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Signed in as:
filler@godaddy.com
Three Wheelers were always a fascination. Motorcycles are great, but with two wheels and no protection, there is an element of risk. It just seemed like there was something that should slot between a two wheel motorcycle and a full-up four wheel car.
So the 'Dream Weaver' was born at Northwestern University in an Engineering lab. Driven by a 450cc motor bored to 500cc with nitrous, racing clutches to handle the weight, custom rims turned on a 24" lathe, and serial seating for two. Street legal and licensed with a top speed of over 110mph. What fun ! Shown here on the streets of Chicago circa 1985.
What did we learn ? Too much power to one wheel is really fun for doing tire smoking donuts... but can be dangerous in less than ideal road situations.
To address the problem of too much power to a single rear wheel, the next design we built had front wheel drive (two wheels powered instead of one). A 3.0 L engine was placed up front, driving the front wheels. Passengers sat side by side, next to each other. This pic is approx 1999.
What did we learn? From this design, we realized that the arrangement felt too much like a four wheel car. It had doors like a normal car, and you looked over the front wheels and engine like a normal car. It solved the single wheel drive problem by having front wheel drive, but it begged a very practical question .. 'If it feels like a car, then why only three wheels?'
So then came kids, soccer, and three wheelers fell to the side. The primary focus was not on three wheelers, but rather figuring out how to get everyone to swim practice. When my son hit high school I thought ... why not a father/son project. And why not try a new idea ... keeping the engine in the rear or mid-section, while driving power through two wheels.
And so, the Dragonfly concept was born. Here is the first 3D printed concept... circa 2012.
The first concept build is based on a gas engine (ICE), which started before there were enough electric components on the market to make it realistic for us. However, we are really excited about Electric. Our interest started with thinking about how we could contribute to sustainability, and then the realization that this design was perfect for an EV. The shapes could provide better aero than a 4 door sedan, and we could get better range with less batteries and weight. We recognized the need for around town vehicles that were designed for shorter trips to the grocery store or errands, where a huge four door SUV was overkill. So, in parallel to the ICE, we started working concepts of full 100% Electric.
We have created concept designs and layouts, and have several system components in testing. We are very excited about these designs.
. We decided to do a two person, side by side seating. Good for a driver and a fun partner next to you !
A shaft drive approach would prove that routing and gearboxes were feasible. Since electric was not viable when the concept started, we decided to use a gas engine. Electric will be for our next model ;>)
Completed by Alex in AutoCAD, the 3D model was a first pass at the mechanical arrangement. A 3D 'Printed' model was produced.
To do more details, we needed to obtain the exact engine to be used. But where to find something we could afford ? A Honda Civic SI engine from a salvage vehicle became our donor. But we did need to get it running before pulling it out.
Engine removal required tracing and tagging of related of the electrical and mechanical components.
Four right angle gear boxes were required. Unfortunately, for this concept build, we could not afford to have anything made, so we sourced some spiral bevel 1:1 gears with roller bearings. Chunkier and heavier than production would be, but good and solid for our concept.
This picture show the basic arrangement of the reverse trike wheels, seats, engine, gearboxes, driveshafts, and gas tank. With engine and gearboxes selected, weight calculations and arrangement details are finalized.
Would there be enough room ? What would the seats feel like ? First framing sets seat and front wheels
Front gearboxes and steering rack is set in framing.
Front/Rear/Side strengthening of core around gearboxes, steering rack, and anti-roll bar.
Set location of rear gearboxes and engine. This finalizes shaft lengths, angles, and weighting.
Rear framing begins. Gas tank, swing arm must be accommodated.
Rear Gearbox mounts , Engine Mounts, swing arm mounts fabricated
Rear Swing Arm is fabricated
450 lb motor and accessory weight testing.
Trunk space for Lawn Chairs and Cooler check. Must have for a fun vehicle !
Note location setting for air suspension compressors and tank.
