The Bench Racers Journal

[Terry Bentley]

Chapter 103

I have been noticing the more Chris works with the tools, just how much better he is at using them. He picks up how to do things really quick. Then even improving on that. Not trying to make it easier for himself or take less time, but doing everything smarter.

There are plenty of ways to do the things I have showed him that takes less time. But it would be useless for him unless understanding why he was doing the work a certain way to begin with.

While Chris was messing with the front wheels I thought about yesterday how quickly he disassembled the kart after we had test fitted everything. He placed all of the parts out in order making it very easy for him to put his kart back together using the correct nuts and bolts.

Most of the time when I tear anything apart, all of the pieces just get dumped together. Every one of the nuts, bolts, just whatever small pieces there are. The reason I like doing it this way is to keep my mind focused so I know how things go back together.

When reassembling whatever is being worked on, I have to remember exactly what parts fit where, and which nuts or bolts are used on what parts. Maybe more of a challenge for me than anything else.

So after we stripped the frame back down yesterday, the bearing hangers finally got permanently welded in place. I also added some new mounting bosses that set the pedals slightly higher than they were originally done on his frame. I thought it would be a good idea to have a couple of positions so Chris could adjust them to his liking too.

These pedals are short, just like the ones on Franks kart. Well except they are made of steel plates welded together instead of being cast aluminum. With them being so short they could get caught under the tie-rods. I remember this happening to Franks kart after he did such an expert job setting it up so well. Raising the pedals slightly higher or just moving back would solve the problem completely. With the pedals raised up also makes it so much easier to depress them with your foot.

When I was setting up to weld everything, Chris got totally focused on what was happening. Then he asked all kinds of questions I did not have much in the way of answers for. I did explain, best to my limited knowledge, the process of using an arc welder, or stick rod as my grandpa always called it.

Chris wanted to watch me as the welding was done. I didnt have another welding hood, but there was that set of goggles with a really dark lens. They was completely useless to weld with. Just some old ancient dinosaur from yesteryear, but would be good enough to watch without him messing up his eyes.

This brought back the dark and painful memory of burning my eyes. It was only two months ago when holding things in place while dad welded the new Cates copy together for me. I was making sure Chris did not make the same mistakes I did. That painful experience is nothing I would want Chris or anyone else to ever have to go thru.

Thinking about the crusty scratchy feeling in my eyes and not being able to see is sort of scary to think about right now. What if that is all it took to become permanently blind? Something to keep in my head so that never happens again.

When Chris got up and close watching me weld, I stopped and explained what he was doing is what he should not be doing. With that old crappy welding goggle, you had to put it in front of your face and hold there. It was difficult to see where to look until after the welding started.

At first Chris didnt cover his eyes until I already arced the rod and welding. I immediately stopped, then told him to keep his eyes covered or go wait outside until I was finished.

He seemed offended and didnt understand the problem until I explained how easy it was to burn his eyes. I learned the hard way. Even doing the same thing he was right now with the same goggles too.

I still dont think he realized that his eyes could actually have blisters all over just from looking at something so bright. It is not worth it Chris, take my word on this. It is very painful and being blind for a few days sucks big time.

Chris also asked if it would be any trouble for him to try doing a practice weld. He was very interested in finding out what it was like. I gave him a choice. We can stay focused on getting your kart finished or take a break and try running some beads on a piece of scrap metal.

It was not that I was getting tired of Chris being here. That is just the opposite. I really enjoy his company and how eager he is to learn to do things. But I am way past ready for his kart to be finished and move on to getting all three of our karts up and running so we can hit the track again.

At first I had not expected his kart to be anywhere near close to ready and all put back together this quickly. He sure got busy and rounded up everything needed in the way of parts in no time. Like in only a few days. That was amazing. But now his kart is so, well, just about finished. I want to fast forward this and get all three karts done then ready for another practice day soon as possible.

Now that his kart is almost finished, I can get back working on the other karts. There are a zillion things still needing to be dealt with. Then the engines also have to be checked over. Grinding the intake manifolds out more for the bigger carburetor should have already been done. Oh crap, I still need to modify two more carburetors. Add that to the list.

OK Terry, I got the front wheels on and now adjusting the big castle nut. So first I run it down tight as possible with my fingers. Back it off, then tight again. Rotate backwards just enough to line up a cotter pin hole. Check for proper side play. From what I understand when you were telling me, it is just barely enough to feel if moving the wheel sideways. Make sure the wheel spins freely the same as the other side.

