Author: roo

  • Summer 2009: The One Gallon Challenge

    http://home.myfairpoint.net/vze6omtd/jorysquibb/id24.html

    This summer,  on Aug 19-22, 2009, and unusual road rally will take place in Western Massachusetts, which will give the public a first glimpse of new-generation ultra-economical cars.  It’s called the One Gallon Challenge. 
          We have rented an old hunting lodge on the banks of the Connecticut River near Greenfield, Mass.  to be our base camp.  Entry cars will gather there on Wednesday August 19 and be on display in downtown Greenfield 4-6 PM.  Wednesday evening we will have a barbeque back at the Lodge, explain the details of the Rally, and get acquainted with other participants.  Cars will be fueled up/charged up at this point.
       On Thursday morning Aug 20,  the cars, now with odometers and energy gauges zeroed,  will re-assemble  in the middle of Greenfield, the checkered flag will go down about 11AM, and a 100 mile drive on country roads to Boston’s Greenfest at Boston City Hall Plaza will begin.    Once there,  they will be on display all day Friday and Saturday,  showing how much energy they consumed during the trip.  Some, having run out of fuel,  may finish the last part of the trip on trailers, but all will be on display in Boston for the public and press.  Travel time will be limited to 3 hours, to encourage normal driving techniques.   
         At this writing, May 17, we are particularly looking for participants.  We hope to have about 15 cars, some from the upcoming Progressive Automotive X Prize.   I will post details of  the entrants as their plans jell.  Moonbeam will be there, showing off 1980’s technology, as well as  two other three-wheel lightweight diesel vehicles: Dirigo and the Roopod.  see www.roopod.com.   There seems to be a run on three-wheelers with Gaia Transport and Exertrike both bringing cars.   At the other end of the weight scale will be the Green Giant from the Physics Lab of Lake Havasu.   It’s great for me,  as a lover of light-weight,   to withold judgement, and just see what those 100 back-road miles tell us about these cars.

     

    http://www.autobloggreen.com/2009/05/22/one-gallon-challenge-sort-of-an-x-prize-lite-coming-to-massach

     

    Here is the official entry form!!!

     

    Thanks you so much for your interest in the One Gallon Challenge!  

    Hearing enthusiastically from you 13 car builders has enabled us to go ahead with plans for the Challenge.  I have purposely sent this email with your addresses exposed,  so you can see who may be coming, so far.  As publicity gets cranked up, I’m hoping for a few more.

     

    What follows is our plan for the Challenge at this point in time. At the end of this email you will find information on registration, and a registration form.

     

    We have booked Schutzen Verain, as our base camp in Greenfield, MA. 

    It is an old hunting camp on the banks of the Connecticut River, 3 miles from downtown.  It has many acres for camping, trailers, and we have planned two inexpensive meals there: a barbecue Wednesday evening Aug 19 and a breakfast the next morning.  It’s about 3 miles East of Greenfield on Route 2 and uses the same entrance as the Barton Cove Campground. Your group, of any size, may camp there for free, or stay in nearby lodgings if your bones are beyond camping.

     

    You should plan to arrive at this base camp on Wednesday, Aug 19 by 2:30PM. We will show off our cars in downtown Greenfield from 4 to 6 PM in the Miles Street Parking lot with press and public welcome. We will leave in convoy from our base camp around 3:30 PM. After the display we will return to base camp.  There we’ll have dinner, explain the rally details, get to know the other teams, and settle in for the night. There are good hiking and swimming opportunities on 

    the site. Families are welcome.   The area is hilly and full of 

    rivers–a fun place to explore.

     

    On Thursday,  with our cars charged/fuelled up for the rally, we will travel together from our base camp to the same little park in 

    Greenfield.    We’ll have a send-off there from 10AM  to Noon, when 

    the Challenge itself will begin.  We may have some escorting cars, but you will probably want to have your trailer make the journey 

    simultaneously to Boston.   The trip will be 100 miles or so, and you 

    may reload your car on its trailer at any point in the journey, if you run out of energy.  We will all end up in Boston City Hall Plaza for the night. The cars will be safe there with 24 hour security.  We will have suggestions for inexpensive lodging in the Boston area.

