town are wonderful. If you’re looking to scratch the monowheel itch, check out this wooden monowheel.

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An electric mini rat rod made from mostly recycled parts.

Electric Mini Rat Rod Starts ‘Em Young

November 19, 2021 by Kristina Panos 4 Comments

These days, a lot of people barely even say hello to their neighbors. But not [dewey302]. They’re so tight with the people next door that they built this bad-ass electric mini rat rod for the neighbors’ five-year-old kid. Talk about community!

Nearly every bit of this rod is recycled — the body is a wheelbarrow, the transaxle is from a mobility scooter, and the frame was welded together from scrap tubing including the wheelbarrow itself, and old bike or two, and some broken lawn chairs. The rear wheels are also from the ‘barrow, though the front ones were purchased (one of few new parts. Power comes from a pair of 18 V tool batteries wired in series and running through the Curtis controller from the scooter. Depending on the weight of the driver, this baby will do 10-12 MPH.

We love the look of this little rat rod, and wish we were [dewey302]’s neighbor. When you’re done poring over the pile of build pictures, be sure to watch [dewey302] and [The Kid] tear up the cul-de-sac in the video after the break.

You may have noticed the mailbox grille. Surprisingly, this is not the first mail-themed rat rod we’ve covered. Here’s one that really delivers.

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For All Their Expense, Electric Cars Are Still The Cheapest

November 16, 2021 by Jenny List 191 Comments

A criticism that we have leveled at the move from internal combustion vehicles to electric ones is that their expense can put them well beyond the range of the not-so-well-heeled motorist. Many of the electric vehicles we’ve seen thus far have been niche models marketed as luxury accessories, and thus come with a specification and list price to match. It’s interesting then to see a European report from LeasePlan looking at vehicle ownership costs which reveals that the total yearly cost of ownership (TCO) for an electric car has is now cheaper that comparable internal combustion vehicles across the whole continent in all but the fiercely competitive sub-compact segment.

TCO includes depreciation, taxes and insurance, fuel, and maintenance. Perhaps the most interesting story lies in electric cars progressing from being a high-depreciation, risky purchase to something you can sell on the second-hand market, even if they cost more up front. For example, the electric VW ID3 costs around $11,000 more than the comparable gas-powered VW Golf up front, but the higher resale price later offsets this and helps keep the TCO lower.

We’ve been following electric vehicles for a while now in the hope that an electric people’s car would surface, and have at times vented our frustration on the matter. It’s encouraging to see this particular trend as we believe it will encourage manufacturers to produce more accessible electric vehicles, especially given that we’ve just complained that driving electric seems like more of a rich man’s game.

(via Heise)

Header image: CEphoto, Uwe Aranas / CC-BY-SA-3.0.

Extending An E-Bike Range From Good To Wheelie Good

November 15, 2021 by Matthew Carlson 25 Comments

It may not look like it in some parts of the world, but electric vehicles are gaining more and more market share over traditional forms of transportation. The fastest-growing segment is the e-bike, which some say are growing at 16x the rate of conventional bikes (which have grown at 15% during the pandemic). [Jacques Mattheij] rides an S-Pedelec, which is a sort of cross between a moped and an e-bike. There were a few downsides, and one of those was the pitiful range, which needed to be significantly upgraded.

The S-Pedelec that [Jacques] purchased is technically considered a moped, which means it needs to ride in traffic. The 500 watt-hour battery would only take him 45km (~28 miles) on a good day, which isn’t too bad but a problem if your battery runs down while in traffic, struggling to pedal a big heavy bicycle-like thing at car speed. You can swap batteries quickly, but carrying large unsecured extra batteries is a pain, and you need to stop to change them.

There were a few challenges to adding more batteries. The onboard BMS (battery management system) was incredibly picky with DRM and fussy about how many extra cells he could add. The solution that [Jacques] went with was to add an external balancer. This allowed him to add as many cells as he wanted while keeping the BMS happy. The battery geometry is a little wonky as he wanted to keep the pack within the frame. Putting it over the rear wheel would shift the center of gravity higher, changing the bike’s handling. After significant research and preparation, [Jacques] welded his custom battery back together with a spot welder. The final capacity came in at 2150wh (much better than the initial 500wh). An added benefit of the extra range is the higher speed, as the bike stays in the higher voltage domain for much longer. In eco mode, it can do 500km or 180km at full power.

It’s awe-inspiring, and we’re looking forward to seeing more e-bikes in the future. Maybe one day we’ll have tesla coil wireless e-bikes, but until then, we need to make do with battery packs.