Go-Kart
Frame, Axel, Brakes, Wheels, Motor
One of the most time-consuming projects I've done. It started as a rolling chassis, however only 1-wheel drive, and too small to fit the motor I wanted. Cut out all the old mounting points and axel, and weld on new ¼in steel plates to mount new solid rear axel on, which had an integrated brake rotor. I sourced a junk '75 Yamaha DT125 to salvage the motor from and rebuild. A Harbor Freight motor would've sufficed but a sequential gearbox was part of the project goal. Complete disassembly, boring of cylinder, and piston replacement. Welding a mount for the motor, designing linkages for shifter and brakes.
Lessons Learned
Overall this was a great project to learn to weld on, understand engine interworkings, and improve more rudimentary design skills. Most of my prior design experience had been on a much smaller scale, typically for 3D-Printing.
Electric Skateboard
Custom 18650 Battery Pack
I was gifted a Boosted Electric Skateboard from a friend which had a severely degraded battery pack. There wasn't much information online for other people replacing the cells themselves, so I decided to open the pack blindly and develop a plan from there. Careful disassembly of the 51V battery pack required desoldering the bus bars and removing permanent epoxy. New 18650 cells were sourced from a reputable manufacturer overseas, producing LG HG2 high capacity, high output cells. The new cells were individually balanced, installed, and spot-welded to new bus bars, creating a 13s2p battery pack. After wiring to the BMS and reinstalling onto skateboard, range and performance were significantly improved.
Self-Performed Vehicle Projects over the years
'94 Land Rover Discovery
'94 Land Rover Discovery
'94 Land Rover Discovery
Full Carpet and Seats, Train horn, Wired Radio, Rims and Tires, Paint Restoration, Spark Plugs and Coils, Electrical Issues
'81 Jeep CJ-7
'94 Land Rover Discovery
'94 Land Rover Discovery
Cutting and replacing a section of rusted frame, Full Interior, Radiator, Radio, Rims and Tires, Sandblasted and Painted, Decals
Ford F-150
'94 Land Rover Discovery
Ford F-150
Rims and Tires, Lights, Bumper, Skid plate, Broke down in the Chihuahuan Desert and did spark plugs, coils, and valve covers.
Cad Projects
Radii, Chamfers, and Threads
This project required designing and manufacturing a placard out of
6061-T6 aluminum stock, meeting specific requirements and passing go-no-go gauges.
Shock Tower
A 1/8th scale trophy truck required a new lower spring seat for the shock assembly. Using imaging and metrology, a suitable replacement was designed and 3D printed.
Real Estate Blueprinting
Real Estate Blueprinting
The use of a Matterport LIDAR scanner allowed for accurate dimensioning when creating blueprints for renovations per the request of an architectural and interior design firm.