Which material for a Bike Car?

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I plan on building something like this http://www.americanspeedster.com/side-kick.htm for cruising around the camp grounds during the summer. We renting something like it at a KOA last year and the kids went nuts and had a ball (I did as well). I thought I would do a project like this during the winter. Weight is a concern since I will be hauling it with me. The original is buillt with PVC.I would like to use aluminum but I don't have a Tig (yet). I have a Hobart 210 with a spool gun. Would it be possible to do with a spool gun or should I stick to steel tube? Not sure how the weight vs strength thing works. I was going to make it in 2 1/2s then marry the two together when we get to the camp ground.This will be my first real project. Any help or advice would be great.Thanks Attached Images
Reply:or a simpler easier one, safer maybe if UR a great welder like me Attached ImagesLincoln Power MIG 215Lincoln WeldPak 3200HDLincon ProCut 25Lincoln WeldanPower 225 AC/DCIf all else fails... buy more tools
Reply:Whichever way you decide to go, it looks like a fun project. Someone mentioned atomiczombie.com in a thread here a few weeks ago. Now that I've seen it, there's no turning back.I don't know which one I'm going to build or when I'm going to build it, but I do know that I'm going to build the first one(s) out of steel because it's cheaper and easier for me to work with.Good luck with yours
Reply:I did think about joining two girl bikes but I make modifications since I want it to look more like a car as well as my son is too small. I have to make a bench seat as well as have it adjustable for the pedals. also put a shaft on the spockets to be able to pedal inside the car.
Reply:Originally Posted by HundredaireSocialiteWhichever way you decide to go, it looks like a fun project. Someone mentioned atomiczombie.com in a thread here a few weeks ago. Now that I've seen it, there's no turning back.I don't know which one I'm going to build or when I'm going to build it, but I do know that I'm going to build the first one(s) out of steel because it's cheaper and easier for me to work with.Good luck with yours
Reply:Hmm.. I really don't mean to discourage you, but that's a very advanced project, specially if you want it to fold down compact.   I'm learning how to build bicycle frames from scratch, and there is a world on info out there.  TIG or Oxy/Acetylene fillet brazed (steel) are two techniques currently in use.. I doubt anyone here would recommend MIG for highly stressed joints like those (particularly when safety is involved...)  I will say, some of this material isn't all that cheap either.   One recommendation.. look for used full size pedal car.. I just glanced at SearchTempest.com... and there is a lot of stuff out there.  I see some used stuff in the $250 range..   One recommendation I might make.. buy something used, fix it up nirvana, consider welding & design skills to make your pedal car transportable (add flanges, quick tear down points, etc...)   Your kids are growing.. at one point you may decide to sell the pedal car.. a name brand will retain more value than a home made item... Again, don't mean to rain on your parade.  I find these projects very very motivational, and its not the money value for me... In learning new skills I often find other opportunities for my future.  Your mileage may vary.. I will say, as a parent.. I sometimes wish I'd spent more time with my kids when they were growing up than I did working on projects for myself.. (Not too often, but sometimes...  "^)Good luck, and let us know how it works out..zip..
Reply:Good luck.  Here's how one company makes it:http://surreycompany.com/surrey.htmHopefully that'll give you some ideas.I'd make it out of 4130 or similar chromoly steel tubing.  That's one of the most durable frame materials, with a pretty good strength to weight ratio if you pick the correct size.  It could actually be lighter than aluminum, because even with a TIG, you'd need to either way oversize the aluminum, or have the entire frame heat treated after assembly to get enough strength (something not really available to a home-builder).On that note, chromoly is easy to weld with oxy-acetylene, and can even be fillet brazed (for smooth and continuous looking joints after filing).
Reply:Thanks zipzit, I was planning on two halves with joining points to make it easier since a fold down would be way to much for me. Also, We are not talking about high speed stuff here. Rolling through the Camp Ground real slow. If I had a crack or something, nobody would get hurt. I will take a look for used stuff but I havent seen any.
Reply:Originally Posted by rlitmanGood luck.  Here's how one company makes it:http://surreycompany.com/surrey.htmHopefully that'll give you some ideas.I'd make it out of 4130 or similar chromoly steel tubing.  That's one of the most durable frame materials, with a pretty good strength to weight ratio if you pick the correct size.  It could actually be lighter than aluminum, because even with a TIG, you'd need to either way oversize the aluminum, or have the entire frame heat treated after assembly to get enough strength (something not really available to a home-builder).On that note, chromoly is easy to weld with oxy-acetylene, and can even be fillet brazed (for smooth and continuous looking joints after filing).
