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SINCLAIR C5 CHAS posted:

Hi I am going to have a go at making the off-roader C5 that only two where ever built .not sure what it will be like but with the help of the photos from Brian who has just bought one of the originals ones

All I am doing first is to see if I can get the parts ....
The photo below is the one that he has just got but this is how it looked many years ago now it's looking a little sorry at the moment but Brian will be restoring it as it looked in the past many years ago







It must of had the indicators fitted later ???????
posted on: 03/01/2016 21:48:08

dave posted:

Chas do you no if the steering setup the same under the shell or is it different ?
posted on: 04/01/2016 16:57:22

Dan posted:

Sounds great Chas, hope you manage to pull it off. The video of the lad riding it around up and down the curbs looks great fun!
posted on: 04/01/2016 18:45:50

SINCLAIR C5 CHAS posted:

Hi dave I don't know about the steering .I will ask and let you know
Bye Chas

Got the wheels now need to sort out the axle .....

C
posted on: 05/01/2016 14:46:11

dave posted:

What size are them ?
posted on: 05/01/2016 16:59:50

SINCLAIR C5 CHAS posted:

Hi just bring you upto date the rear wheels are not as strong as I thought so will not be using them .
So I have ordered another set .so in the mean time I have cleaned sanded sprayed one of my frames as you will see

Also sorted the front wheel and forks not sure of the height but I can adjust it when the body is fitted
You my think the tube is not very strong but there is another one inside making it twice as strong






posted on: 07/01/2016 18:01:30

SINCLAIR C5 CHAS posted:

Hi all here are my new tyres great very strong and hard wearing ????

posted on: 08/01/2016 10:47:55

SINCLAIR C5 CHAS posted:

Just had a go at there steering just about done just needs a little welding ....



posted on: 08/01/2016 15:14:45

dave posted:

Chas you got a link to the rear wheels
posted on: 08/01/2016 17:38:04

SINCLAIR C5 CHAS posted:

Hi just checking how things will or will not fit ....









Hi Dave the wheels are from petrol scooters



posted on: 09/01/2016 14:27:29

SINCLAIR C5 CHAS posted:

Just put the wheels on (not fitted just slid on) to see what needs doing ...








posted on: 09/01/2016 15:09:06

SINCLAIR C5 CHAS posted:

Hi just seen this photo of Brian's off-roader belt tensioner so I thought I would have a go at making one I don't have a belt or a spring but will start to look for the items





posted on: 10/01/2016 11:58:39

dave posted:

Looking good
posted on: 11/01/2016 09:40:48

SINCLAIR C5 CHAS posted:

Thanks Dave .....
Just had a few keys cut


posted on: 12/01/2016 12:57:15

SINCLAIR C5 CHAS posted:

Belt sorted out ....

posted on: 13/01/2016 13:38:23

dave posted:

Any more chas ?
posted on: 15/01/2016 11:36:22

dave posted:

What size belt is that ?
posted on: 15/01/2016 11:36:58

SINCLAIR C5 CHAS posted:

Hi axle nearly sorted out just the brake cup to be made then it's time to start building it up













posted on: 15/01/2016 12:14:18

SINCLAIR C5 CHAS posted:

Hi just fitted a Shimano axle cog on the back also fitted the brake drum also sorted out the chain by fitting two chain tensioners the one on top is to keep the chain of the frame without it the chain would be very noisy and wear out the frame
Not sure about using the other cogs on the cassette ....j
What I now need is to have all the parts of the axle welled in place ....













posted on: 18/01/2016 13:28:41

SINCLAIR C5 CHAS posted:

Chain fitted also fitted two chain tensioners top one is to stop the chain catching the frame ....bottom one to keep the chain tight ......



posted on: 18/01/2016 13:29:56

SINCLAIR C5 CHAS posted:

Back wheels painted ready to fit




posted on: 19/01/2016 17:49:01

SINCLAIR C5 CHAS posted:

Axle now welded ready for fitting .














posted on: 20/01/2016 15:21:26

SINCLAIR C5 CHAS posted:

Just finished with the steering had to modify it after contacting Brian ...








