Get Ready for Spring with aTOTE-ALL SCOOTER

You can lug all your gear and cover groundfast and easy, whether you're playing golf,

hunting, or just plain roamin'

By LYLE GILLIOM Craft Print Project No. 326

ST A R T w i t h an old b ike f rame and a usedo n e - l u n g eng ine , add a l i t t l e e x p e r tscrounging, and w i t h less than $40 you can

bu i l d one of these mi le-shr inkers for you andthe kids to zip around on.

For week-end hun t ing or camping, BeatsWa lk in ' (F ig. 1) increases your range andmobi l i ty . Car ry i t in your car t r unk as faras your car can go, then unload and take off.Y o u can make this high-power, h igh-rat iosports version for off-the-road use, or w i t hh igh power and low rat io, b u t w i thou t theload-rack, and you have a fast street job. Thesame machine w i t h low power and high rat iois idea' for the younger tots to learn on(F ig . 11).

If you ' re in a real h u r r y to save shoe leath-er, the quickest answer is the Buzzbike (Fig.2 ) , w i t h a one-stage reduct ion dr ive for h ighspeed (26-28 mph), and bike-pedal foot rests.

Beats Walkin' for street operat ion haspneumatic t i red wheels and a top speed ofabout 26 mph w i t h a 2-1/2 or 3 hp 4 cycle en-gine. The child's model is p r imar i l y for back-yard operation by chi ldren as young as 6years old. W i t h semi-pneumatic t ires and a10.5 to 1 dr ive rat io it w i l l have a top speedof 10 or 12 mph using a 1-1/2 to 2 hp engine.

Controls for a l l versions consists of a handthrot t le on the handle bars, a brake operatedw i t h the heel of the r igh t foot, and automaticc lutch ing w i t h a centr i fugal c lutch.

A n y 26 in . bal loon t i re type frame can beused. The gir ls ' model (Fig. 11) is preferablefo r use by smaller chi ldren since the absenceof the top bar makes it easier to get off andon. Junked bicycle frames are not hard tof ind and they are usable for our purposes inalmost any condit ion. Many shops w i l l sella used frame torn down and str ipped of paintvery cheaply. Or you can buy a " j u n k e r " andtear i t down yourself, discarding unneeded orunusable parts.

Modification of the bicycle f rame to ac-commodate the engine is shown in Figs. 3 and5. Saw out and discard a section of the upper

rear fo rk f r o m about1 in. behind the seatpost to 6-1/4-in. abovethe center of the rearaxle slot. Then benddown the lower fo rkun t i l the f ront fork,pedal crank housingand rear fo rk rest on acommon base. Hack-saw a lmos t t h r o u g hthe fo rk just behindthe crank housing, i fnecessary , and b e n dthe fo rk down. Thenclose the gap by weld-ing.

The simple woodenw e l d i n g j i g (F igs . 3and 5) positions andholds together al l thecomponen ts o f theframe so that it can bet a k e n to a w e l d i n gshop for weld ing, a l -ready fitted and as-sembled. A local we ld-ing shop took approximately 35 minutes to doours inc luding the weld ing of the brake shoeassembly; tota l charge was $3.50.

Make the Welding Jig f rom construct iongrade f i r assembled w i t h 2-1/4 in . # 1 0 f la theadwood screws. Bo l t the bicycle frame to thej i g w i t h the f ron t and rear axle bolts, spread-ing the forks as necessary to fit the blocks ofthe j ig . For cleaner welds, clean a l l paintf r om the f rame in the areas to be welded.

Check a l l dimensions w i t h your framemounted on the j i g before making the partswh ich are to be welded to the f rame, as thereis considerable var ia t ion of sty l ing in frames.Make the brake shoe components too (F ig.10), so that this assembly can be welded onthe same t r ip .

Secure the Pipe U-Frame in position withC-clamps (Fig. 3). Fil ing a concave notch

SCIENCE and MECHANICS54

Young man-in-a-hurry gets around on campus theeasy way on the Buzzbike.

Why walk a country mile when Beats Walkin'wi l l tote you and all your gear? Convert it tocamping use by packing a bed-roll instead of

the golf bag.

i-

floorboard, gooseneck, andsplash guard according to Fig.7. If you are making the sportsmodel of Beats Walkin', youwill also need the floorboardextension, load rack, and racksupport blocks in Fig. 7These can be attached to or re-moved from the finished ma-chine as desired. A coat of shel-lac or enamel undercoat on allwood parts before assemblywill make painting later easier.