     

    The Boston Greenfest takes place on Friday and Saturday from 10 until 6.  The cars will be displayed under a tent, and you are free to meet as much or little of the Press and Public as you wish.  I’ve attended many of these events in the past with “Moonbeam” and I’ve found the intense public exposure both fun and exhausting.  You’ll find some hints late on this page:  http://home.myfairpoint.net/vze6omtd/

    jorysquibb/id18.html

     

      Your car will display a placard showing miles driven, energy used, and an MPG equivalent. All contestants will receive a medallion for their participation.  We don’t want to single out a “winner” since all of our efforts are part of the change process.

     

    What we need is to know that you are coming!.

    And, if you are, we need your registration, your favorite photo and a description of the car, for our publicity.

     

    Registration fees:

    $50 until July 1    Note  this early bird discount!

    $75 from July 1-July 15

    Please send your registration fee and registration form to:

     

      Jory Squibb, 13 Pleasant Ridge, Camden, ME 04843.

     

    The early bird registration fee is refundable if you have problems, but it should represent about a 90% certainty of bringing a registered, road-worthy vehicle to the rally.

     

    Feel free to email or call at 207 236-8962 if you need additional 

    details.    I plan to keep my website, moonbeamplans.com  up-to-date 

    on the rally page.   Once we know who’s coming, we’ll keep you 

    updated with details, places to stay, a press release, etc. by email.

     

    I’m very much looking forward to this event, which I hope will be informal, co-operative more than competitive, and fun. It will allow the public to glimpse an amazing reality: that cars can be built today which are 3-4 times more efficient that those currently available.

     

    Hoping to hear from you soon,

     

    Sincerely, Jory Squibb

     

     

     

     

                                   REGISTRATION FORM

     

    The One Gallon Challenge.   Greenfield to Greenfest

                           August 19-22, 2009

     

    Send to:   Jory Squibb; 13 Pleasant Ridge; Camden, ME 04843

     

    Name_______________________________________

     

    Company____________________________________

     

    Car’s Name__________________________________

     

    Address_____________________________________

     

                  _____________________________________

     

    Phones:  work________________________________

                     home_______________________________

                     cell_________________________________

     

    E-mail______________________________________

     

    Website _____________________________________

     

    Fee enclosed_________________________________

     

    Description of your vehicle (for our press releases) _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

    _____________________________________________

     

    Any special support you will need?  lodging, power for charging, etc.__________________________________________

    _____________________________________________

    _____________________________________________

     

    Please send a photo (JPEG) to jsquibb@myfairpoint.net my preference is for a photo including people.

     

    here is a link to a pdf version of the entry form:

    https://share.acrobat.com/adc/document.do?docid=7bc9af07-790b-4027-9647-ad60ce6168f0

  • Boston Greenfest 2009!

    boston greenfest city hall plaza

    http://www.bostongreenfest.org/

    ROOPOD WILL BE THERE!

  • roopod

     

     

     

     

    this is what the roopod will look like: no paint on the aluminum body

    [slideshow=2]

  • who I am

    My Name is Roo Trimble, I grew up in a family of 8 boys (I am second to the youngest.)  Just about all of my brothers design, build or make something or other…a couple of architects, an interior designer/furniture maker, a computer system designer, a bicycle designer/builder, a camera expert and me! (my littlest brother is disabled, if you are counting)  That leaves me, I guess,  I always did tons of art when I was a school kid.  That was just about all that I did in high school!  Then I went to a community college for a year, and got my grades up and applied to some schools that I really wanted to go to.  I got into Rhode Island School of Design www.risd.edu.  I actually was accepted for a illustration major, but quickly decided that I wanted to do Industrial design…and then there was no looking back, I just loved it!  At the time, I was addicted to everything bicycle (common in my family) and I had to work hard to explore outside of “bikedom” while I was at school.  My thesis project turned out to be a racing wheelchair made from carbon fiber (the closest RISD would let me get to a bike project).  I graduated in 1990.

    Racing Wheechair 1990 RISD Degree Project

    When I was done with school I got a job working for a bike company that was producing a bike, the kestrel www.kestrelbicycles.com, that my brother, Brent had gotten a patent on.  When I got out to California, Kestrel decided that they needed me to work with their sister company MCT, that designed wheelchairs and walkers…It was not for me, and It was my first and last “real” job.