The wires hanging out at the top are from the micro switch at the top and will need to be inserted in the tube and connected later
posted on: 21/01/2016 16:49:00

SINCLAIR C5 CHAS posted:

Hi just finished the frame .....








posted on: 21/01/2016 17:32:42

SINCLAIR C5 CHAS posted:

Ok now I have the body needs a good clean then the harnes fitting ..






posted on: 22/01/2016 11:48:21

SINCLAIR C5 CHAS posted:

Cleaned it with soap and water .will need more time spent on it later with Jiff cream cleaner



But it's looking good









Before its fitted I will have to check out a harnes then thread it through the body ...
posted on: 23/01/2016 14:00:53

SINCLAIR C5 CHAS posted:

Hi just placed the body onto the frame just to see how it looks and fits and it looks ok so it now needs to be taken off and the harness needs testing and fitting .













posted on: 23/01/2016 17:01:52

Area51 posted:

You have done a Very nice job Chas
posted on: 23/01/2016 17:46:24

SINCLAIR C5 CHAS posted:

Thanks but there's a long way to go yet but I look forward to it every day

I just realised that the steering handle should go forward .....not as it is in the photos .....
posted on: 23/01/2016 21:13:34

SINCLAIR C5 CHAS posted:

Hi started to check out the wiring harness as you will see that all seems to be ok so the next thing is to thread it through the tube in the body ....
















Not sure what to do about the indicators and the horn what I think I will do is to wire it up for them then decide ...
posted on: 24/01/2016 15:12:08

SINCLAIR C5 CHAS posted:

Did a little on the wiring decided to fit the indicators and a horn ....









posted on: 24/01/2016 18:25:25

SINCLAIR C5 CHAS posted:

Ok made my mind up and fitted indicators + a horn the added one of my hazard warning kits ...all tested just the wiring needs tidying up

[/URL








posted on: 25/01/2016 16:00:10

dave posted:

Where's the photos ?
posted on: 27/01/2016 12:09:07

dave posted:

How wide is it with the rear wheels covers when fitted ?
posted on: 27/01/2016 12:11:55

SINCLAIR C5 CHAS posted:

Hi Dave the total width (tyre to tyre ) is 32ins



Just finished making and fitting the wheel archers to see what they look like and how they fit . They will be sprayed black ASAP then fitted with the proper screws ....:-({|= \:d/ :-({|=




posted on: 30/01/2016 16:36:23

SINCLAIR C5 CHAS posted:

Wiring now complete ..steering handle now has the start button at the top and the horn switch at the bottom ..

Now need to make sure that the steering handle does not go to far to the left ..



posted on: 31/01/2016 15:48:28

SINCLAIR C5 CHAS posted:

Did a bit more on the off roader












posted on: 02/02/2016 19:52:07

dave posted:

Looks good chas
posted on: 04/02/2016 19:50:41

SINCLAIR C5 CHAS posted:

Here we are finished as last on with the next one












d



Hi this C5 was made following photos from one of only 2 ever built and is now owned by brian in the USA who is restoring the original ...
Thanks to him I was able to build this one ....
posted on: 05/02/2016 13:21:38

fox1976 posted:

Awesome!! The final result looks fantastic!
posted on: 05/02/2016 17:07:12

Area51 posted:

Nice job Chas
posted on: 05/02/2016 17:37:37

SINCLAIR C5 CHAS posted:

Thanks I enjoined making it as it is maybe the only one running ...in the country .
posted on: 05/02/2016 17:55:24

SINCLAIR C5 CHAS posted:

Hi here is the original from 1985





And how it is today





And here is my copy of it

posted on: 05/02/2016 22:31:58

Karl posted:

Hi Chas,

needless to say another piece of your marvellous work.

Just as a matter of interest, have you altered the motor drive ratio to compensate for the smaller wheels?

Cheers.

Karl
posted on: 09/02/2016 21:15:41

SINCLAIR C5 CHAS posted:

Hi thanks great to hear from you again ....
The answer is I have as you will see had a 6 speed cog on the back and using a large cog but I have not done anything to the front peddle cog as yet I do want it to go slower but until I can get it out and take it for a test run I will check the speed and power then decide if I need to put a smaller front cog on ...
I would like to put a bigger motor on it but as it is it's as the original one was built ....in 1985

Bye Chas \:d/ :-({|=
posted on: 09/02/2016 21:29:26

Karl posted:

Hi Chas,

I did notice the casette on the rear axle, but I was asking about the motor gear ratio and not the peddle ratio.

If I could say I'm up to my neck in work that would be great, but that would also be wrong, the work level at the moment is about 30 feet over my head.

Cheers.

Karl.
posted on: 09/02/2016 22:04:45

SINCLAIR C5 CHAS posted:

Hi Karl I would like to put a larger drive cog on the axle but I have tried in the past and I can only get one with a few more teeth on it
I will have to get on the net and see what I can find one larger
Bye Chas
posted on: 09/02/2016 22:12:25

Karl posted:

Hi Chas,

you've got me lost with your last post. By fitting smaller wheels you'll decrease the top speed, and by fitting a larger cog on the rear axle you will decrease the top speed even more. You'll end up with the snails chasing you.