Attach the engine deck to therear fork with three 1/4-in. car-riage bolts (Fig. 8). Notch theengine deck and floorboard tofit around the pedal crankhousing. Saw out the goose-neck to match the contour ofthe bicycle frame (Fig. 7). Nowassemble the floorboard withthe splash guard, gooseneck,and engine deck. Bolt the

gooseneck to the bicycle frame with two 1/4 x5-1/2-in. carriage bolts. The entire bike frameis now complete and ready for painting. Useimplement paint, which works equally wellon wood or metal.

Wheels for Beats Walkin' are the popular4.10-3.50 x 4 in. (10.6 in. O.D.) pneumatickart wheels with 3/4 in. bore ball bearings Oruse 3.4/3.00x5 in. wheels, which wil l workequally well. If the bike is to be geared forhigh speeds, wheels with tapered roller bear-ing hubs should be used (See Materials List).

Sprocket, spacer ring, and wheel assembliesare shown in Fig. 12. The 40-tooth sprocketand wheel with matching bolt holes can bepurchased from Sears (made by Indus Corp.,1815 Madison Ave., Indianapolis 25, Ind.)'Replace the original bolts which assemble thewheel with 3/8 in. x 3-3/8 in. long studs cut from

in the sawed ends of the bicycle frame tomatch the round contour of the pipe wil l aidin keeping the U-frame in position.

Fit and position the two jackshaft bearingsupports (Fig. 3) and bolt them to the ply-wood location block. Determine exact dimen-sions of these parts by fitting to the frame.Tack-weld all joints, including threaded pipejoints, then remove the frame from the jigfor final welding.

A 3/8 x 3 in. long pipe nipple drilled outwith a 1/2 in. dril l serves as a bearing forthe brake pedal pivot bolt. Install it in thepedal crank housing with two spacers—5/8-inwrought washers—(Fig. 9), held with twopipe lock-nuts. These spacers bear againstthe inner races of the pedal crank bearings,the rest of which are discarded.

Wooden Parts. Saw out the engine deck,

JANUARY, 196255

3/83/4in. threaded rod (Fig. 12), and three nutsfor each rod. The spacer rings are cut from3/4 in. fir plywood and Vs in. hardboard to fitsnugly inside the rim of the wheel. Totalthickness should be 7/8 in., or enough to in-sure that the chain wil l clear the tire. Paintthe rings prior to installation. Standard rearwheels for go-carts made with extended hubsand flange for attachment of sprockets, can-not be used as the width is too great for thebicycle rear fork. (See Materials List for asource of special parts.)

Wheels for the Child's Version are themuch less expensive semi-pneumatic 2.75 x 10in. O.D. with either 3/4-in. or 5/8-in. ball bear-

The sports version of Beats Walkin' has a two-stagespeed reduction ratio of 14.5-1, giving a top speed of

about 8 mph with a 2-1/2 to 3 hp engine.

56 SCIENCE and MECHANICS

adult use. For a child's bike, 1/2 in. bicyclechain and sprockets are suitable. An offset orhalf- l ink may be used along wi th a regularconnecting l ink to get the needed chainlength.

The Brake consists of a drag-shoe applied

JANUARY, 1962 57

ings. Sprocket, wheel, and spacer rings areshown in Fig. 12B. (The use of 1 in. pitchsprockets and chains is not suggested becausematching engine sprockets are not generallyavailable.)

Vehicle Speed is easily calculated w i ththe following formula:

Speed (mph) = Engine RPM X Wheel Circumference in feet88 X Overall drive ratio

For example, to find the speed wi th the engineturning at 3600 rpm, a wheel circumferenceof 2^2 feet, and a drive ratio of 4 to 1:

3600 X2.5 9000Speed (mph) = 88 X 4 = 352 = 25.6 (approx.)

Also, you can determine desired drive ratios,starting wi th a known speed, wi th the sameformula rearranged:

Engine rpm X Wheel circumference in feetDrive Ratio = 88 X Speed (mph)

For example (using the same values as be-fore) :

Axles and Jackshaft (Fig. 10) are the onlymachined items required. Mil led keyways inthe jackshaft are strongly recommended.Jackshaft bearings of the self-aligning typecan be sealed ball bearings or bronze bear-ings. Use #35 or # 4 1 roller chain andmatching sprockets on bikes intended for

Drive of this Buzzbike is a one-stage 6-1 reduction,gives speeds up to 18 mph. For this outfit, a simpler

frame alteration is employed.

