my latest wood build, some desing problems solved

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my latest wood build, some desing problems solved

Postby Fast Eddie » Mon Jun 25, 2012 10:43 am

For years now I have been building/riding rail design wood luges as a hobby, and ive run into some problems a) the sleds will twist/bow length-wise over time b) the boom to chassis/pan connection isnt strong enough c) over time the truck mounting hardward will damage the wood it's bolted to d) i wanted a concave body pan and curved fender. below are some of my solutions

for the pan and fender i started with a buttboard from Tim. I cut a section off of the front that I later flipped upside down and mounted on top of the front boom over the front wheels for use as a fender.
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i cut/drilled/rounded the corners of my own plates. these are drilled with the same hole pattern and size as the truck baseplates. they go on top of the boom and act as a large washer (as is seen in later photos)
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the booms were the parts that bowed/twisted over time, so i made my own 2 x 4s out of stacking 2 layers of 3/4" plywood, then another layer of 3/4" ply for the spacer, then glued them together, and left them clamped for about a year.
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the connectiong between boom, pan, and rail on this desing uses two large bolts that are recessed into both the bottom and the top of the connection. this is done on both the front and back. these use locknuts and washers but are not permanently fastened.
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Ive had this slep up to speed just once and after tweeking the trucks it rode like a dream. i sitll have to fabricate handles, do all of the finish sanding, disassemble and paint it, but i am confident that this will gimme years of fun. i hope the idea of using a buttboard like this comes in handy for guys wanting to build solid sleds on a budget.
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Re: my latest wood build, some desing problems solved

Postby Fast Eddie » Mon Jun 25, 2012 2:31 pm

i should have mentioned (in case ya cant tell from the pix) that there is a rail under that bodypan, it's a pine 2 x 4
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Re: my latest wood build, some desing problems solved

Postby FrankW » Mon Jun 25, 2012 3:22 pm

That's a very slick wood design. I like the idea of using Tim's buttboard as the pan and the plywood booms. But you left them clamped for a year?!?!?

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Re: my latest wood build, some desing problems solved

Postby Fast Eddie » Mon Jun 25, 2012 7:42 pm

they stayed clamped for a year, not as part of the desing .. just cuz after i clamped 'em i didnt back to 'em for a while!
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Re: my latest wood build, some desing problems solved

Postby ChrisMcB » Tue Jun 26, 2012 1:28 am

That is an interesting idea. Looking forward to seeing the finish product.

By the way, if anyone else wants to try this... It might be cheaper to by the concave wood from the lumber yard (might need to go to a specialist) I believe you can by the wood in 2 or 4 foot wide strips, so it might be difficult to cut the concave length wise. But it might be cheaper than purchasing a prebuilt board.

Would like to see the finished design,
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Re: my latest wood build, some desing problems solved

Postby skateluger » Tue Jun 26, 2012 5:08 am

I had blemished buttboard decks I repurposed over the years.
Here's the successful ones:

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Very heavy but fun to ride.
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Re: my latest wood build, some desing problems solved

Postby ArtLuger » Sun Jul 15, 2012 2:35 pm

I would use solid maple 1 by 4 for the front and back joints. put a 45 in them, stack it and glue and clamp them. you can keep doing that until you get your deck low enough. mine are either 2.75 inches of 2 incheds off the ground. That method has worked well for me. my wood boards arent that light usuall around 15 to 20 pounds but they dont felx much at all. Im starting to favor just bending the drop in the board and not having to bolt anything on for the wheels now though. more elegant that way.
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Re: my latest wood build, some desing problems solved

Postby Fast Eddie » Sun Aug 02, 2015 6:42 pm

it's finally DONE!!! been riding for a few years now but now i can finally call it done. there are several low-buck ideas used in this build and i hope some garage monster makers can use and improve on them. Any feedback from builders and experiences riders is very much welcome. please keep criticisms polite ! here is a link to the facebook page where i kept a build journal:
https://www.facebook.com/media/set/?set=a.10152543820845057.956472.568960056&type=1&l=6e34ae6170
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