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PERSONAL TRANSPORT: GROUND, WATER, AIR
Microcar Mouse. Personal transport
Directory / Personal transport: land, water, air The first microcar "Mouse" I built for my children. As a result, I gained some design experience and conceived not a children's, but an "adult" car - for myself. He called her "Mouse-2". He built for a long time, or rather, not so much built as he was looking for the necessary parts, assemblies. This, in particular, explains the use of mechanical brakes in Mouse-2 (now I am changing them to hydraulic ones). The development of drawings and construction were carried out simultaneously, although the main parameters of "Mouse-2" were thought out by me in advance. Let me give you a brief technical description. This is a two-seater four-wheeled car with a 14 hp engine. With. (working volume 346 cm3 located at the rear. Equipped with two independent brake systems: the main (working) with pedal drive to all wheels and the spare (parking) with lever drive only to the rear wheels.
The car is dynamic and stable. The braking distance at a speed of 30 km/h is not more than 6,5 m. The smallest turning radius along the outer wheel track axis is 4,5 m. The maximum speed is 65 km/h. Electrical equipment - from a motorized carriage FDD, 12-volt, slightly modified. It includes devices for external lighting and light signaling, a sound signal, a windshield wiper, instrumentation.
The salon is finished with modern materials, isolated from the engine compartment with a noise-absorbing panel with foam filler. The driver and passenger seats are anatomical, glued from fiberglass, lined with foam rubber and trimmed with leatherette; the machine is equipped with seat belts. The car has been in operation since May 1985. There are already many thousands of kilometers of Sakhalin roads on the speedometer. There were no major breakdowns along the way. True, I must note that when fully loaded, the engine power is not enough to overcome the steep and protracted climbs that are often encountered on our roads. And this forces you to turn on the first gear. I am also critical of the doors that open upwards - they are not convenient in everything. Otherwise, I'm happy with the car.
Now I would like to talk about the design features of "Mouse-2". It is assembled mainly from spare parts of "Zaporozhets" and sidecars SZA and SZD. The body is frame, with fiberglass panels on a tubular frame. The rear hood is hinged or removable, which provides free access to the engine. The body is the most time-consuming part, three-quarters of the time was spent on its assembly and equipment.
First, I made a life-size model of the body. I would just like to warn you: it is better not to use a mixture of sand and gypsum, as it is difficult to process. I used pure plaster. To save money, I first laid concrete on the grid, and when it set, I applied a layer of gypsum 15-20 cm thick on top. I sanded and painted the completely dried surface of the model with nitro enamel. The processing was carried out very carefully, so that the flaws did not pass to the matrices. Then I marked out the panel split lines. In order for them to be clearly printed on the matrices, I drew them with an awl to a depth of about 1 mm. The finished panels were adjusted to them.
Typically, matrices are made of fiberglass. But I needed to save resin and fiberglass, and I had to cast them, like the model, from plaster and concrete. Casts of each panel were taken separately: I rubbed the surface of the model with a thin layer of vaseline or grease and washed it down with plaster, overlapping the parting lines by 10-15 mm, and then with concrete, reinforcing it with steel bars d 5 mm. To obtain casts from vertical surfaces, he made formwork from boards and plywood.
After the concrete had dried (after about three days), I removed the matrices, dried the gypsum layer, carefully processed and painted. The main load-bearing panels were glued from six layers of fiberglass with a lining of two layers of glass mat, which gave a thickness of about 4 mm. Before that, the fiberglass was burned with a blowtorch flame so that it would better absorb the resin. He burned with great care, as the fabric crumbles in places of burns.
Due to the fact that the glue quickly thickens, it was necessary to prepare it in small portions. Ingredients: epoxy resin (100 cm3), plasticizer (10 cm3) and hardener (10 cm3). You can do without a plasticizer. If the resin is too thick, acetone or solvents No. 646 or No. 648 can be added to it (no more than 10% of the total volume). However, given that such additives somewhat reduce the strength of the product, they should be used as a last resort. To obtain the desired color, a dye is introduced into the resin - an ordinary art oil paint from a tube (before adding a hardener).
Before gluing the panels, I cut the fiberglass in layers with a knife on a sheet of plywood (linoleum) and stacked the pieces. Glued in one go with short breaks for rest or breeding a new portion. After laying the last layer of fiberglass in the matrix, I covered everything with plastic wrap and, having made the formwork, covered the surface with sand. A day later, he removed the sand press and left the panel to "ripen" in the matrix for another three days. The resin completely polymerizes in a week.
The opening for the windshield in the front panel I adjusted to the frame of a two-millimeter aluminum sheet. Then this frame is glued into the panel and a frontal triplex from the ZAZ-968 car is inserted into it. The rear glass panel was made in the same way. I cut the finished panels along the parting lines on the body layout and fitted them to the tubular frame. I attached the panels to it with screws, choosing the gaps with wooden slats with grooves and gluing them from the inside with 4-6 layers of fiberglass. The joints between the panels were cut with steps and filled with strips of fiberglass on glue.
