As the Days blur to Nights

It has been an incredibly busy time in the life of Josh McGuckin. With two races coming up fast and two cars that seem like they will never be finished it has been a rush to try to make all the parts and assemble everything.

With Project Baja we need to have a running car that is ready to race by, gulp, July 7th. Holy crap that is way too soon and we are having terrible luck with parts right now. Shipments are being sent to the wrong place, the wrong unit, sent back, or they are simply delayed. It is very stressful right now, but we are pushing forward to make that car happen.

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We have been fairly fortunate to have some good folks stop through the shop. Emme Hall was one of our recent guests. She was ready with her work boots on and we showed her how to make sparks the PB&J way.

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Because we can’t seem to get enough punishment, we were offered a slightly larger work space which we have accepted! This sounds great and really, it is great. It is just really bad for timing. Our new space is about 150 ft away from our current space and we have to move in this week. THIS WEEK! HOLY CRAP! Last night we were down there throwing a bit of epoxy on the floor to clean it up a bit and make it easier to clean in the future. Tonight that will finish up and tomorrow we are putting in Pallet racks to create better more usable storage. All that time we are also working on the car, so there will be a bit of a rotation of people doing many things at a high rate of speed…

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Of course if you know me you know that I have been helping out the RaceKern team for a while as well. I can’t just abandon them and even though I have helped out a lot less than I have in years past I am still down there helping whenever I can. The Kerns are gearing up for Pikes Peak again. When is that again? Oh yes, that is July 4th-8th. Oh and when is testing again? FRIDAY! Holy CRAP. Seriously, how does all of this stuff get jammed together!?

So the EVO (aka EVIL) is still in many parts, but it does run now. It has suspension, tires, wheels, engine, exhaust and more! What doesn’t it have? Basically, it has no body panels from the front quarters back. Yeah, that is a lot. However parts are popping off molds, fasteners are flying about this way and that and hopefully this thing will be bolted together by Thursday… Wow, that seems so close and wow there is so much left to do!

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Late nights are pretty common these days and I am sure that sleep will become more and more rare as the month wears on.

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We’ll be back at it again tonight, Keep your eyes peeled for new posts soon and listen to this engine sing for a quick minute before you run away!

Project Baja: The story

I have been working hard on my current project, Project Baja. If I haven’t mentioned it too much on here it is because I spend most of my time writing about it on the Project Baja site. I started thinking about this project though: why do you do this stuff? That was the question that crossed my mind. Why? Well. These are the interesting things in life. The adventures that many look at and few do.

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One day, many moons ago I watched the movie “Dust to Glory.” When the movie finished I thought to myself “I could do that.” I have watched that movie repeatedly since then and I always think the same thing. “I could do that.” The real question is why though. Why spend all the time, the money and the effort on something like this? For me I think it comes down to one word: Experience.

In 2008 while sitting around with some friends we decided to make a soapbox car for the RedBull soapbox race. Cars for these events are often cardboard, taped together. Some of them are more complicated but none are taken to the level that we wanted to go. The purpose was not entirely winning. The reason for that is experience. If my team or I choose to do something we do it so we get something awesome of of it and what is more awesome than education? We learned a lot from that car. Little lessons like: “Wow, fiberglass sucks to sand!” or “Body work sure does live up to the ‘WORK’ part.” When we went to the race we had an amazing time, we met a ton of people we answered questions and we basically had an amazing experience.

In 2009 we did it all over again. The Mach five wasn’t just another fiberglass car, it was a completely different molding technique. We decided we needed to learn how to do make a female mold on this one. It was a completely new experience and we were able to learn how and be successful making the project all in a very short period of time. When we took that car across country we had so many experiences along the way. Meeting new people, showing our vehicle and well, creating the story of the trip. We have friends that I am glad to say that we would not have developed otherwise.

So when we circled around to the Baja Car I thought to myself. Imagine the places you will go, the people you will meet and not only that but the stories you will have from this project! We jumped in and yes! As usual we flailed a bit but we are going strong.

Already I have met some amazing people. I traveled to California to go to Lisas Wedding and I was able to meet the Desert Dingos. Specifically I met Jim Graham. They showed me around the car as well. Jim has been an amazing resource and has quickly become a friend. It was a great experience walking through their outdoor shop nestled in the redwoods. It was fun to check out their car and learn as much as we could. I only wish I was able to go back! Now that we have made the progress that we have it would be great to see it all again. In addition we have met Yves Braun. Yves is in the desert racing community and just happens to have a shop that is just up the street from us. He has been one of the most generous people and has provided us with a tow when we need it and a free donor car too!

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The more we learn about all of this the more the experiences are becoming apparent. I met Paul Massey through all of this as well and his friends at the Fire Guys Racing Team. Paul has told stories, showed pictures and just added fuel to the fire. The other night as we chatted he was telling me how excited he is to go to Mexico for 2012’s race and he also said “there is always a big part of me that is excited and a small part that is pretty nervous.” I think that about sums it up. Everyone that goes to this event knows that there are a lot of question marks. When you are in the middle of the desert with nobody around and you are relying on this vehicle to save the day… Well. It is plenty to make you nervous. Add to that the possibilities that simply exist in Mexico. Unpredictable law enforcement, unpredictable fans, the challenge of getting everything you need into Mexico and the additional challenge of getting everything you own out of Mexico. There is a lot to worry about! But every piece of that is just another chapter in the story that is the Baja 1000!