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to the tread surface of the t ire by an adjust-able rod and foot pedal, Figs. 8 and 10. Brakecomponents are attached to the underside ofthe engine deck. Position the shoe close tothe tire surface so that contact wi th the tireis on the upper two thirds of the brake shoefor more effective leverage.

Brake parts and kick stand are bolted to the under-side of the engine deck. Brake pedal pivots in the

crank housing.

On all models, pedal crank-arm housing is used formounting the brake pivot, a piece of 3/8 in. pipedrilled out to 1/2 in. Note notches in plywood engine

deck to clear housing.

Modify a bicycle kickstand as shown in Fig.8 and attach it to the underside of the enginedeck. If your machine is to be used on softground, add a strip of hot-rolled to the kick-stand foot (Fig. 4).

Engine. Almost any horizontal type lightweight engine of 1-1/2 hp or more can be used

MATERIALS LIST A—BEATS WALKIN'

MATERIALS LIST B---BEATS WALKIN'

Two of the author's children here demonstrate thelow-power, low-speed version of Beats Walkin'.Girls' model at left is best for the smaller tykes.

and the drive ratio altered as desired by-changing the jackshaft V-pulley, the chaindrive sprockets, or both. The Beats Walkin'(street model) or Buzzbike ratio is approx.4.3 to 1 which should give a top speed of ap-prox. 26 mph at 3600 engine rpm. With a 2-1/2 or 3 hp motor this ratio provides for rapidacceleration and good hill climbing ability.

Use the formula previously given to de-termine pulley sizes for the two-stage drive.For instance, a 3-in. engine pulley and an8-in. jackshaft pulley give a ratio approxi-mately 2.6 to 1. Multiply this by the sprocketratio (say 4 to 1) to get the overall ratio: inthis case 10.4 to 1.

Engine Drive is by means of an automaticcentrifugal type clutch which attaches di-rectly on the engine shaft and takes eitherA or B belts. Because of variations in enginesand frames, belt length must be determinedon assembly.

Left, a wheel, spacer, and 40-tooth sprocket for ahigh speed model. Tire is 4.10-3.50x4 pneumatic.Threaded rods replace original bolts. Right, similarparts for child's model, with 10x2.75 semi-pneuma-tic tire, 48-tooth bicycle sprocket, and spacers.

Note steel inserts in spokes to position rods.

Install a throttle lever of the lawn mowertype on the handle bar with a 6 ft. cable con-nected to the governor or carburetor. Somenewer engines now provide for direct carbu-retor control between idling and full throttlepositions. Such control would be ideal forthese bikes.

Belt Guard. A hardboard or plywood beltguard is shown in Fig. 7. Because of varia-tions in engines and frames, dimensions mustbe checked and the pattern altered as neces-

You don't have to be in the chips to build a Buzzbike.This one has 6 to 1 reduction for 18 mph top speed.

sary. The aluminum angle has part of oneflange removed to clear the clutch. Bolt theremovable U-frame brace to the guard withtwo 3/16 x 1-1/2 in. rh stove bolts, so that for en-gine service, the brace and guard can be re-moved as one unit.

Make fenders (Fig. 10) of half-hard alu-minum sheet (0.040 in. thick) and is easilyhand-formed or 22 to 26 gauge sheet steel.

All That is Left is to gas up and go. BeatsWalkin' should have a range of 15 to 20 mileson a quart of fuel. Some of the newer engineshave 2 quart fuel tanks that would double thisrange. Many standard bicycle accessoriessuch as luggage carriers, baskets, lights, andhorns can be added. Street operation wil l re-quire both a license plate and a licensed op-erator so check with your local license bureauor police department for regulations in yourarea.

• Craft Print No. 326 in enlarged size for building Tote-AllScooters is available at $1.50. To avoid possible loss of coinor currency in mails, remit by check or money order (noC.O.D.'s or stamps) to Craft Print Dept. 2168, SCIENCEand MECHANICS, SOS Park Avenue, New York 22, NewYork. Now available, our new illustrated catalog of "194Do It Yourself Plans," 25C (Refundable on first order).

60 SCIENCE and MECHANICS