How to build Moonbeam, a 100 MPG microcar

Links to Check Out

Home
Moonbeam's Activities 2008
Specifications
The Microcar Concept
Why three wheels?
Why Not Electric?
Street Legality
Safety
Test Drives
How to Build Moonbeam
photos 1 and 2
Photos 3 and 4
Photos 5 and 6
Photos 7, 8, and 9
Some more Pictures
Improvements you might make
How you may use this information
Links to Check Out
Report from Boston's Altwheels Festival 2006
Maine to Santa Monica at slow speed
Report from Santa Monica's Altcarexpo
Some interesting videos to look at
The upcoming Automotive X Prize and the Maine Team
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        When I was doing electric cars in the 70's, I tried to get phone numbers of companies I had heard about. I wrote for their literature, waited impatiently for things to come in the mail,  and once I drove to D.C. to test drive an electric,  the "Citicar", which I later owned for years.
    When the time came to share my ideas, I typed up smudgy mimeos, hand cranked a machine, sent them to about 40 others for a dollar, and published an article in crackpot central, The Mother Earth News. 
     Thirty years later, I'm  dizzy and excited by the difference.  Going to the web for ideas in the evenings during the planning and building process, was entering a wonderland of instant, free information.
    This is the world I so love, and naturally want to contribute to. 
       Here are three fun sites to get started.
Microcarmuseum.com      This will give you a great history
 
www.scootcoupe.com    3 wheeler, made in far east, sold in Florida $5200  I looked at one while in Santa Barbara.  The dealer didn't think much of it, having had many replacement problems. Two cycle engines are pretty dirty.
 
www.suntrike.com   This is probably a better bet than the scootcoupe.  Their 150cc version is now out and imported from Uraguay through Miami FL.  The engine is a CPI clone of the Honda GY6 engine.  I hope to drive one in Miami in April 2007.
 
www.twike.co.uk/start.html   Swiss/German 3 wheeler $25,000   Definitly worth studying.
 
The Europeans already have high-MPG cars, called "vehicules sans permis" , also known as quadri-cycles.  Here are three:
 
micro-car.co.uk
ligier-automobiles.com
aixam.com
 
All cost about $11,000, get 70 or 80 MPG, use a two cylinder Kuboto diesel and variable speed drive.  And, as far as I know, can't be imported to the USA without safety standard modifications.
 
If you are thinking of building a Moonbeam, you need to do homework on motorscooters.  Doug Simpson's website is a great place to start:   www3.telus.net/dougsimpson
As you surf around his site, you will see info on the Honda Elite 125/150/250 which is the scooter I chose.
 
   A great site for getting three wheeler ideas is Jim's page:  www.ccpc.net/~jaho/3link.html
 
Microcars are already a dime-a-dozen in present-day China.  see made-in-china.com and, if you have time and don't mind spam, go through the frustrating log-in procedure.  Then, search "tricycles".  About a dozen passenger-carrying microcars, both gas and CNG!  About $1200-$1800 FOB China. I Haven't found any which pass EPA and DOT certification.  See my page, "Why three wheels?"
 
       A very important site is  rqriley.com  As you surf around that site, you'll come to "how-to information" and "technical papers" and there you've stumbled into  a real mother lode!  Riley also has a helpful book, "Alternative cars for the 21st Century", which I hope to borrow.
     I originally was going to sell Moonbeam plans for a twenty dollar bill, and try to recoup the car's cost.  But that soon became absurd amid the generous sharing of so many websites, like this one.
    Riley's website will help you at least partially engineer your project.  I am far too impatient to truly engineer a car.  Moonbeam is beginner's luck and hand-me-down Honda smarts.
     Riley will teach you how tricky light-car suspension is.  Moonbeam rides rough, plunging into potholes with its tiny tires and jouncing you mightily with the large 'unsprung weight' compared to its paltry 400 pounds.
    Does it have to be so?  Drive Citroen's 2CV.  Just over 1000 pounds and it floats you along like a baby carriage, swaying, diving.  Large tires, enormous suspension travel, big soft springs linked to trailing and leading arms, no shocks, bungey-cord seats.   It would be fun to try such engineering.
 
     One very interesting link to look at as you think about which fuel to use to propel your microcar is
     Here you will see a side-by-side comparison of all the fuel possiblities.  Bio-diesel and Natural gas look very good.  Electricity too, although battery amortization cost may not be added in, and the electricity needs to be cleanly produced.   
    You might look at teslamotors.com to look at lithium-ion battery technology, and revopower.com to see drivetrains engineered into wheel hubs.  There, too, is the excitement of putting your ideas right out there to inspire others' thinking.  Full speed ahead!
    If you're really at ground zero, look into engines using the bourke cycle. bourke-engine-project.com
 
You can learn a lot by studying what the bike people are up to, such as at bikelist.org  and the human-powered people, at ihpva.org.  also lucabike
theres tons of stuff on continuously variable transmissions, fluid drive, etc. which I'll send along in time.  But, as a hammer-and-tongs mechanic, my advice is not to get too far out, but dream a dream you can actually build, something shockingly simple.  Henry Ford was a complex guy,  but is well worth following in this regard. 
    A good video on alternative fuels can be found by googling Google videos  under the title "better than ethanol?"  the actual site is video.google.com/videoplay?docid=363807137347714545&hl=en    See if you can figure out what BTL is.  These California guys are pretty sure plug in Hybrids using bio-diesel are the next step. 
    You might also investigate the exhibitors at the upcoming alternative car exposition in Santa Monica at altcarexpo.com