Cheers.

Karl.
posted on: 10/02/2016 17:50:19

SINCLAIR C5 CHAS posted:

Hi Karl I was waiting for you to get back to me thanks as I wasn't sure what would happen if I put a larger cog on the drive cog
Thanks Chas
posted on: 10/02/2016 18:09:48

Karl posted:

Hi Chas,

upping the motor drive cog size is the way to go. Not knowing the circumference of the smaller wheel it's hard to say how many notches need to be added to the cog. If on the other hand you are going to drive offroad the present gearing maybe of an advantage.

Have you made a test run with the new C5, if yes how did it hadle?

Cheers.

Karl.
posted on: 11/02/2016 21:24:37

SINCLAIR C5 CHAS posted:

Hi Karl just been for a test run started ok but then the chain came off due to using the standed C5 chain so it looks like I need a different chain size and change the peddle cog besides that I need to make it smaller ...as I cannot peddle fast enough ..
Bye Chas
posted on: 15/02/2016 13:01:54

Karl posted:

Hi Chas,

I swopped some bike components for the Nuvinci hub that I mentioned, but ran into the same problem that you have. The Nuvinci hub cogs are for a smaller (width) chain, there are no cogs produced for the C5 size chain.

A few years back the only chain ring I had available for a derailleur bike was one for a hub gearbox (e.g. a C5 sized chain), so I ground the teeth down until they fitted the chain.

I was wondering why you used a derailleur cassette on the rear axle, can you not find a suitable cog for the C5 chain? Would it not be simpler to increase the final drive cog as apposed to replacing the chain ring and chain?

Cheers.

Karl.
posted on: 17/02/2016 06:06:58

SINCLAIR C5 CHAS posted:

Hi Karl the reason I used a 6 speed cassette is that I could move it along the axle to get the right speed that I wanted I first had it on the biggest cog but found that I was peddling to fast so I think I will move the chain onto the third cog then try it out regarding the chain I used the original one thinking it would be ok but with it being to wide it came off so I have cut out the middle of the original sprocket and done the same with a derailleur peddle crank ..not welded yet but it should be done today .i should have filed it down the same as you did but it never crossed my mind but next time I will do the same thanks Chas
posted on: 17/02/2016 08:56:56

Karl posted:

Hi Chas,

just take care that you buy the correct chain width as derailleur chains come in at least three diferent widths, plus I don't think half links are avilable.

Anyway have fun, and keep posting.

Cheers.

Karl.
posted on: 18/02/2016 06:19:48

SINCLAIR C5 CHAS posted:

Thanks Karl I thought they where all the same but no problem as I will check the chain and the sprocket ..

How far have you got on with the nuvinell hub ????
Bye Chas
posted on: 18/02/2016 08:38:22

Karl posted:

Hi Chas,

I only received the hub and no accessories. I'm having a hell of a job finding the parts that I need as I can't find a dealer who stocks everything that's required.

Finding quarters for all my gear isn't working out as first planed, plus building up a new workshop, and sorting out all the tools is consuming quite a bit of time. Unfortunately it'll be a lot smaller than the old one. Plus the housing company keep changing their minds as to what's going to be ripped down next.

It'll be at least April before I can restart with the C5 work. I keep injuring my back, old age catching up, which delays the heavy work for quite some time.

I'll keep you posted ASAP.

Ok olé.

Karl
posted on: 19/02/2016 15:51:07

SINCLAIR C5 CHAS posted:

Hi Karl I have had a look on eBay and there are a few item for the hub l think you want
I have had the peddle sprocket welded with a 34 tooth cog also fitted a new chain (thin one ) and all seems ok but it will need to be tested before I can say it's finished ....bye Chas take. It easy we are all getting a little older every day ...
posted on: 21/02/2016 09:07:14

SINCLAIR C5 CHAS posted:

Hi had a test run but it's not going as I wanted it's to slow and the peddling was not right ,so I went back the the original front cog and moved the chain on the back cog down to the forth cog tested the peddling again still not right ....so the next thing is to move the chain on the back down to the fith cog which is smaller it should be ok ....But I still have to sort out the motor drive gear box insert to say 25 teeth so I will have an alloy one made and see how it goes ....
Chas
Ps Karl I filed down the teeth on the original peddle cog so the chain would , fit just as you recommended thanks ..... :-({|= s:-({|= :-s
If all fails I will have to fit a more powerful motor ...
posted on: 08/03/2016 22:01:49
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