Had quite a long day today, but in a few hours to work on the trike. Following the old adage "measure twice, cut once" I measured my 10 foot length of 1.5" square tubing and cut a 77" length for the main boom. I measured the center between the wheels and and marked it on the rear frame, marked the location for the main boom, and clamped it down. Then I panicked, re-measured a few times, and then calmed- I had cut correctly! Here she is:
I bummed around a bit looking for a head tube that would match the fork and front wheel from an aluminum-framed Trek kids bike. I found one in another kids bike, cleaned it up.
On that note, I realized that the Lode Runner
has to cut into the 2" tubing and have the head tube fully enclosed, and the Meridian can't: 1.5" is too small to enclose it completely.
I found the 65" angle for the head tube by clamping the forward 1.5" tubing into my vise at a 45 degree angle which was found with a level. Then I used my speed square to add 20 degrees to the angle, and then I marked that on both sides of the tube with the speed square. Then I drew the outline of the head tube on both sides and traced the outline of the head tube onto a length of 1.5" tubing (far too long for now) , sliced into it with a cutoff disk, and then finished it off with a grinding disk. I tapped in the head tube with a bit of wood and then tack welded it in on the bottom seam.
To me, it is amazing the amount of precision you can get with just a grinder! There was very little gap. As you can see in the picture, I temporarily mounted the fork and wheel. This was, of course, so that I could clamp the assembly to the already clamped together frame and see it stand on its own for the first time:
Whoa- that's front tube is short;
TOO short! I have plan that will solve 2 problems at once. At the point where the main tube meets the rear frame, I'm going to notch the bottom just a little and introduce a 6 degree bend downward. This will drop the front of the tube 5", which will make the front tube longer and space the wheel out further forward, as well as lower the cranks, which was something I had been concerned with. Hopefully it's as tidy a solution as it seems!
As always I appreciate any comments and input.