    Next was a stint hanging out at my Brother Brent’s shop (check out www.trimblemtb.com for some of his work) as I developed an Idea for a mountain bike suspension frame. The suspended mountain bikes of the period were heavy, complicated and inefficient.  I was determined to develop a bike that had what I termed “bicycle” technology the “Gizbag” was the result and I think it did a great job of answering the suspension problems of the day.

    GIZBAG prototype 1992 Carbon/steel composite

    I then moved back east to Florence, MA to work with a friend, Mike Augspurger, www.titaniumarts.com  that was making custom titanium bikes at the time.  I had free use of his great shop, and I quickly developed some metal framed versions of my Gizbag design, I then began the process of getting a patent on my suspension system.  Mike built several of my bikes in titanium (for a royalty of one burrito each) and I sold the Japanese rights to my design to Bridgstone Inc.  I took my design to the big bike trade show Interbike, in Las Vegas and did not have much luck selling the design to anyone.  A couple of years later, some of the features (patented) of my design did start to show up here and there on produced bikes, but nothing that I could go after with my resources.

    About this same time, my brother Sam Trimble, trimble-architecture.com started asking me to make some custom items for his architecture projects in New York City,   This began in about 1994 and has continued since.  This work, For Sam, and other clients is my bread and butter. Check out my other website www.rootrimble.com to see some of the stuff I have done. Susan Hanna, began working with me in 2000 helping me streamline and turn ROODESIGN into something that almost looks like a business.  She continues to help run things today, as well as using our shop to produce her incredible steel sculptures, check her work out at www.bluemetaldesign.com Susan keeps me real.

    About a year ago (2007) I began to dream about building a car that would embody, what I believe are the most basic common sense features of light weight and economy, and so, my ROOPOD project was born!

  • construction progress blog

     

    Here are some pictures and drawings of ROOPOD progress: Check it out, I add new pictures often…subscribe to the feed, you will see when it is done!  NOTE: if you want to see a bigger picture of any of the pics in the blog look at the gallery at the end of the post…you can click on a thumbnail for a bigger view.

    3/4/09

    check out the new pictures!  I have started to mount the front suspension perches and build the arms/ spindles/ shock mounts etc the shocks are from the rear end of a Harley “bagger” chosen for their’ air-adjust-ability and small size they have 3″ of travel, giving me a bit over 4″ total wheel travel.  The biomorphic looking suspension arms will be 3d machined from 6061 solid “hate the word billet”

    also look at the pictures of the windshield, this is the stock unit from a VW New Beetle and I built the frame to have about the same curves…I just have to cut the sides off!  If anyone has the “killer” way to do this without ruining the windshield, please let me know!  I am very happy with the way that the windshield looks with it’s compound curves etc, but I will have to make the hood and the “roof” behind the windshield with those same compound curves and that means learning to use the English wheel…wish me luck…

    next up, the cross bars that run across the floor between the lower “A” arm perches and then the floor…

    3/8/09

    I am posting a pic with the canopy raised for people wondering how you get into roopod…

    canopy1-copy


    I also ordered a handheld tile saw from home depot that I saw recommend on a “rodding” blog as a good way to cut the windshield down…it has a 4″ diamond blade and looks like a small skillsaw…it is used with water coolant will practice on my “practice” free windshield hope it works, it was about $100…

    tile saw to cut down windshield
    tile saw to cut down windshield

    3/14/09

    I received my saw,and have made some practice cuts, and it seems to work quite well…I will put some pics on shorly…still need to figure out a curved guide for the saw to make those big, sweeping curved cuts…it did cut great freehand curves…

    4/1/09

    The good news…the bad news…I cut the windshield and I got the cuts just perfect…the bad news, I got several cracks along the cuts…the good news, I can use the windshield as a mock up, etc to keep building with, I will just have to figure out what went wrong…I am thinking that using a “fence” to cut along may have made the blade rub on the sides of the cut more, and that may have caused the cuts to crack…I made several cuts freehand in the left over pcs and got nary a crack…may have to “freehand” it on the next one…img_4728

    I used snow…probably the last of the season, to provide a supportive bed for the glass as I cut it..

    img_4729

    This is probably the problem…I bent a pc of alum to the shape of the curve, and the shape of the windshield and ran the saw along it…it probably made the blade rub on the sides of the cut and heat up too much…

    img_4731

    This is the pc I cut off

    img_4733

    Windshield in place, my cuts were right on! oh well I think it is going to look pretty cool!

    img_4734

    front view of the windshield fits just perfect…

    img_4737

    you can see that the curve is just a bit more shallow than the curve of the tube, but it is close enough…now, just make those cracks go away!

