The first little micro-car “mouse” I built for my kids. As a result, I accumulated some experience of designing and has already planned not as a child, and “adult” car. Called it “mouse-2”. Built a long time, or rather, not so much built, how many were looking for the necessary parts. This, in particular, due to the use of “Mouse-2” mechanical brakes (now I change them for hydraulic). Design drawings and the construction was carried out simultaneously, although the basic parameters of the “Mouse-2” was thought out by me in advance.

Bring him brief technical description. This twin four wheeled vehicle with an engine producing 14 HP (working volume of 346 cm3 located behind. Equipped with two independent braking systems: a primary (working) pedal with drive on all wheels and spare (Parking] lever drive only on the rear wheels.
Fig. 1. General view of the
Fig. 1. General view of the “Mouse-2”
The car is dynamic and stable. The braking distance at a speed of 30 km/h not more than 6.5 m minimum turning radius along the axis of the track the outside wheels — 4.5 m. the Maximum speed of 65 km/h.
Electrical equipment, from motorized wheelchairs FDD, 12-volt, slightly modified. It includes exterior lights and light-signalling devices, horn wiper, instrumentation.
Fig. 2. The layout of the car
Fig. 2. The layout of the car:
1 — front buffer, 2 — sidelights — direction indicators, 3 — retractable headlights with covers, 4 — battery, 5 — front axle, 6 — steering shaft, 7 — the Luggage compartment, 8 pedals brake and clutch, 9 — accelerator pedal 10 — grip hand brake, 11 shift lever and reverse, 12 — seat driver, 13 — lift headlights, 14 — “coins” of the decompressor and concealer, 15 — valve fuel tap 16 — differential with reverse gearbox 17 — chain, 18 — engine, 19 — fuel tank, 20 mufflers, 21 — rear bumper, 22 — rear lights.
Salon decorated with modern materials, isolated from matousek sound absorbing panel with foam filler. Chairs, driver and passenger anatomic, laminated of fiberglass, lined with foam and covered with leatherette; the machine is equipped with safety belts.
The vehicle is operated from may 1985. The speedometer is many thousands of kilometers of the Sakhalin roads. Serious breakdowns in the way it was. However, it should be noted that, if full engine power is not enough to overcome frequently encountered on our roads are steep and long ascents. And it forces to include the first transfer. Critical of I also to a flip-up doors — not all they are comfortable. Otherwise, the machine is happy.
Fig. 3. Tipovi diagram of the docking panel
Fig. 3. Tipovi diagram of the docking panels:
1 — tube frame, 2 wooden rake insert with a groove, 3 — fiberglass lining, 4 — the sealing of the joint of the panels with fiberglass, 5 — panel, 6 — screw.
Now I would like to tell you about the design features “Mouse-2”.
It is assembled mostly from spare parts of “Zaporozhets” and sidecars, SZA and SZD. Body frame, with fiberglass panels on a tubular frame. Rear hood, hinged or removable, which provides easy access to the engine. Body — the most difficult part, Assembly and equipment spent three-quarters of the time.
Fig. 4. The breakdown of the body on the panel.
Fig. 4. The breakdown of the body panel.
First I made a mock body in natural size. Just would like to caution that the mixture of sand and gypsum should be used as it is difficult to handle. I used pure gypsum. To save put on the grid first concrete, and when he grappled caused the top layer of plaster thickness of 15-20 cm Completely dry surface layout, polished and painted by nitroenamel. The treatment was conducted very carefully, so that the flaws are not passed on matrix.
Then spaced lines of connector panels. So they clearly imprinted on the matrix, show them with an awl to a depth of approximately 1 mm thereon and fitted the finished panel.
Fig. 5. Main power elements of the body
Fig. 5. Main power elements of the body:
1 — front buffer, 2 — front axle (steering gear and suspension arms not shown), a 3 — frame vehicle, 4 — piping
the Luggage compartment 5 — front support frame body 6 — pipe frame, 7 — lower support of the core, 8 — rod doors, 9 — door frame 10, the hinges of the doors, 11 — rear support frame, 12 — frame of the hood, 13 — hinges of the hood, the 14 — rear bumper
Usually the matrix is made from fiberglass. But I had to save resin and fiberglass, and had to cast them as the layout of plaster and concrete.
