Since I returned home from Burning Man I have been extremely busy with a new job and a lot of new changes in life so I have not been able to post any updates. Now that I have finally come up for air, here are some pictures of the final product. Check out the Flintstones art car photo set on Flickr.
With Burning Man less than two weeks away my buddy Aaron and I are getting close to completion. All the finish work adds up but its the most exciting part. All the details are what makes this car authentic. Just recently Aaron finished rounding and staining the canopy supports and I finished rewiring the thing. All the seats are now upholstered and I just finished painting on the faux stone on the car.
In the picture above you can see that we now working the side logs what I think we have figured out. Below you can see all the switches and lights. We hollowed out bones to cover the switches and shells cover the indicators but glow at night.
For more pictures check out my Flickr page.
This week my father flew to San Francisco to help me, and teach me, to build a banister and repair a staircase. We tore down the wall that used to be there, replaced all the treads, and put in a matching banister and railing that we copied from the upstairs banister. For the past five days of the build I have been blogging over on SanFranVic.com where you can follow the story and see all the photos.
Since space is always at a premium, especially in my kitchen, its important to use every inch as best as possible. Instead of having two separate trash bins it made more sense to combine them into one piece of furniture and gain table top space. So I searched the internet to find something that would fit but unfortunately nothing came up. So it was off to the shop to solve the problem.
With the help of my roommate, we built this trash and recycling center out of maple plywood using simple dowel joinery. We finished it in a cabernet color and added some simple hardware like magnetic latches and handles from our local hardware store. All in all the project only took a few hours total and solved a big problem.
My long time friend Caroline and her fiance Regan asked my housemate Brian and I to do the lighting for their wedding because they had seen our renovation work on sanfranvic.com. We were both honored and excited to help out. Not only did it save them thousands of dollars from hiring a lighting expert it allowed us to give them something they will always remember.
The light array was pretty simple and only took a few hours to setup. We hung up five strands of 32 foot strings of ping pong ball lights from the reception house to a rope 10 feet up that we ran parallel to the house. That rope was held up by two pieces of 10′ galvanized steel conduit that was anchored to the ground with a few pieces of rope and some stakes. The hard part was just getting the lights up and taught so they were high above everyones head. I’m happy to say that even after the storm that came through they still stayed up and everything went off without a hitch.
I’d like to thank Caroline and Regan for having me and I was honored to be a part of your wedding. I was happy to help and even happier to give you a present that you’ll always remember and cant be returned. It was a great time and something I wont soon forget.
This year, my friend and campmate Aaron and I decided to take our skills and build something for ourselves, on top of our usual Duck Pond duties. We had been talking about an art car for a while and my friends old one just kinda fell into our lap. Above you can see a picture of what we are working with.
We bought this cart as well as a trailer with benches on it that was setup to hold about 6 to 8 people. It was owned and operated by my friend Andy under the name ‘Liberace’. It’s seen many trips to the playa with them and before that it was owned by someone in the Space Cowboys. Pictures of its past life can be seen here on Flickr.
The cart is of an unknown manufacturer, displacement, and any real history. All names and logos are long gone and stripped off. What I do I know is its a simple bidirectional 2-stroke motor with a small single barrel carburetor and a centrifugal drive mechanism. The part I found strange was that there is no idle. When you lift your foot from the gas the motor turns off. Just as well, its more environmentally friendly and wastes less gas. Nevertheless, I’m pretty happy with it as it is a simple drive mechanism and much easier than the car I usually work on.
As you can see from the picture above its a pretty uninspired looking cart. Rather than slap some color and fur on it and call it a day, we wanted to create something different with a lot of attention to detail. Something that would grab the attention of passerby’s on the Playa. The Flintstones idea, like many good ideas, came to us out the blue when we were thinking of other ideas.
The picture above is our inspiration photo. I found it on one of my favorite maker sites, instructables.com. A family had made it for their kid and its a perfect jumping off point for us to follow. I also got the ideas for the fake wooden side rails made of foam from them. The article can be found here.
As I mentioned before, our idea is to be very authentic and detailed. We are using real bones for handles, twine to hide modern bolts or materials, and all of our electronics will be hidden. We are also using real wood and branches wherever possible to complete the look. Below is a sketch of the vehicle.
Our car is going to be mostly operating without the trailer behind it. Although we will take it out from time to time, its mostly a personal transport/ice hauling vehicle. On the back, we will have a bench seat and removable foot rest for when we are not using the trailer; however, when the trailer is in use we will remove it and not allow people to sit back there as it is dangerous. For more pictures of the trailer please see my Flickr page.
The most complicated part of our project is going to be the wooden canopy. Not only is it going to be tough to turn 4×4 square pieces of wood into round looking branches, we will need a lot of support structure. We are going to be bolting the canopy into the frame rails as well as using metal pipe to support the heavier components of the canopy.
