billycart-soapbox-racer.pdf

New-fashioned billycart

Your children will love this modern take on the old-fashioned billycart

R emember the fun you had as a child, whacking some wheels on a couple of bits of wood,

adding an old fruit box, and pointing the contraption down the nearest slope you could

find? Well here’s the billycart of the new millennium and it’s guaranteed to be just as much fun.

Here’s how

Step 1 From rear of chassis beam

(A), measure 200mm along one side.

Measure seven further intervals of

50mm. Draw a line down centre of

this side and mark hole centres with

a centre punch. Drill 10mm holes

through both sides of the chassis. On

top surface, drill

a 10mm hole through the beam, 17mm

from the front.

Step 2 Drill a 10mm hole in the centre

of the front axle bar (B), midway along

its length.

Step 3 Mark the centre of the back

axle bar (C) and the centre of the

end of the chassis beam. Align the

two marks and check the parts are

square. Tack-weld in place. If the metal

is galvanised, set up a fan to blow

fumes away from you and wear a fume

mask. Check the angle again, then fully

weld in place. Weld the end caps (D) to

the open ends of the bars and beam.

What you’ll need

Item Part Size Material

A Chassis beam 35 x 35 x 2.5 x 1250mm Steel square section

B Front axle bar 35 x 35 x 2.5 x 600mm Steel square section

C Back axle bar 35 x 35 x 2.5 x 650mm Steel square section

D End caps (5) 35 x 35 x 2mm Steel bar

E Braces (2) 20 x 20 x 2 x 800mm Steel square section

F Stub axles (4) 19mm dia x 130mm Steel rod

G Wheels (4) 10 x 1.75 (250mm dia) Solid steel/rubber

H Push/roll bar 35 x 35 x 1.5 x 1660mm Steel square section

I Steering arm 10mm dia x 1900mm Steel rod

J Chair Recycled plastic

K Seat carrier (2) 20 x 20 x 2 x 320mm Steel angle

L Seat spacer (3) 35 x 2 x 240mm Steel bar

M U-bracket (6 makes 2) 35 x 2 x 40mm Steel bar

N Sleeve (2) 12mm id x 100mm Steel tube

O Brake rod 12mm dia x 720mm Steel rod

P Brake pad (2) 35 x 2 x 65mm Steel bar

Q Spring bracket 20 x 20 x 2 x 50mm Steel square section

R Spring lever 12mm dia x 100mm Steel rod

S Spring 75mm Steel

T Brake handle 12mm dia x 520mm Steel rod

Step 4 Mark 30mm in from the ends

of the rear axle bar. Hold a brace

(E) with its outside edge on the

mark and so it just crosses the

chassis beam. Mark

the angles, cut, then weld between

bar and beam. Clean up all welds

using an angle grinder.

Step 5 On the underside, draw a

line along the

centre of the rear and front axle

beams. Round the ends of the stub

axles (F) slightly and drill a 3mm

hole through the axle, 8mm from the

outer end. Slip through a split pin,

add a washer, a wheel (G), then

another washer. Align axle beams

with the line and tack-weld at end.

Check alignment of wheels. Tap

axle with hammer to adjust. Remove

wheels or cover with several layers

of aluminium foil or leather to

protect against welding spatter. Weld

axles in place.

Note: id = inside diameter, dia = diameter

You’ll also need: eight 19mm washers; four 3 x 50mm split pins; 100mm x 10mm bolt with

three washers and nylon locknut; plastic seat without legs; two 50mm bolts and nuts; paint

http://www.bhg.com.au

Step 6 Join the front axle beam to the

chassis with a 10mm bolt. Slip a washer

under the bolt head, between the bar

and the beam, and under the nylon

locknut.

Step 7 Set a sliding bevel to 50° and

draw a ‘V’ 700mm from each end of the

push-cum-roll bar (H). Cut out the Vs

with an angle grinder, without cutting

through the fourth side. Bend the bar

to two angles of 100° and weld along

the seams. Trim off bottoms to a 10°

angle. Centre the bar on the back axle

and weld.

Step 8 To bend the steering arm

(I), measure 175mm from the centre

of the rod and start a 50mm radius

right-angle bend by wrapping around

a 100mm pole. Repeat on other side.

When bent, the two sides should be

about 450mm apart. From the bends,

measure down 470mm and bend both

sides to about 150°. Trim off ends to

about 125mm long. Centre and weld to

the front axle bar. Lengthen or shorten

the steering bar as needed. If you

find the steering bar awkward to use,

replace with two eye bolts welded to

the axle bar and use traditional rope to

steer the cart.

U-bracket (M). Weld the sides to the

base, then weld to the seat assembly,

spacing the brackets so their holes

are 200mm apart and so they coincide

with the holes in the chassis beam.

The U-bracket gives four positions of

adjustment on the beam. Secure with

bolts.

to allow for a few millimetres of travel

before it hits the axle bar. Add two little

blobs of weld near the bottom of the

spring lever to contain the spring. Add

another two blobs of weld to the

brake bar, just inside the sleeves,

to stop lateral movement. Add the

spring (S) by hooking it into

the opening of the spring bracket and

between the blobs on the spring lever.

Let the spring hold the brake pad in the

off position, and weld the brake handle

(T) to the brake bar at a comfortable

height. Check that the brake pad clears

the wheels by a few millimetres when

the spring holds the brake off, yet

is effective when the brake handle is

pulled upwards.

Step 10 Slide the sleeves (N) onto the

brake rod (O). Cover the back wheels

with foil, and place the brake pad

(P) on the wheel. Weld the sleeves

to the push bar, allowing about 3mm

clearance for the brake pad. The left

sleeve is fixed flush with the inside of

the push bar, and the right one sits

20mm inside the push bar. Weld on the

brake pads.

Step 11 Weld the spring bracket (Q) to

the axle bar. Add the spring lever (R)

to the brake rod, sloping back a little

Step 9 Seat assembly construction

depends on the chair (J). Cut the two

seat carriers (K) and drill holes to

coincide with the screw holes in the

seat base. Note the distance they are

to be apart, and weld them to the three

spacers (L). Drill a 10mm hole, centred

19mm from the bottom edge on four of

the pieces that form the sides of the

Step 12 Remove seat and wheels, then

paint the frame, either by brush or by

applying several coats of spray paint.

Reassemble all of the components,

bending the ends of split pins so they

don’t fall out. Tape some padding to the

steering bar, brake handle and push bar

(pipe lagging is ideal) and you’re ready

to let her rip.

http://www.bhg.com.au

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