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With all of these potential experiences laid out just imagine the stories that are going to come out of it. Now consider that we aren’t even there yet. We are working like crazy to find sponsors, money to join our team and help make this happen. We can figure out a lot of stuff, but we can’t just create money. So now we spend a lot of time trying to figure out exactly how we can get money. You know what? Well it turns out that we have been developing relationships, we have been able to be very creative with some marketing ideas, we have just learned a ton about dealing with potential sponsors and it just adds to our experiences. Our marketing plan is always evolving but our webisodes are something that we love to make and people love to see. It has been a lot of fun and a big learning experience figuring out all of this!

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If you have a chance follow along on our build. Sign up for Rally. It will provide you email updates and if you choose to you can help support the build as well. You can also follow us on Facebook and Twitter or you can head on over to our Project Baja Website.

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Making a Rack

I built up a Schwinn a week or so ago and I just simply need something to carry my groceries on the back of it. There are lots of racks out there but… well I can’t leave well enough alone. So I had some extra steel at the shop and I also found a 1950’s High explosives box that John Grimberg gave me for this project as well.

Today I headed down to the shop to get started on this one. I don’t have all the parts that I need just yet but it is a great start. I started off with some 3 inch rings that I bought for this project. I could have bent the material, but it was definitely cheaper to buy rings and make corners out of those than it was to buy an Oxy-Ace torch!

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With the rings I just cut down some material and sanded it down to get a proper fit to my dimensions.

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In an effort to make this thing as square as possible I took my time and welded up each side using a template that I made in order to make sure they all end up at the same dimension. There is nothing quite as frustrating as getting some arbitrary pieces that aren’t square or matched in size. So these are all matched up and ready to go.

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With that done I measured out the dimensions on our welding table and tacked some ends down in order to make sure the dimensions stayed accurate then I cut the ends and tacked those in. I had the bike down there to keep an eye on things as well.

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Once the first ring was finished I clamped the sides of the second ring directly onto the finished first ring then tacked up the ends on that as well, it left me with two matched rings that will form the bottom and top of the rack.

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I called it a day after that. I need to get a 3 inch diameter tube soon in order to finish this project or I need to roll some sheet metal to a 3 inch diameter. Then I just need to weld up the top and bottom of the rack, set it up on the bike and fabricate the connections to the bike. I have some ideas for how that is going to work but I think I will cut a cardboard template in order to get it right the first time. Once all of that is done and welded I will then finish the steel and inset some wood on the sides. Hopefully it will finish up nicely and give some good character to the bike!

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Check back soon for the final product!

Anthem Branding

I have been doing some tinkering in the shop! Last year I had the opportunity to help with the design of Anthems new space. Jeremiah and I had the chance to measure, analyze and design a new space. We got to be creative and we got to make some cool stuff. In the end I had the chance to put a lot of input into the front receptionist desk and some other elements of the space. It was a great opportunity and I really enjoyed working with him on the project.

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This year however Anthem Branding has expanded, their space has stayed the same and they are trying to figure out how to get more people into their space! Jeremiah has been working in New York so I stepped up to help out. We talked about a lot of options and we ended up with the simplest options. Two very large library tables. With two tables each with three 40 inch sections we could house 12 people in the same space that seven people were occupying now.

I sent over some final drawings of the space and they were sold. so construction began!
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This is the largest project that has come out of the “creation station” so far, at least in physical size! 4ftx10ft tables! With minimal flat surfaces to work with around the shop it was an interesting experience getting everything squared up.

Anthem Table

Anthem Table

Anthem Table

The design is intended to be raw, very simple materials, exposing the materials for what they are. Exposed welds and nice wood grain. I spent a bit of time getting things straight, square and sturdy. I choose 16g 2 inch square tubing. It came out nicely with some nice heat coloration from the MiG welds.

Once the two bases were built I cut down the wood to six 40inch sections and put a coat of finish on the bottom of each board. Everything mounted up square and nice so I routed a nice 1/8inch round over on the edges that met between each board and bolted them all in place on the tables. Once they were all attached I did a 3/8 roundover around the entire outside edge of the tables. This provides a friendly feel for the end users when they are at the table, rather than just a sharp machined edge. After a bunch of sanding and a bit of masking they all got 4 coats of finish. They all came out nice and smooth. Perfect finish and I think that they will hold up for quite a while.

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You can see my nice cardboard cot under the one table, at one point it was easier to just stay at the shop…

I was able to borrow a friends Sprinter Van to deliver the tables, the delivery went smoothly, everyone involved realized how much steel and baltic birch weighs very quickly. Now that it is installed it looks perfect in the space. Anthem is still working out a few finishing touches for their new space, but overall I am very satisfied with their new tables and they seemed to be enjoying them as well.

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Anthem Detail

Anthem Details

Anthem Offices

Anthem Offices

Another fun project in the works. I do enjoy designing and building these spaces! It is really fun to see it all come to life.