Manufacturing the donkey cart and ambulance
Practical Action
Picture 4: A completed wheel jig
10. The final phase is the making of a
small device capable of locking the wheel
hub concentrically. This of course will
depend on the size of the wheel hub you are
using. In the cart outlined in this manual
the OD of the bearing is 92 mm. Therefore
a circular piece of material is required with
an OD of 90 -91mm and a 20mm clearance
hole in the middle for the locking thread.
This will probably need to be
prepared on the lathe unless suitable
size washers can be found. This disc
is then welded concentrically to the
nut. This needs to be made twice to
lock the hub concentrically at the
bottom and at the top. Finally the
handles are welded to the top locking
disk as shown in diagram 4. In
pictures 4 and 5, instead of using
M30 nuts, specially manufactured
round bar material has been
Picture 5: A completed wheel jig from above
(Note: The diagonal parts of the jig base
should be at 45 degree angles as shown in
the technical drawings).
threaded; as stated in the
introduction there is more than one way of making some of these components.
Note: Please see Technical Drawing Number WJ - 01 and 02 for more details.
3. Manufacturing the wheel
3.1 Parts List
Part Material and Notes
No
off
A
Mild Steel Round
2
Section Bar
B Mild Steel Flat Plate 1
(Rim)
C * Mild Steel Tube – * 1
see method NO 6
before starting
Length
(mm)
1300
Width or
cross
section
(mm)
N/A
1240 100
100
D Mild Steel Right
5 150 50 x 50
angle section (spokes)
E
Mils Steel Flat Plate 5
60
50
Depth /
Wall
Thicknes
s (mm)
N/A
Diameter
(mm)
15
3
8mm
(4mm for
the
bearing
surface)
4
External
100
N/A
5 N/A
5