I started this project when I saw a post about US cycle carts. As I have twin grandsons I thought that I could build them the billy cart that I always wanted! One day when walking through my local Bunnings in Hawthorn I spotted 4 wheels that would be the perfect size and axles to suit. With these in hand I had no choice but to begin. I love Morgan cars and as they are largely built with timber frames I decided to creat a 1:2 scale of a 1952 Morgan, plans and drawings of the original car were hosted on their UK website. With these in hand I popped back to bunnings to buy materials and some new Ryobi tools. Many hours and trips later learning new skills such as welding, timber bending and uplostery, the cart hit the road. This year we are taking it to the Red Bull billy cart chanllenge in Melbourne not to run down the hill jumps but in the build competion. I am just finishing the electrification so that it will drive under its own power.
Welcome to the Workshop and thank you so much for sharing.
First off WOW. I'm picking my jaw up off the ground.
That is some amazing work you have done there a true credit to you. I have restored my fair share of VWs over the past few decades that have won awards so I know the amount of work that goes into something of this nature big or small. Learning new skills including welding and coming out with this result is fantastic. Did you form the aluminium at the front I can't quite make it out?
This looks stunning. Thank you so much for sharing your project with the Bunnings Workshop community @SRBENET. I'm sure you will get countless admirers and plenty of questions coming your way.
Let me extend a very warm welcome to the community. We're so pleased to have you join us. It's obviously you have a lot of skill, knowledge and experience to share with the community. I trust you will receive plenty of inspiration and helpful advice in return. Please don't hesitate to post whenever you need a hand or have something new to share.
Hi, thanks for the kind words.
The base of the grill is made of a few pieces of hardwood this was hand crafted into the desired shape. I then made the front flat piece from two sheets of 4mm aluminium, made a paper template of the shape of the grill, cut it out of 1mm aluminium and using a soft headed hammer beat the aluminuim to the shape of the grill. The badge was 3D printed by a friend and will be redone as we have access to a far better printer now. The headlights are from a Harley and the rears from a Triumph both work from switches on the dashboard. The steering wheel was also made from a 6mm sheet of aluminium as was the windscreen frame. Perhaps the hardest part was cutting the perspex front screen to perfectly fit the frame, first atempt had a few cracks the second is perfect. The brakes are hydralic from an old mountain bike, they required specific mounts each side as the calipers one the left had to be reversed. In order to get the brakes activated by one peddle I created a linking box one line in from the brake pedal with a line out to each brake caliper.
For a moment I thought you were recreating a Morgan 3-wheeler. I am beyond words about your ingenuity, is that wheel turning mechanism from a traditional manual hand drill? Where did you source the universal joins for the steering rods? Would it be possible for you to please show us how you plan to attach the electric motor to the rear drive? What kind of power source will you be using to power the motor? I know these are a lot of questions, but I'm sure our members are keen to know more details about this fantastic billy cart creation.
Thank you so much for sharing this amazing billy cart project.
The last photo shows wonderful woodwork - it looks reminiscent of early aircraft construction.
Happy to share, the motor is from an electric golf buggy powered by a rechargeable mobile scooter battery. There is a second battery in the front for the head and tail lights. All electrics are controlled by a swithch panel on the dashboard with a speed controller on the left, having a foot throttle was too hard as my grandsons feet could not reach. The bolt on the left of the motor sets the tention on the chain drive the wheels are locked in place on the axle but can be set to free roll as well. The axle runs through two pillow bearings. Yes the steering box is an old Slanley hand drill, the universals and tie rods all came from RS Components in Sydney huge range of stuff for many projects mainly specialised that I have not found anywhere else. You can see a video of most of the build on Facebook https://www.facebook.com/SRB.Morgan.52/
Thanks for the interest Stephen
Re: Ol'55 billy cart
@SRBENET your billy cart is not how I remember them in the good old days, with a piece of rope and your feet for steering.
When I first saw the picture of the car , I thought that you had refurbish an antique model, this is more than amazing, looks like a lot of work/hours has gone into the build, well done.
Good luck at the upcoming competition, I'm sure you will do well.
Your twin grandsons will be so proud and happy to drive it. It will become a family heirloom.
Yep not as I remember also but I have also built each a traditional biily cart as this one took over 12 months...