While I watched closely as Chris was reassembling his kart, I told him to stop. One more very important thing is missing. There are no dust shields on your front wheel bearings.

Wont these old flat washers right here work, Terry?

I looked over at the ones in his pile of parts. They were regular thick stamped out washers that fit very loosely on the spindle. But I had a better idea and this would be a lot more precision.

Chris, I got a great idea, if you dont mind the extra time and work it will take.

Sure, if you think it is better.

I went digging in my my big bucket of spare nuts, bolts, washers and anything related. There should be a bunch of large fender washers in here somewhere. Finally I picked out four matching very large thin washers. These are a lot thinner than the standard flat washers. Unfortunately they only have a small 3/8 inch hole in the center.

You can use these washers here Chris. They will work much better. These are just a hair smaller than the outer bearing race. That works out perfect.

Those washers wont fit my spindles. The hole is way too small.

That is why you are going to use the Craftsman lathe again. Then bore them out just big enough to fit perfectly on your spindle.

The reason for using these is the diameter is a lot larger and nearly covers over the bearing completely. This closes up the gap so less crap can get in there. But we have to do some work to make them fit. If it is too much trouble then use those other ones. But if it was my kart.........

You know I still dont know anything about using your lathe. So you have to show me how or let me watch. But I think it is worth doing everything the best way possible, even when it takes more time. I want my kart to be right as I can make it with your help.

I gave Chris the basics about running the lathe earlier. But without being around one before, it would not do much good making him run it. So I went thru each step it took to set up these washers in the chuck then drilling out the hole. The last step is setting up a small boring bar to machine for a perfect fit and running dead true. I guess using a reamer here instead might work just as well.

Wow Terry, that sure is a lot of work just to make a thin washer. But it does look a bunch better than those other ones. So this is almost like we did the lock collars, but like drilling out instead of cutting off. Then using a different kind of cutter to finish the hole instead of just a drill bit.

Just think Chris, a few years ago you would have to almost make every part if wanting to build a kart from scratch. I guess that really is building one from scratch. This is before there were shops making the parts like are used on most karts these days.

Is that all we need to do to those washers? Can I finish putting the front wheels on now?

Uh, maybe use some Emory cloth to clean the hole of any burrs or sharp edge. That edge can cut like a jagged razor blade right now. After you clean them up then yes go ahead. But look at your old washers first. Those are wheelbarrow parts. These you just made are racing kart parts.

OK so after they are put on, I install the cotter pin and bend the longer end tightly up against the spindle. Cut off the ends sticking above and below the castle nut. Is that right?

You got it right Chris. Good job. Your kart looks great right now. We need to take a picture. But think I am out of film again. It was used up at the races. But I didnt take that many shots last night. Some reason I am completely out of pictures on the roll. Dont remember if there is another roll or not. Oh well, I will bring the camera when we go to the track next time.

Hey Terry, did we forget to put grease in the bearings? Isnt that what you are supposed to do? Or can I run them the way they are right now?

No grease, it causes way too much drag. My dad explained all of that to me during the summer when putting my kart back together. Grab the squirt can over there on the work bench and just put a few drops of motor oil on them now. Then each night at the races add only one or two drops. Wipe off any excess with a rag. That is all you need to do and they will last for ever.

Oh, OK, I see now. Basically the same thing we did on the rear axle bearings. It all makes sense, now that I realize what we did earlier. These Timken bearings are really just a different type. The bearings on the rear axle had round balls, instead of the tapered rollers.

Wow I had no idea there was so much different stuff like that. Both of the bearings basically do the same thing but completely different in how they are designed. I have heard of Timken bearings before. If I guess they designed the tapered ones, would that be right?

Hey Chris, do you know what a facial tissue is?

Well, uh I guess something made special for like actors to remove makeup and stuff? Is that right? I dont really know for sure. Nothing I ever thought about. What does that have to do with my kart?

Chris, do you know what a Kleenex is?

What is this 50 questions? Of course I do. What does this have to do with my kart?

I handed Chris a beat up worn out battered, that has seen better days, box of Kleenex.

What are those for? Do I need to clean my face or something like that?

No Chris, nothing will help all that dirt on you anyway. What does it say on the box? Those tiny letters under the name.

Kleenex, uh, it says facial tissue. Oh that is what you mean. I understand now. Well sort of. But not sure what that has to do with my kart.

Chris it has nothing to do with your kart. But did you just learn something you had only assumed?

Yea I guess I did learn something. But it still made more sense when I thought it had something to do with my kart.