    4/2/09

    I got a bunch of frame work done today…I cut and installed two floor cross pieces, the main dash cross piece and the curved piece that holds the front of the windshield…also the two pieces that run vertically to form the “pocket” that the shock fits into…

    img_4738

    you can see all the installed pieces in this pic…next will be the side pieces that go from the dash cross piece to the bottom of the windshield pc…and the rest of the frame for the “canopy”

    img_4739

    A typical weld…not the best in the world…but better than some of the other ones!

    img_4740

    another view of the frame…there will be a heavy tube from the bottom of the two verticals to 4″ in on the dash cross-piece to brace the shock loads…

    img_4741

    another weld…

    img_4755

    I taped up some of the spaces, so I could see if everything will fit…rack goes right under dash….and 4 gallons of fuel, radiator, battery and heater core/fan fuse panel headlights etc…there will be no extra room in the dash/hood area….but we need as much weight as possible in the front…the loose tube is for the “side impact” door beam…it will go from the top of the front shocks to the rear swing arm pivot…

    4/3/09

    img_4758

    I took the frame off the jig for the first time today!…roopod looks so much smaller when it’s down on the ground…I am stepping in to show the step-over when you get in…

    img_4766

    looks short too! that’s the 145-80-r10 tire…seat to be upgraded…lol

    img_4768

    this was one test that I was dying to do…I am guessing that there is about 100lb of aluminum in the frame so far…I don’t have my scale handy, but it was not too hard to hold while my daughter took the picture!

    4/7/09

    img_4780

    I just got done with removing the old strait-across dash beam, and put this double curved one in…the strait-across version was too close to where my shins wanted to be…now there is plenty of room…the horizontal blue tape line is where the rack will be…it is several inches ahead of the dash, and therefor not a problem to be that low….

    img_4779

    another view: this design makes the dash a very strong “truss” that will resist the loads twisting on the front end when one wheel hits a bump…not yet installed is the vertical tube that holds the actual shock mount it is about 3″ in from the side and directly below the arched dash beam…blue tape in this picture is to visualize the shape of the dash sheet metal…

    spindle

    here is a drawing of the front suspension geometry…note the curved dash, and the vertical tubes that hold the inner pivots…go to this drawing in the “gallery” at the end of the post and click it two times to get a full size pic…

    4/8/09

    img_4813

    Am working on the front suspension today, these parts are the “uprights” some people would call them spindles…they will hold the actual spindles and link the upper and lower ball joints and hold the brake caliper, steering arm, and fender…guess they do alot…here is the 1.5″ x 3″ bar of 6061-t6 aluminum getting cut on the cold saw…

    img_4815

    Cnc drilled the holes that will hold it down to the fixture plate, then later they will be used to mount the brake caliper hanger and steering arm…

    img_4817

    block bolted to the fixture plate ready to be “profiled”

    img_4820

    part starting to take shape: the 1/2″ end mill travels around the “countour” at 1/4″ deep intervals

    img_4823

    taking the part off…nice and smooth!

    img_4824

    here is the part off the mill…polaris lower ball joint, and heim joint for the top, and the spindle that was removed from the polaris upright. next are the pockets for the spindle and the ball joint castle nut.

    here is a youtube video of the cnc doing it’s thing…

    4/13/09

    [singlepic id=238 w=320 h=240 float=none]

    here is the spindle bore being drilled…later to be reamed…

    [singlepic id=235 w=320 h=240 float=none]

    here are the pockets milled to lighten this thing up…the bar started about 4lb now down to about 1.5lb

    [singlepic id=240 w=320 h=240 float=none]

    now almost done, just have to make the tapered seats for the lower ball joints and the tapped hole for the heims at the top…

