HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

Evaluation: Time plan Evaluation: At the end of week 6 I was ecstatic as to the progress of the project as using my time wisely I was able to make the dashboard too which was proposed for the following week on the time plan as I estimated the rear cowling to take a fair amount of time due to the accuracy and difficulty of the piece. I'm really happy that I was able to get the rear cowling made up and welded in a week early which allowed me to move ahead of time and therefore make and weld in the dash also.

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

blew threw minorly where covered by liquid steel and grinded back flush to the body. When it was all bare again I used a can primer to seal and cover the whole body and prevent rust.

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

Evaluation: Time plan Evaluation: During week 2 I was only able to get thus far on the steering components which I was with as I estimated that just the chassis was going to take me the 2 weeks. So by having all the pieces cut and grinded was a massive advantage leading into the next weeks. I’m pleased with my progress and once again after a week 4 break on the project due to exams and holidays Im one week in front. Quality - Relating statement of intent, research and planning: The chassis turned out nicely and fits very well in the body with enough room to slid in and out so that when it is painted it doesn’t get scratched up. The only issue that I had was that the front piece was a little slanted on an angle which is not visible when inside the body but might affect other components later on. Linishing all the ends of the pieces completely round makes the steering in general more pleasing to look at and adds an extra safety feature. They are clean and simple by effective and replicates exactly how pedal car steering was made back in the 1930’s.

Weeks 3-4 Production: Steering components: Because all the pieces were already cut all the holes now needed to be drilled, this was achieved in the pedestal drill. I initially started with a centre drill after marking all the holes and centre punching them and worked my way up until I was drilling the correct size for the nuts and bolts. Once all the holes were drilled some sections were bent in the vice and the bar bender along with the two side stub axle pieces which were welded and the steering column plate was welded too. After all the holes were drilled and pieces were welded the correct bolts and lock nuts were acquired to fasten it all together for a test fit. Subsequently the middle section was filed down to allow for more room to turn as it was restricted (during testing phase).

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

rubbers on and marked where the holes needed to be positioned for the 2 split pins on each pedal. These were followed up by drilling small holes, 4 in total. Front Axle: The front axles were made identically using 18mm round bar in the lathe. I faced both sides and turned 40mm down to a diameter of 10mm to fit the wheel. Using abrasive paper on a high speed I finished off the cut smoothly whilst also deburred all the edges by angling a file and applying pressure on a 45 degree angle. The circlip groove was then made by moving 1mm inwards at the point where the wheel ends with the circlip grooving tool on the lathe at a low speed. To finish the axles off they were cut down to size on the cold saw.

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

Evaluation: Time plan evaluation: After a long two weeks and being on track I decided to push myself and take on a bit of an extra load to make some extra progress I did get through everything I wanted too except for the rear axle due to running out of time and being a complex component I didn’t want to rush it. After week 3 I was in front of where I wanted to be according to the time plan as I started the steering a week earlier therefore it allowed me to finish it on time and complete the steering column a week early. I was quite happy with how I progressed in the fourth week and pushed hard to get everything done that I could. Although i didn’t finish the rear axle I wasn’t behind as I could easily make up for it in the next couple weeks. Quality - Relating statement of intent, research and planning: Post assembly of all the steering components and testing I was extremely pleased to see after all that work that it was moving well and actually replicated a small pedal car steering system which again relates to the functionality mentioned in the statement of intent and planning. Everything worked smoothly and the quality of the entire system was well done. The pedal frame worked well and was functional also. At first i made the pedal frame too high so i had to cut it down twice until I got it to a suitable hit corresponding to the height of the

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

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HSC Major Work Portfolio Student number: 29809798 1934 Pedal Car

then with the buffing machine was given the paint work a final buff whilst all the chrome and alloy was polished also. Reassemble Pedal car: After it came back from body work and paint I carefully put the whole car back together whilst fastening all nuts and bolts tightly to make sure everything fit back nicely. All split pins, rubbers, wheel, nuts and bolts were all put back on and secured Seat Upholstery: The seat was sent off to an Auto Trimmer and Upholstered to the design I created using the my choice of smooth black vinyl. The base cushion was made from half inch timber and foam with horizontal and vertical stitched flutes. Including a 2.5 inch roll on the edge and thin foam covered with vinyl for the sides and back rest. Wiring: Now that the car was all back together I could start on the wiring. To put it simply all the lights were soldered and connected back up to a 12V battery under the bonnet whilst also earthing the body. The front lights were wired up so that they can put on a bright parking light but also has a flashing light for a front blinker. A two way toggle switch in the dash is wired to turn the headlights on and off. Whilst a three way toggle switch was wired up so that the blinkers on the tail lights, dash and front blinkers all are connected. To make these flash I added a flasher cam which allows for the lights to come on and off as a good pace and all in sync. Two fuses were added in for extra safety and taping everything up to make it neater.

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