Drift Trike From 16 Gauge Steel Sheet

15,987

202

42

I have access to a CNC waterjet via The Foundery, a community makerspace in Baltimore MD, so I thought it'd be awesome to design some kind of go-cart that uses the waterjet to cut all the parts from a single sheet of 16 gage steel. I used the waterjet to cut perforation lines in the steel so that the whole frame could be folded up to create the chassis like a pizza box using just a couple adjustable wrenches.

Parts List with costs:

  1. 4'x8' 16 gauge steel sheet ($60) King's Architectural Metals
  2. Rear Axle kit ($284) http://www.bmikarts.com/Drift-Trike-Axle-Kit-with...
  3. Head Tube Bearing Kit ($13) https://www.amazon.com/gp/product/B003J7XCRO/ref=...
  4. Front Fork ($50) https://www.amazon.com/gp/product/B00J3VSDQA/ref=...
  5. Twist Throttle ($33) https://www.amazon.com/gp/product/B0062PNBTE/ref=...
  6. 26" x 4" front mountain bike wheel
  7. Front Hangle Bar ($20) https://www.amazon.com/gp/product/B00M9MGY6G/ref=...
  8. Handlebar stem ($8) https://www.amazon.com/gp/product/B017YRH88S/ref=...
  9. Hydraulic Brake Kit ($35) https://www.amazon.com/gp/product/B01MQO6LDL/ref=...
  10. 6.5 hp engine ($119) https://www.harborfreight.com/65-hp-212cc-ohv-hor...

Step 1: Drink Some Coffee and Put on Some Music

It's like Thomas Edison once said "anything worth doing, starts with caffeine and Beastie Boys". As much as I love the Beasties, there are a few music options that are close in work performance facilitating, which include but are not limited to:

  • Dropkick Murphy's
  • The Dirty Heads
  • Sublime
  • Flogging Molly
  • Ted Nugent's "Stranglehold" (the only song worth listening to by Mr. Nugent...but it's super long and will almost get you through this entire build.

*Thomas Edison may or may not have been the originator of that quote...it may have actually just come from myself.

Step 2: Cut Out the 4 Frame Components

OK, this is it! This is the most important section of this instructable. All my hours spent designing this trike frame, free for anyone to build their own!

Using either a CNC plasma cutter, waterjet or laser; cut each of these 4 parts out of the steel sheet. You could break these up and cut all the parts from two 4'x4' sheets of 16 gage steel.

Once you cut them out, clean all the parts with acetone or alcohol. DO NOT clean the parts with brake cleaner! In case you did not know, welding steel parts that have been cleaned in brake cleaner or any thing chlorinated creates a phosgene gas (a very toxic gas) that can kill you at very low levels of exposure! You're welcome ;)

trike.dwg

trike.dxf

Step 3: Bend Up the Frame Parts!

Bend up the frame components as shown. Be careful to bend them in the correct direction, if you bend them wrong and bend them back you'll most likely fatigue the parts and split the seam.

Step 4: Assemble and Weld the Trike Frame Components

Now you're getting to the fun parts! The parts should fit together like the birds and bees!...I think that's how that analogy works ;)

The two largest parts fit together to create the main chassis while the smaller parts form the neck. Once the two sub-assemblies are welded the neck tube can be welded upright. make sure the base of the neck tube is flush and parallel with the chassis' bottom surface.

When welding, you can stitch weld 1" on, 1" off to create more than enough shear strength to hold everything together. I used a millermatic 211 MIG welder set to voltage level 4 and a wire feed of 40. Wear a respirator even if you're welding in a well ventilated area. Don't take any health risks.

Step 5: Weld on the Head Tube

I turned my head tube from a piece of 1.5" round tubing to create the right inside diameter from my neck bearing kit. You can buy 8" neck tubes already for welding on to your frame from a local bike shop for online stores that sell parts for building your own bicycles.

Step 6: Paint Your Frame

The Foundery has a powder coating station, so I'm spoiled. Spray painting the frame will be just as good. Take your time here, because after assembly things will be very difficult to touch up.

Step 7: Assemble the Trike!