    4/15/09

    A lot done! here are some pics of work on the spindle upright…drilling, and reaming the tapered hole for the lower ball joint and the steps to get there, how I pressed in the spindles and a pic with the thing mounted to a wheel:

    [singlepic id=241 w=320 h=240 float=none]

    [singlepic id=242 w=320 h=240 float=none]

    [singlepic id=244 w=320 h=240 float=none]

    [singlepic id=245 w=320 h=240 float=none]

    img_4865

    This is the upright almost done, all that is left is the pinchbolt for the upper ball joint screw (to lock it) and of course the brake caliper bracket and steering arm…

    4/23/09

    I ordered my rack!…here is the drawing from woodward…ships friday…also ordered a steering-splined shaft and u joint…can’t wait to get it…

    woodward-drawing

    4/28/09

    These are the upper suspension perches…they hold both the top of the shock and the upper A-Arm they get welded right into the frame…

    [singlepic id=251 w=320 h=240 float=none]

    [singlepic id=250 w=320 h=240 float=none]

    [singlepic id=252 w=320 h=240 float=none]

    4/30/09

    Here is a pic of the upper and lower front suspension perches…on a sample tube…they will be welded to that tube and to other frame tubes…

    img_4882

    5/1/09

    The “RACK” came in..yay!!! here are some pics with the rack about where it will go and also some details of how the suspension perches and diagonal braces (armrests) will mount…time to do some welding soon!

    from the front…

    img_4891

    img_4894

     

    Driver’s view

    img_4895

    img_4896

    img_4897

    Note the “armrest” braces coming in to the dashboard tube…I think this will help triangulate the top of the frame

    img_4898

    5/29/09

    Finally! some more work  done, I did not get to take a pic of all the steps..too much of a hurry…but here is the results:  the front suspension perches are all in, and mosstly welded…there are a few gussets to add and the like, but mostly it’s done…these pictures show the rack where it will mount, and I will be able to attach the wheels as soon as I make the upper and lower control arms…too much “regular work”!

    img_5050

    note here (below) that the upper perches are for the upper arms and the top of the shock…

    img_5051

    this is the lower perch…you can see the .5″  heim here…

    img_5052

    the other side

    img_5054

    img_5055

    side view…you can see the “slot” that the shock fits into…

    img_5056

     

    2/5/09

     

    I know this is out of order, but I will fix it later…but this is the rack and pinion steering unit that I am going to use:

    they will build it to my specs: cost: about $700.00! yikes, but it will be nice…Doug Milliken suggested this one.

    rack-drawing

    mc20rack20front

     

    This is a gallery of all the pictures in the post...if you click on the pic, you can get a full sized picture if you want to see more detail...



  • technical

    all the measures

    This page will evolve as I build ROOPOD, but I will put down what I specs there are at this point.

    Frame/Body:

    6061 t651 aluminum throughout main tubes 1.5″ X .125″ wall bulkhead square tubes 1″ X .125″ body “skin” .060″ sheet.  Frame completely joined by TIG welding using 4046 wire and 100% argon.  Whole body to be heat treated at www.countyheattreat.com after all welding is completed (to restore anealed areas caused by welding) complete body to be in the 200lb range.

    Suspension:

    Tires:145/80R 10’s  19.1″ diameter (used on the clasic Mini Cooper) (Khumho brand)

    Wheels: Douglas aluminum ATV Wheels 10″X5″ 1X4 offset 4X156 bolt pattern.

    hubs: Polaris “Predator 500” hubs

    Brakes:Polaris “predator 500″ 7″ hydralic disk brakes.

    spindles/uprights: ROOPOD made: polaris spindles/6061 machined uprights-polaris ball joints.