The molds each panel was shot separately: rubbed surface macattack layer of vaseline or grease and washed down with plaster, overlapping the parting line of 10-15 mm, and then the concrete by reinforcing it with steel bars 5 mm. d To obtain casts from the vertical surfaces did the formwork boards and plywood.
R and p. 6. The skeleton of the body
R and S. 6. The skeleton of the body:
1 – front support, 2 — ninie support, 3 — rear support, 4 — support tubes.
After drying of the concrete (approximately three days) removed the matrix doseusual plaster layer, carefully treated and painted.
Main load-bearing panel villeval of six layers of fiberglass with lining of two layers of stalloreggi, which gave a thickness of about 4 mm. Fiberglass before it burned the flame of a blowtorch to make it better like Ala resin. Annealed with great care, as the burned spots in the fabric crumbles.
R and p. 7. The frame of the car
R and S. 7. Frame vehicle:
1 — mounting brackets of front axle, 2 — mounting brackets shift lever and reverse, 3 — support passenger seat, 4 — side nodes podstanovki the core of the body, 5 — hinges passenger seat, 6 — support pillows sub-frame, 7 — tow plug, 8 — pin bonnet, 9 — angles 40 X 40 mm, 10 — fixing points of the rear suspension wheels.
Due to the fact that the glue hardens quickly, had to cook it in small portions Ingredients: epoxy resin (100 cm3), plasticizer (10 cm3) and cure eh (10 cm3). You can do without plasticizer. If the resin is too thick, it is allowed to add in IPI acetone solvent No. 646 or 648 (no more than 10% of the total). However, given that such supplements reduce the strength of the product, use them in a pinch.
To obtain the desired colorant in a resin is injected dye — ordinary artists oil paint from a tube (before the addition of atheer sunroof net).
Fig. 8. The engine on the underframe
Fig. 8. The engine on the underframe:
1 — engine, 2 — adjusting screw, 3 — adapter, 4 — front bracket engine mounts, 5 — under engine frame, 6 — traction suspension differential, 7 — differential with reverse gear, 8 — protective pan, 9 — rear bracket-engine, 10 — plate sample exhaust 11 — the left silencer.
Before Villenoy panels I cut out the fiberglass layers with a knife on the plywood sheet (linoleum) and put the pieces in a pile. Glued at one time with short breaks to rest or for the production of a new portion.
After laying in the matrix of the last layer of fiberglass covered everything with plastic wrap and making the formwork, and covered the surface with sand. A day removed sand and press left panel to “ripen” in the matrix three more days. Fully resin polyme entering its week.
Fig. 9. Under engine frame
Fig. 9. Sub frame:
1 — front bracket-engine, 2 — longitudinal side members, 3 cross rails, 4 — cover the pan, 5, 6 — traction suspension differential, 7 — cheeks rear bracket engine mounts, 8 — tie rods, 9 — hole stud mount differential, 10 ribs, 11 — tube under the clamp of the rear bracket 12 clamp.
The opening for the windshield in the front panel I customized to fit the frame of two-millimeter aluminum sheet. Then this frame is glued into the panel and it is inserted into the front glass of the car ZAZ-968. In the same way was made the rear and glazed panel.
The finished panel I cut the parting lines on the layout of the body and customized to the tubular frame. Panel to it was fastened with screws, choosing the gaps of the wooden slats with grooves and podkladyvaya them inside 4-6 layers of fiberglass. The joints between the panels were carved steps and was filled with strips of fiberglass on the glue.
Fig. 10. Installing the adapter
Fig. 10. The installation of the adapter:
1 — front bracket-engine, 2 — adapter, 3 — adjusting screw 4 — adjusting hole, 5 — pinch snips.
