Board Track Racers - Project from Bulgaria.

Hello!
My name is Zdravko, I live in Bulgaria.
http://www.mapsofworld.com/bulgaria/maps/bulgaria-location-map.jpg

I am 16 and since I was a little boy I really liked old bicycles, motors, automobiles, and I am a fan of them.
I also like to do mechanics and built random stuff.
Recenly I had an idea of building a moped. I decided to make it king of like a boardtracker.
I shared my idea with my friend Vini and he also liked it.
We decide to create two boardtrackers. We quickly build a workshop, and gathered a decent amount of scrap metal - pipes, tin, and others. We decided to use to base it on old bicycles. Then we gathered some old Russian and Bulgarian bicycles and we began.

At First we made a testing frame. My idea was to see if there are whether there will be any bugs, which will be removed from the real frame. Like the distances. The distance between the seat and the handlebar was ok. But between the seat and the pedals was to small, and it was very uncomfortable to ride it. Since we know all the bugs we started working.
And this is the test frame:
http://media.snimka.bg/8651/023556691-big.jpg?r=0
http://media.snimka.bg/8651/023556693-big.jpg?r=0
http://media.snimka.bg/8651/023556697-big.jpg?r=0
http://media.snimka.bg/8651/023556698-big.jpg?r=0
http://media.snimka.bg/8918/024092318-big.jpg?r=0
http://media.snimka.bg/8918/024092319-big.jpg?r=0
http://media.snimka.bg/8918/024092321-big.jpg?r=0
http://media.snimka.bg/8918/024092322-big.jpg?r=0

This is the moment to say that we don't use high tech instruments. We cut the metal with a hand saw. We make holes with a normal electric drill. And we make the welds with welding electrodes.

Here are pictures of the new frame in proces of work:
http://media.snimka.bg/8918/024092327-big.jpg?r=0
http://media.snimka.bg/8918/024092329-big.jpg?r=0
http://media.snimka.bg/8918/024092330-big.jpg?r=0
http://media.snimka.bg/9059/024372989-big.jpg?r=0

We have to make new front fork with leaf spring suspention. Just like the old Indians.
http://www.bucksindian.com/images/1930 Indian 101 Scout 37 cu. in. 600 cc.JPG

We haven't chosen an engine yet. But I think an industrial engine from a water pump or an electic generator, would be perfect. It is possible that we will build a gearbox with 2 or 3 gears.

Improvements of the rear sprocket.
The smaller one is the original
http://media.snimka.bg/9059/024373004-big.jpg?r=0

This is me:
http://media.snimka.bg/9062/024379536-big.jpg?r=0

And this is my friend Vini:
http://media.snimka.bg/9062/024379535-big.jpg?r=0

Thank you for reading.
Have a nice day.

Thank you all for the king words, I am happy that you like the project!

The last days have been mainly in welding. When we maked the frame we perposly left all the weldings week and small.
The idea was when we make the frame, and make sure everything is right, that it doesn't have any deformatios ot twists to weld everything strong.
Because if there is a mistake, we have to cut the weldings, which is bad, and takes a lot of time. So far, everything is going well.

Here are some pictures from the past couple of days:

To make the welding smoth we use hand metal file. Here we use two nails to fixate the frame for the wooden table.
http://media.snimka.bg/9077/024409245-big.jpg?r=0
http://media.snimka.bg/9077/024409246-big.jpg?r=0
http://media.snimka.bg/9077/024409247-big.jpg?r=0
http://media.snimka.bg/9077/024409251-big.jpg?r=0

Here is something interesting:
The tube on left is original old bicycle tube. The tube on right are the tubes we use for the frame (and front fork).
http://media.snimka.bg/9077/024409252-big.jpg?r=0

And something wich is not very good.
Only element in the frame, wich is not very thick is the pipe with the bearings for the front fork. We cut it from old bicycle frame. And after so much weldings, i think from the heet, it cracked.
http://media.snimka.bg/9077/024409248-big.jpg?r=0
The problem is, that it is thick only at top, and bottom, where the frame pipes are welded. Between the pipes it is thin. The tin there is about 0,5mm.
So with our welding technology (electrodes) its not very easy to wield the crack. But at the end we managet to weld it.
http://media.snimka.bg/9077/024409243-big.jpg?r=0

There will be some progress soon!

We had front fork, wich was twisted, and we decided to use it. We cut the central pipe:
http://media.snimka.bg/9088/024430484-big.jpg?r=0
Then, after lot of hand cutting i managed to remove all original weldings from the pipe.
Here we cut some pieces of tube we needed:
http://media.snimka.bg/9088/024430486-big.jpg?r=0
One of the most important tools in our workshop is the grinder:
http://media.snimka.bg/9088/024430609-big.jpg?r=0
The interesting about it, is that it's homemade from old washing machine electric motor. And it's very, very, very old.... from early 60s...
So i used the grinder to make this shapes:
http://media.snimka.bg/9088/024430489-big.jpg?r=0
http://media.snimka.bg/9088/024430487-big.jpg?r=0
http://media.snimka.bg/9088/024430490-big.jpg?r=0

Then, after some welding, the fornt fork start to look like something.
http://media.snimka.bg/9088/024430493-big.jpg?r=0
And this is at the end of the day:

harry76 said:

Is there much of a bike scene where you come from?

Click to expand...

Actualy, Bulgaria is a former East Block country. So here we have got lot of Soviet/Russian, bikes and bicycles. We have a lot of bikes from East Europe, and bikes manufactured in Bulgaria. In the last 10 years a lot of bikes from the whole world started to appear. Some of them bought by internet, from Bicycle shops and other places. Most of the new bicycles come from China, and the quality is... not very good. So I prefer to ride something old and stylish.

And here is about the project!

We maked a temlate for the gas tank out of hardboard.
http://media.snimka.bg/9162/024578940-big.jpg?r=0
http://media.snimka.bg/9162/024578938-big.jpg?r=0
http://media.snimka.bg/9162/024578937-big.jpg?r=0

And we instaled the rear wheel by unique ultra high precision technology (using flooring boards haha!)

http://media.snimka.bg/9162/024578897-big.jpg?r=0
http://media.snimka.bg/9162/024578898-big.jpg?r=0
http://media.snimka.bg/9162/024578900-big.jpg?r=0
So, after everything was in position we marked where to cut and drill. After a while it looks this way:
http://media.snimka.bg/9162/024578906-big.jpg?r=0
Still we have to make it more reliable. We don't want to loose a wheel on the road! haha! I think to make some ajusting system like on the old Indians.


And as I said we are going ot build working leaf spring front fork. So we find rear leaf spring from old Moskvich 408 (http://media.snimka.bg/9162/024579663-big.jpg?r=0)
Here is the leaf spring already disassembled:
http://media.snimka.bg/9162/024578903-big.jpg?r=0
http://media.snimka.bg/9162/024578904-big.jpg?r=0
And the frame:
http://media.snimka.bg/9162/024578901-big.jpg?r=0