Reply:i think if you could find a tubing bender and use the 1 inch thin wall steel tubing and bend radius in the frame rails that would stiffen it up... like you say your not building an offroad buggy and its not going to be going through alot of stress and such.. just cruising on pavement for what its worth, you could make it collapsible and hinged and use quick pins and pin it together..
Reply:EMT would work good if you grind off the galvanizing.  Or some mild steel tube about the same thickness.  No need to go with the high dollar stuff.  Like you said, this isn't a high speed type of deal.  I saw some cool single seat pedal cars when I was little and vacationed to California.  They were three wheeled with two in the rear set up like trucks on a skateboard.  They looked very simple and could be compact, maybe one for each kid?My name's not Jim....
Reply:Check atomiczombie.com. Bike-porn!!!! How about a tadpole trike and a bench trailer for the kids. Gets you two parts and you can use just the tadpole for yourself. You can build it. It's not rocket science. If you can MIG well on steel then stick to that or use a spool gun and and practice alum.. You'll save about a 1/3 of weight with alum. Guys make bikes out of electrical EMT and some hacked bits from old bikes. Fun project. Go for it. Get the kids involved too!200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:1/2" sch 40 steel pipe, notched and welded with 3/32 6010 at 50-60  ampswe aint building a race car
Reply:Originally Posted by weldbead1/2" sch 40 steel pipe, notched and welded with 3/32 6010 at 50-60  ampswe aint building a race car
Reply:Originally Posted by weldbead1/2" sch 40 steel pipe, notched and welded with 3/32 6010 at 50-60  ampswe aint building a race car
Reply:If you decide to go absolutely nuts like this guy you will have a project for months http://www.thirstybeachlandscaping.c...ke/page11.htmlSeriously though, there are quite a few methods used here that are very clever.
Reply:as i suspected i continue to have a lot to learn.....
Reply:Some great ideas. Thanks. I would like to use chromemoly. I will have to price it out. Never bought the stuff before. Usually use reg thin wall tubing. Hope to have it done in the spring. I seen some cheap bikes for 60 bucks at walmart but they werent multi speeds. Definately not going to the extreme like the thirstybeachlandscaping guy. Man that does look cool. If it wasnt so complicated, I would like all seats to pedal but its just too much to do. I have a pretty good idea of what I want. Just hope it works out.Thanks again for taking the time to respond. Mike
Reply:Originally Posted by bert the welderThat's not the way to go. Thinner wall and larger dia. will be less flexy and give more weld area. I would think .063 would do it.
Reply:Originally Posted by serious_leeIf you decide to go absolutely nuts like this guy you will have a project for months http://www.thirstybeachlandscaping.c...ke/page11.htmlSeriously though, there are quite a few methods used here that are very clever.
Reply:the circumference of 1/2" sch 40 pipe is 2.6"  . *the circumference of  1.5 "  .063 wall tubing is   5.1 " ..( or is tubing measured by the OD which would make this number 4.71")so the circumference of  the large tubing is 1.96 times that of the small..(1.81 if measured by OD)the wall of the 1/2" pipe is .109"  *    ( * from Frankland pipefitters and pipewelders handbook p.148)the wall of the 1- 1/2" tube is 0.63"so the wall of the pipe is 1.73 times thicker...so the thinwall  has 1.73/1.96=  88% as much steel as the pipe...( 1.73/1.81=95% if measured by OD)not a huge difference in the weight ( i didnt have a thinwall tubing chart,hence the calcs)so i'm guessing the advantage of the thinwall  has to do more  with the actual shapes / curvatures  than the amount of steel...???
Reply:Originally Posted by weldbeadso i'm guessing the advantage of the thinwall  has to do more  with the actual shapes / curvatures  than the amount of steel...???
Reply:One place the bicycle guys go for non-butted tubing is aircraft spruce...  check out the tubing pricing (by the foot) at   http://www.aircraftspruce.com/catalo...tubing_un1.php     I've checked my local tubing suppliers and aircraft spruce seems to be very competitive in pricing.  This stuff is strong, light BUT I still don't see you using your MIG for this, the material thickness is very thin.. I think you will have to use Oxy/Acetylene and fillet brazing techniques.. Note:  When you are ready to start cutting templates for joining tubes don't forget: http://cobratorch.net/ttn_dxf/   (Generic Version includes .dxf output for CAD stuff.  And hey they sell oxy/acetylene torches)http://www.cycle-frames.com/bicycle-...e-Notcher.html  (Bicycle specific stuff. If you want butted tubing, these are your guys..)--zip