The assembled body is completely plastered and sanded in preparation for painting. Irregularities were sealed with putty on the basis of the same epoxy glue by adding fillers: talc, aluminum powder and the like.
The skeleton of the body is assembled from thin-walled steel pipes, they are welded attachment points to the frame of vehicle: front, bottom and back support. Tubular design has the frame of the folding hood. If necessary, the latter can generally be removed, for example in the repair of the engine.
Fig. 11. The shift lever and reverse
Fig. 11. The shift lever and reverse:
1 — lever, 2 — casing, 3 — sector gear with the drive 4 — sector reverse, 5 — pressure plate, 6 — finger, 7 — area of the vehicle frame, 8 — fork thrust reverse, 9 — plug the shift rod, 10 — a bracket of fastening of the lever, 11 — plug, 12 — spring retainer 13 and ball lock, 14 — pull the gear shift.
The main power element of the body — a rigid frame of steel pipes and corners. She carries a skeleton, hood, front axle, engine with under-eye frame and the differential, suspension rear wheels, trunk and so on. For mounting these units the fixing brackets, nodes and supports.
The front frame is mounted the axle of the sidecar, SZA, has been modified for drum brakes from a cargo scooter.
Fig. 12. Rear suspension
Fig. 12. Rear suspension:
1 — power transfer 2 — frame vehicle, 3 — arm, 4 — mount, 5 — panel, 6 — wheel hub 7 — eyelet fastening arm, 8 — bushing 9 — rubber liners, 10 — finger 11 — the case of the lower mount and shock absorber, 12 — edge 13 — eyes of the upper mount and the shock absorber, 14 — Klondike solitaire.
On the rear of the frame on a makeshift rubber pads mounted lodotra frame with the power plant from the scooter FDD is deployed to 180°. Front” on her mount adapter, offset vertically relative to the mounting bracket of the engine. Rear point — hinged: bracket, covering the collar of the tube sub-frame, allows a small rotation of the power unit in a vertical plane. It was made for tensioning the drive chain adjusting screw, which, being wrung out from a reference platform for the front bracket. lifts the engine. Fixation of the degree of tension of the chain is the collar and tie-rods (see Fig. 9 and Fig. 10).
The torque is transmitted single-row roller goal step 15,875 mm differential with reverse gear from a cargo scooter. The differential is suspended on four studs under the engine on rods and sub-frame. In principle it differs little from motocoaster — the same compact and reliable. However, to obtain the desired number of revolutions of the wheels had to make a new sprocket with 16 teeth.
Fig. 13. Silencers
Fig. 13. Mufflers:
1 — through bolt 2 — clamp, 3 — a casing of the silencer 4 — inlet flange, 5 — coupling nut, 6 — plate attachment to rear mounting bracket engine, 7 — ejector, 8 — perforated pipe, 9 — bottom, 10 to the exhaust pipe.
Transmission, as is known, is built directly into the engine, and reverse — differential. To manage them you must have two levers with the separate drive. I used a single drive switching gear, and reverse, which is much simplified control of the car.
The shifter in the cab is pivotally mounted between the two gear and reverse and is constantly pressed by a spring to the first. In the neutral position the sectors of the fixed balls, which under the action of its springs are in the grooves of the discs.
Fig. 14. Modified shock absorber
Fig. 14. Modified shock absorber:
1 — absorber, 2 — plates under the additional spring 3 — rubber buffer, 4 — spring shock absorber, 5 extra
spring, 6 — cracker.
For reversing sector gear to translate the lever forward — include the first transfer. Then the lever returns to the neutral position (transmission in this case does not turn off) and again, but with a sector of the reverse, forward serves, including reverse.
Other engine controls — gas pedal, clutch and the ignition switch is usual, regular.
Fig. 15. Hub rear wheel
Fig. 15. Hub rear wheel:
1 — driveshaft with u-joint, 2 — the axis of hub 3 — hub body, 4 — bearing 5 — flange of the brake shield, 6 — disc wheel And brake drum, 7 — segment dowel, 8 — a nut of fastening of the disc 9, the inner rim 10 to the brake drum 11 is the outer rim, the 12 — brake pad, 13 — brake shield.