The assembled body was finally puttied and polished, preparing for painting. Irregularities were sealed with putty based on the same epoxy glue, adding fillers to it: talc, aluminum powder and the like. The body frame is assembled from thin-walled steel pipes, the attachment points to the vehicle frame are welded to them: front, lower and rear supports. The frame of the folding hood also has a tubular structure. If necessary, the latter can be removed altogether, for example, when repairing the engine.
The main power element of the body is a rigid frame made of steel pipes and corners. It carries the frame, hood, front axle, engine with subframe and differential, rear wheel suspension, trunk and so on. Brackets, knots and supports are provided for mounting these units. In front of the frame there is a bridge from the SZA motorized carriage, modified for shoe brakes from a cargo scooter.
On the back of the frame, on home-made rubber cushions, a lodmotor frame with a power plant from a FDD motorized wheelchair, rotated 180 °, is mounted. The front strut of its mount is an adapter shifted vertically relative to the engine mount bracket. The rear point is hinged: the bracket, covering the pipe of the sub-frame with a clamp, allows a slight rotation of the power plant in a vertical plane. This is done to tension the drive chain with an adjusting screw, which, while pushing out from the support pad of the front bracket. lifts the engine. Fixing the degree of chain tension is carried out by a clamp and tie rods (see Fig. 9 and Fig. 10). Torque is transmitted by a roller single-row target with a pitch of 15,875 mm to a differential with a reverse gear from a cargo scooter. The differential is suspended on four studs under the engine on the rods of the sub-frame. In principle, it is not much different from a motorized stroller - it is just as compact and reliable. However, to obtain the required number of revolutions of the wheels, a new sprocket with 16 teeth had to be made for it.
The gearbox, as you know, is built directly into the engine, and the reverse is built into the differential. To control them, you must have two levers with a separate drive. I used a single drive for shifting both gears and reverse, which greatly simplified driving. The shift lever in the cab is pivotally mounted between the two gear and reverse sectors and is constantly pressed against the first by a spring. In the neutral position, the sectors are fixed by balls, which, under the action of their springs, enter the grooves of the disks.
To reverse the gear sector, move the lever forward - turn on the first gear. Then the lever is returned to the neutral position (the gear does not turn off at the same time) and again, but with the reverse sector, it is fed forward, including reverse. The rest of the engine controls - gas pedals, clutch and ignition switch - are regular, standard.
The layout of the power plant in the engine compartment also dictated the replacement of one factory muffler with two self-made ones - the first did not fit into the engine compartment. Silencers welded from sheet steel. I connected them to the exhaust pipes of the cylinders (with union nuts) and to the engine mounting bracket (with hinge plates). It should be noted that the exhaust sound of homemade mufflers is louder than that of the factory one. Probably, their small internal volume affects. However, this does not affect engine power.
The rear axle is assembled from two self-made independent suspensions with longitudinal swing of the levers. I installed levers made of thick-walled steel pipes d 32 mm with supports in the ears - attachment points to the car frame. To the opposite ends of the levers, I welded the rear wheel hubs and the lower shock absorber attachment points, which are cylindrical housings with bushings for axle bolts and rubber liners.
The upper attachment points of the shock absorbers are eyelets on the scarves welded to the tubular elements of the vehicle frame. The hubs and axles of the rear wheels are from a cargo scooter; rims and brake parts - from a motorized carriage FDD. In a single whole, they are connected by flanges and disks.
The rear axle of the "Mouse-2" is heavily loaded, and the elasticity of the shock absorbers from the "Ural" motorcycle, as it turned out, is not enough. Therefore, they had to be finalized - to install additional springs, which I made from one spring of the rear suspension of a ZAZ-968 car, cutting it with a gas burner. The edges of the cuts, while they were hot, bent, and then turned on emery for an exact fit into the plates. The shock absorbers were not subjected to a more complex alteration. I removed only the outer casings. And to prevent dirt from getting on the rods, I used protective covers made of thin canvas.
Power semi-axes with cardan joints - also from a cargo scooter. But since the track of the "Mouse" is wider, they had to be lengthened. I cut the axle shafts in half and pressed them into a steel bushing. Adjusting their length in place, welded to each other. The front wheel suspensions are assembled from the parts of the running gear of the SZA and SZD sidecars. To connect them together, I machined additional flanges and spacer rings. Details of the chassis (except for the hubs) did not modify. And the hubs were only turned in three places, as shown in the figure. A curious element of my car can be considered retractable headlights. Similar ones are sometimes found in homemade designs. During the day, when there is enough light, the headlights are hidden in the engine compartment, but in the evening they are pulled out. The headlights I still have with a manual drive (over time it will be replaced with an electric one) installed in the cab. From the turntable to the worm gear with a gear ratio of 1: 80, a speedometer cable in a sheath stretches. Further, from the worm wheel of the gearbox, the rotation of the shaft hidden in the spacer sleeve is transmitted through the levers and rods to the headlight housings, and they are extended. They are adjusted by shifting the shelves, which are then fixed with side fastening screws. Author: V.Veselov
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