Assembling the trike was my favorite part of the build. My son, Aidan, helped me assemble it and it was awesome. Things went together pretty smooth. Here's the order at witch i assembled it:

  1. Front fork and wheel
  2. Front brakes
  3. Rear axle
  4. Engine and centrifugal clutch
  5. Rear wheels/tires
  6. Handle bars
  7. Twist Throttle

Step 8: Take It for a Spin!

OK, I lied...and I feel bad about that. Taking the trike for it's first ride was definitely my favorite part of this project. This thing had me grinning from ear-to-ear. It's just a blast to ride!

I hope you enjoyed this Instructable! Let me know if you have any questions.

-Corey

Metal Contest 2017

First Prize in the
Metal Contest 2017

Share

    Recommendations

    • First Time Author

      First Time Author
    • Plastics Contest

      Plastics Contest
    • Make it Glow Contest 2018

      Make it Glow Contest 2018

    42 Discussions

    0
    None
    AlexV208

    11 months ago

    Is the 16 ga. Too light do you wish you made it out of thicker material? Looking to make.

    0
    None
    cleokarts

    1 year ago

    Hi,

    I would like to make this drift trike with the plans. But for the front wheel, I have an old dirt bike fork with a 21-inch wheel. Will this wheel work with the frame?

    Thanks

    Cleo

    1 reply
    0
    None
    cfleis1cleokarts

    Reply 12 months ago

    It might work, you would probably need to extend the head tube you weld on to the neck so that if comes a few inches further down.

    0
    None
    DelB2

    1 year ago

    Works great. Thanks Corey!

    0
    None
    DelB2

    1 year ago

    The vector files you uploaded (dwf & dxf) are still not downloadable. The pdf is downloadable but it is not complete when you download it. It covers about half the document. I tried this on 2 different browsers with no luck. Perhaps I'm missing something? This project is really cool. I'd like to give it a go on my plasma table.

    2 replies
    0
    None
    cfleis1DelB2

    Reply 1 year ago

    try my newest uploaded zip-folder with the vector files.

    -Corey

    0
    None
    famfilho

    1 year ago

    Sorry my friend, but it is impossible to download the trike files dwg/dxf. And trike.pdf it1s not correct.

    Could you make them available to us? Or informe where we can do this downloads.

    Thanks in advanced.

    1 reply
    0
    None
    cfleis1famfilho

    Reply 1 year ago

    Just up-loaded a zip-file with the vector files. Let me know if it does/doesn't work!

    -Corey

    0
    None
    scrat2008

    1 year ago

    perfect project. please upload "trike.dxf" or "trike.dwg" one more. this is not downloadable.

    thanks

    1 reply
    0
    None
    cfleis1scrat2008

    Reply 1 year ago

    I added the a zip file with the 3 file formats. Let me know if this does/doesn't work.

    -Corey

    0
    None
    wrsexton

    1 year ago

    Excellent idea. And makes me wonder if one couldn't build a fun gokart using this same technique. wouldn't spin as much but might be fun off road.

    0
    None
    famfilho

    1 year ago

    UHAUUUUUUU!!!

    This project is the best my friend, I want to congratulate you on the initiative and the detail!! Thank you very much!!

    0
    None
    EddieH10

    1 year ago

    I cant get the DXF file to download for cutting. Can you Help?

    2 replies
    0
    None
    cfleis1EddieH10

    Reply 1 year ago

    I just re-uploaded 3 types of vector formats for the trike files. I hope that fixes it!

    -Corey

    0
    None
    EddieH10cfleis1

    Reply 1 year ago

    Thank you sir... I'll see what I can do with them. I hope it works

    0
    None
    markwhitefab

    1 year ago

    I've got the plasma table ready to cut the parts but I cant download the DXF file. What am I missing? Any help would be greatly appreciated.

    1 reply
    0
    None
    cfleis1markwhitefab

    Reply 1 year ago

    I just re-uploaded 3 types of vector files! Let me know if that doesn't fix it!

    ps don't forget to vote for this instructable in the "metals" contest!

    Should we avoid acetone or brake cleaner or both? - text is ambiguous. Otherwise kudos and congrats with an awesome build!

    1 reply