    Dual A-arms: ROOPOD made: 6061 machined billit. .5” heim joint inner pivots

    Front shocks: Air-Coil spring adjustable shocks from Progressive  Suspension

    Rear Swing arm/engine cradle 6061 welded/heat treated aluminum

    Rear shocks: Air-Coil spring adjustable shocks from the rear of a Harley “bagger”

    Steering:  woodward rack and pinion manual

    Powertrain:

    Kubota Z482 with Comet 94C CVT and Comet FNR Gearbox
    Kubota Z482 with Comet 94C CVT and Comet FNR Gearbox

    Kubota z482 water cooled two cylinder Diesel engine 482 cc 12hp @ 3600rpm

    (I may see about adding a turbocharger to this if it is too wimpy)

    Comet variable belt Transmission “94C-Duster”

    NOVA RACING Reverse gearbox custom to match comet CVT

    Chain final drive +/- 4:1 (520 chain-roopod built rear sprocket)

    polaris “preadator 500” radiator, front mounted

    Heated fuel tank:  ROOPOD made (to enable SVO use and b100 winter use) 3 gal

    Starting fuel tank:  ROOPOD made(to hold petro diesel for starting) 3 gal

    Body Features:

    Windshield:  middle portion of a VW New Beetle windshield cut-down

    Side-rear windows:  .125″ Marguard lexan

    Headlights: Hella 2.375″ modular projecters two high/two low beam

    Directional/tail/brake lights: LED ROOPOD built

    Door:  ROOPOD made hinged along dashboard, gas strut supported.

    Heater: heater core/ variable fan dash mounted/ servo control valve

    Legal:

    ROOPOD: will be registered in Massachusetts as a motorcycle, it will bear the vin from a donor bike, and in the eyes of the state, will be that motorcycle that I have “modified”  I have talked to someone who has done this, and it worked for them…keeping my fingers crossed!  I am hoping that I can get away without having to require helmet use…insurance will cover it as a modified motorcycle.

  • THE SHOP

    Some pics of the shops where roopod is being built
     

  • footprint

    discussion of roopod’s carbon footprint

    footprint

    I am building roopod out of aluminum for it’s durabilty and recyclabilty…and mostly trying to use as little (aluminum) as possible (by making roopod as light as possible)

    [slideshow]

  • support/sponsors

    Help support my project/ become a sponsor!  Please contact me if you would like to help prove to everybody that a great, green and efficient car can be created right here at home!

    HI there everybody!  (8/17/08)

    ROOPOD has it’s first sponsor!  Ben Licata, of Northfield, MASS has contributed an old bike with a good title that will be reborn as ROOPOD!  Just so you know…it is a 1980 Kawasaki KZ44A2 (440cc) and probably the only thing that will make it onto ROOPOD will be the VIN!   Thanks Ben,  your help is really appreciated.

    Hi again (2/17/09)

    the countless pieces of advice from so many people: thanks to you all, I will mention names when I check and see if you all care!  but many thanks you know who you are…

    (7/30/09)

    REBEL WIRE (http://www.rebelwire.com/) Has contributed a complete wire harness for the roopod! many thanks to Bob Miller at REBEL WIRE!

     

     

     

  • reasons

    Why I am building ROOPOD:

    Disclaimer:  I know full well that the best vehicle there is to be had is no vehicle, then one that burns no fuel, but barring those options (walking and biking come hard to a lazy oaf like me)  I Just had to start thinking about this car problem!

    It all started one day, when I came across the sticker inside the door of my VW New Beetle…it said…3,704 gvrw…that’s how much it’s supposed to weigh fully loaded…3 passengers, the driver and fuel/cargo etc…

    Then I thought, yikes! For a small car, when I drive this car myself…I can take about 600lb off that weight and get about 3100lb actual weight …I am dragging around just under 3000lb of car just to carry my 250lb body around…I am not so hot at math, but if you divide  say 2800 by 250 you get a ratio of 11.2:1 and then I realized, out of my 1 gallon of gas I buy for this car, I use 11 parts to carry the car around, to the one part that is used to carry my weight.  If I add a passenger, I do a little better, even another big guy like me…lets say 500lb and that brings the weight up to 3050lb so that ratio is 6.1:1 a lot better but still six parts of my gallon of gas goes to move the car around…!  I won’t even talk about more passengers as it is incredibly rare to carry more than one…

    I thought: I can do better than that! I think I can build something that will get me around, in relative safety and comfort and improve that ratio a whole hell of a lot!  Then the head scratching began.  My eventual goal…A ratio of 1:1 with two people in my vehicle…my numbers would go like this…very simple…250X2 (two of me) (500) that gave me how much my car would get to weigh 500lb.  If I am just in the car then my ratio will be 2:1 so very much better than my VW!

    Discussion about why I am building ROOPOD

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