The layout of the power plant, Matousec dictated and replacing one of the factory muffler on a homemade two — the first did not fit in the hood space.
Mufflers welded from sheet steel. Connect them to the exhaust ports of the cylinders (swivel nuts), and to the mounting bracket of the engine
(insert sample). It should be noted that the exhaust sound from homemade silencers louder than factory. Probably the impact of their small internal volume. However, engine power is not affected.
Fig. 16. The front wheel hub
Fig. 16. The front wheel hub:
1 roller, 2 — gland, 3 — knuckle, 4— additional flange 5 — bolt brake plate, 6 — hub, 7 — backing plate, 8 — brake pad, 9 — drum, 10 — pinch bolt, 11, 12 rims wheels 13 — ring spacer.
Rear axle assembled from two homemade independent suspension with longitudinal swing arms. The levers of thick-walled steel pipe d 32 mm I installed bearings in the ears — the points of fastening to the vehicle frame.
To the opposite ends of the arms welded to the hub of the rear wheels and lower the attachment points of the shock absorbers, which is a cylindrical body with an axial bushings under the bolts and rubber inserts.
Fig. 17. The layout of the actuator retractable headlamp
Fig. 17. The layout of the actuator retractable headlamp:
1 — bearing, 2 — axle housing 3 — lamp housing, 4 — screw fixing shelves, 5 — the rope of speedometer, 6 — arm drive, 7 — thrust, 8 — lever 9 — bearing housing shaft, 10 — spacer sleeve from the shaft 11 of the gearbox casing, 12— panel mount lights, 13 —headlight
The upper mounts of shock absorbers is the tabs on the gussets, are welded to the tubular elements of the frame of the car.
Hub and axle of the rear wheels from a cargo scooter; rim and brake components from motorized FDD. In a single unit they are connected to the flanges and disks.
Fig. 18. The drive mechanism of the headlights
Fig. 18. The drive mechanism of the headlights:
1 — arm, 2 — flywheel, 3 — case fans 4 — the rope of speedometer, 5 — cable sheath, 6 — worm shaft 7 is a worm wheel, 8 — housing, 9 — clamp lever, 10 — lever 11 — bearing housing shaft, 12 — shaft 13 — spacer.
Rear axle “Mouse-2” is heavily loaded, and the elasticity of the shock absorbers of the motorcycle “Ural”, as it turned out, insufficient. So they had to modify to install additional springs that I made from one of the rear spring of the car ZAZ-968, cutting her gas burner. Sheared edges while they were hot, buckled, and then grind on the grinder for a precise fit in the dish.
The more complex the alteration the shock absorbers were not exposed. I removed only the outer covers. And dirt from falling on the rods, used protective covers made of thin canvas.
Fig. 19. Sprocket differential
Fig. 19. Sprocket differential.
Power axles with cardan joints — also from a cargo scooter. But since the track “Mouse” wider, then they had to be lengthened. The axle shaft I cut in half and pressed in a steel sleeve. The length and fit them in place, welded to each other.
Front wheel is assembled from parts chassis sidecars, SZA and SZD. To connect them together I machined the extra flanges and ring spacers. Of suspension components (except hubs) were not modified. A hub only grind in three places as shown in the figure.
A curious element of my car can be considered retractable headlights. Such are sometimes found in improvised structures. In the afternoon, when there is enough light, hid headlight in the engine compartment, in the evening time they push out.
The lights I have with manual transmission (eventually it will be replaced by electric) installed in the cockpit. From the turntable to a worm reducer with a gear ratio of 1 : 80 stretches the cable of the speedometer in the shell. Further, from a worm wheel gear rotating the shaft, hidden in the spacer sleeve, through the levers and the thrust is transferred to the housings of the headlights, and they are put forward. They are governed by the offset shelves, which are fixed then the side screws.
V. VESELOV, Kholmsk, Sakhalin region.

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