Six driveshafts (3 each side), with CV joints to accommodate motor vibration damping and wheel travel. In production, these would be shorter/longer versions of what is in your car today.
Exhaust with stainless mesh sections for vibration damping, muffler, and Cat to keep clean air :>)
Last picture of open framing with major components. Sheet metal to complete drivers cabin begins.
Would there be enough room ? What would the seats feel like ? First framing sets seat and front wheels
Front gearboxes and steering rack is set in framing.
With raw chassis complete, major components are removed, and chassis is flipped for bottom work. Once completed, frame will be painted and sealed on bottom before returning upright.
Bottom of chassis is completed, and flipped upright. Major components will begin final install. Here, engine goes in for final install.
A fan suggests appearing at car show. Idea of showing chassis is interesting to many. Decision made, chassis components are installed and prepped for show. With only 4 weeks to complete, feels like TV show build.
2017 Car show. Lots of interest and great people. Thanks to everyone who talked to us, and all the positive energy and comments.
After listening to the fans, we decided to alter the body style slightly, and create dual intakes with roll bars, instead of the original F1 style intake.
Exhaust system coatings require heat treatment. Grill is re-purposed.
With exhaust finalized, new radiators and sizing can be determined. Note that pivoting steering is in place
Lots of fun creating different body styles, headlight locations, and windshield sizes. Many options, some really crazy.
Wood templates give a real life feel to body. Sheet metal fabrication begins.
Friend's 1987 Electric Porsche conversion. Next Dragonfly version will be electric example. Starting sketches now anticipating the future :>)
One of two series based linear linear actuators for Canopy lift. Wireless and control unit show on inset.
Routing of Air Intake to Side Air Scoop (note CSF Radiator in wheel well)
Wood templates give a real life feel to body. Sheet metal fabrication begins.
Exhaust system coatings require heat treatment. Grill is re-purposed.
Quick cardboard verification that rear canopy will open/close . Canopy moves backward before raising up. This provides necessary clearance.
Lamborghini Lee voices approval. Front canopy lifts and controls are in place (silver pieces). With basic mechanicals complete, front sheet metal can begin.
Sheet metal for front end starts coming together. Starting to look like a real three wheel car !
All steel center console and dash clusters. Steel is extra work, but adds to centerline strength of vehicle.
Lots of wiring and system control units are hidden in the body. This view is under the front console. You can see the Power Steering control unit (yes, she has power steering), the CAN Bus Intefaces, the Lift Controls, and a whole host of critical wiring. This step is very complex. The multimeter is close by to check each piece. !
Starting the engine for the first time is always an exciting milestone!! Gas and fluids are now in the system, and all the the supporting electronics are fully functional.
These are Intellitronix Guages. They are interfaced to and fed directly from the CAN system.
Thanks to sponsorships from CSF Cooling! Side radiators, small size, performance cooling... who can meet our specialized needs ? Well, meet CSF Racing and High Performance. CSF Radiators | Ultimate Performance Cooling (csfrace.com) They had THE goods, and were generous enough to support our efforts. We are using two CSF All-Aluminum High Performance King Cooler (#7065), one on each side. Very nice!
When we made the first Dragonfly design, we needed to select an air system for design detailing. Unfortunately, that was many years ago and the old K-Sport control system had no ride height control and was slowly failing. Searching for a replacement that could support our radical needs, AIR LIFT has graciously agreed to help sponsor our endeavors. Their new systems are really slick. Check out AIRLIFT at https://www.airliftperformance.com/ . More to come as we set up the system.
The dash and gauges are all custom, so we needed a system that could be easily adapted to these needs. Intellitronix has a complete line that can adjusted to pretty much anything. We are looking forward to designing the dash with Intellitronix guages (link: Intellitronix Gauges ). The Multi-Gauge LED Bargraph Set – B9999 - will be used, along with the GPS sender . Looking forward to it !
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