Once the final structure is said and done, we will wrap all the joints and cover all metal pieces with twine to keep the look authentic. And of course we will have a burlap white canopy to shield us from the sun.
Our next challenge will be to add modern electronics without having them show and ruin the look we are going for. We are going to be adding a small 50-or-so-watt stereo and speakers in the dash as well as some other lights and switches. Below is a sketch of the fake slate dashboard we will be building.
Below is a photo of the trailer. It can hold three people on each of the side benches and two on the back bench. Time permitting we are going to tackle the redesign of it but as of now we have our hands full. Luckily for us its fully operational and ready to go, it just needs more lighting.
We do plan on driving at night so we will clearly illuminate our car and trailer. We plan on having a few different types of lighting. The first and most blatant for safety will be amber lights underneath the car on all sides. Not only will it help others see us, it will us to get on and off. The second type of lighting will be under-canopy lighting that will be red to allow us to see while others will be able to see us. I feel that should be enough; however, we are planning on creating some lanterns with dim little flicker bulbs hanging off the canopy and maybe on the front to really help complete the look.
Our trailer will also be equipped with lighting in the case we want to take our friends out at night. It barely had lighting when we got it from our friend other than the rear red running lights. We will add amber underneath/side lights to clearly illuminate the ground below which will help us be seen. Also this will aid in our passengers ability to safely get on and off.
As I’ve said before, when all is said and done we want this car to be true to the theme and interesting to look at out at Burning Man. We are even creating Flintstone character costumes to complete the look. We are not just creating a transport vehicle, we are creating something interesting and artistic, melding form and function and contributing back to the community.
(Follow up post, Flintstones art car is coming together)
Finally, after redoing my engine, fuel and air delivery, and spark management I have gotten around to putting on a set of step headers to help the motor breathe a little harder. Since I have 4 individual throttle bodies its only fitting that I let that air get out of the motor faster as well. Also, it will help the engine run a little cooler.
Putting the headers on wasn’t all that hard although it was tricky at first getting them to fit around the tie rods. The trick was to turn the wheels all the way to left and they slid right past. Other than that, fitting the exhaust was real chore! I have always had problems with it rubbing on my rear subframe so this time I was determined to get it right. It probably took 2 or 3 different times taking it on and off after driving it around only to find that something was still rubbing. In the end, what worked best was fitting the exhaust from the collector back, fitting it just right, taking it off and pounding it place so there was no chance of movement. After a few hours of work and help from my house mate it was perfect.
Since I have installed it I have noticed a few things. First off my low end torque has improved. Not by a lot but definitely noticeable. Also, the high end power feels quite improved as well. Once I pass 4k it really screams. Finally, I have noticed my coolant temperature being much lower throughout different duty cycles. Overall, a great buy and a noticeable difference. Thanks again to Ireland Engineering for their great parts.
Its always been my dream to have an automated house and the first step is hardwired Ethernet. Whether you are going to be running video over Ethernet, VoIP, or just the good old Internet you really just cant beat copper. Although wireless has come a long way since 802.11b it will just never keep up. Besides the fact that copper performs flawlessly and extremely fast, there are no reliability issues that you inevitably run into while using on WiFi. If anyone out there reading has found a perfect WiFi Access Point that can run at gigabit speeds for hours at a time with 5 – 10 devices on it please let me know. It would have saved me a lot of trouble!
For the full writeup with tons of pictures please see my post Wiring For High Speed Ethernet on San Fran Vic.
In true geek blogging obsession/narcissism, I have decided to blog the restoration of my 1890 San Francisco Victorian home at www.sanfranvic.com. Its going to be a long journey and I’ve decided to document it for my friends, family, and any future owner of the house.
It should be interesting to learn what goes into an old house like this one, where it came from, and where its going. Although I have a lot of experience engineering and building many many things, this is my first home restoration. So follow along with me, learn from my mistakes, and try not to yourself like I am going to. Enjoy!
One of the most simple and useful things I have made in my shop so far is this crosscutting jig. It is perfect for when your chop saw just doesn’t reach far enough to cut a big piece of wood. Also, I have much nicer blades for my table saw then I do for my chop saw. Either way, it is a quintessential jig to have in your shop.
I made this one with some scrap wood I had lying around the shop in a matter of an hour or so. The base is made from birch veneered plywood and the rails are made from oak. I bought the T-tracks to guide the sled from Rockler, my new favorite store. Other than that, there’s not much to it. I decided to use dowels to hold it all together but screws or any other type of joinery would work just as well.
The most important part is getting it square obviously. What I did was made the base perfectly square, measured the distance between the tracks on my saw, then attached the tracks to the sled. Then I clamped the jig the saw, turned on the blade and raised it up through the wood. Now with my T-square I am able to line up the pieces that hold the wood perpendicular to the blade. Thats all there is to it. This design is very simple and straightforward but if you browse around the web you will find all sort of different designs, additions, and safety additions.
(More pictures can be found in this Flickr set)