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Old 10-20-2016, 01:58 PM
Bwdeaton Bwdeaton is offline
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Default 2016 - Hill climb buggy build

I am going to be building one heck of a buggy I hope. I've been buying parts for a little while and have most parts I need to at least get started.

Just starting the build so maybe it is build off worthy? I'm not starting ground up though, I already have parts of a kart I'm using.

Here's the breakdown...

I have a china buggy frame to start with. I have a 250cc liquid cooled engine that I want to use for now, until I can buy a raptor 660 engine!

It will have 25" rear tires, 23" front tires, and all wheel disc brakes.

Will be geared for torque over speed to give me some hill climbing power.

It will have fox racing air shocks all the way around.

Racing seat with 4 point harnesses for safety.

What needs done now:

I have to completely redo the front suspension with new a arms, hubs, shocks, and brakes. I have bought some parts that I think I can fit on there.

I need to fix a crack in the belt housing/ backplate of the motor.

I need to reinforce some points on the roll cage.

I need to redesign the front steering a little bit.

There are plenty of little things that also need done like some wiring glitches, need a new battery box, i want to add a light bar and a digital gauge cluster. I need fix a few things like bad throttle cable, and small radiator leak. There are some ugly welds on the exhaust I'd like to fix.

And, as always, I have pics.
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  #2  
Old 10-20-2016, 02:07 PM
Bwdeaton Bwdeaton is offline
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Starting with the muffler because I should have enough time to finish it before class.

Does anyone think this could qualify to enter in the build-off?
  #3  
Old 10-20-2016, 06:39 PM
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Absolutely. You can enter the contest!
Just remember there are only like 70 days left!
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Old 10-21-2016, 09:21 AM
Bwdeaton Bwdeaton is offline
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I'll enter then. I think I can get it moving by christmas. I have some days where I get a lot of free time between classes.

I cleaned up the muffler with a wire wheel on an angle grinder (got a little carried away and stripped almost all of the paint). I ground down the old weld and then I went over it again to fix a couple pinholes before grinding and then shining it up with a flap disc. Looks much better now, but there's a little crap left over where I couldn't get the angle grinder into easily.

I will paint it this weekend with high heat 2000 degree paint.
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Old 10-21-2016, 09:29 AM
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All right! Here we go. Can this thread be moved to the build off area?
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  #6  
Old 10-21-2016, 10:15 PM
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A moderator should be with you shortly.
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Old 10-24-2016, 11:24 AM
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I have removed the engine entirely and will attempt to weld the crack. Welding cast aluminum isn't easy so I don't know how this will go. If it doesn't turn out good, I may end up buying a different engine.
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Old 10-25-2016, 07:52 AM
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Going to chamfer the edges of the aluminum crack today and see if I can weld it. If I can't fix it then I know someone local with much more experience who may be able to weld it.

Working on the design for suspension tabs and upper suspension mounts to send to a laser cutter to get them cut out.

Anyone on here know anything about setting fox shocks? I know that I will need to adjust the oil level to adjust my dampening and that I can use the nitrogen pressure to adjust the ride height, but I don't know where to start on the oil level.
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Old 10-25-2016, 02:23 PM
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Got it welded. Just one pass for now, may end up going back over with a wider bead later, but it looks like it should work. The outside cover is also aluminum so it will help hold the structure too. used a dremel to groove lightly into the crack so the filler would get more depth and penetration.

Some pictures of the progress and welder used. I had some help getting this welded up. I have access to the welder and people who are better at using it than I am through my college.
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  #10  
Old 10-26-2016, 07:29 AM
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Nice!
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Old 10-26-2016, 05:47 PM
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This is a sweet looking build, I would love to build a buggy some day!
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Old 10-26-2016, 05:56 PM
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Quote:
Originally Posted by maxpower49 View Post
This is a sweet looking build, I would love to build a buggy some day!
I have been wanting to do one for a long time, but never had to funds. Then this project just sort of fell together. I found the buggy for sale from a guy about 2 miles from my house, and I already knew where I could get the shocks and other parts, so I could get started affordably. When I looked at the buggy and found all the things damaged I was able to negotiate the price from $600 down to the $100 I gave for it.
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Old 10-31-2016, 02:37 PM
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New front suspension acquired. Designed new suspension tabs and sent to laser cutter for a quote. Should be putting it together soon. Also ordered some new parts, including sprockets, throttle cable, axle bearings, and rear brake pads.
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Old 11-22-2016, 04:24 PM
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Been a while since I've updated here, but I've been pretty busy with school. Today I finally had time to get some work done. Since last post, I obtained the new suspension tabs I needed, and some other parts including my new sprocket, bearings, and some tubing for upper a-arm mounts.


Today I got this far. Rear end back together, installed and added nitrogen to the shocks(about 240 PSI in them). Started on front end. One side is installed and tacked up. I had to make some changes from my original plan, but everything turned out alright. Now that I have it figured out, I hope I can knock out the other side in half the time.

After I install the other side A-arms i still need to install the shocks, connect the steering, set up the brakes(which I'll need new lines for), and then re-install parts including the airbox, coolant hoses, fuel tank, carb, and some other odds and ends.
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Old 11-28-2016, 06:26 PM
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Tacked up the other side tonight. I have to order new brake lines(old ones too short) and a chain(same problem).

I'm going to install a uni air filter and rejet for a little more performance, and later possibly get into the CVT weights and adjustments, but not for now.

I also want to add a tail light/ brake light. I believe it had one originally, because there is a fluid pressure switch, but not a light itself.

Any thoughts, concerns, questions?
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Old 11-28-2016, 06:54 PM
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Looking good so far. To me it looks short and stocky? Worried that you are going to do a lot of rolling over in this thing should be fun!
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Old 11-28-2016, 07:07 PM
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I have the same thought. It looks short for Hill Climbing. You do a Wheelie on a steep hill and its going over.

Then again I also think me and ProFiT are overthinking this.
It is not a 4WD V8 powered competiiion Hill Climbing machine to go up 45 to 60 degree inclines.

Or is it?
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  #18  
Old 11-28-2016, 07:13 PM
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I don't have any ridiculously steep hills I want to take it on, but I do agree that it is sort of short looking. The distance from the center of the front to the rear hub actually increased from stock, but the larger tires kind of distort the appearance. I will have to test run it to truly find out how stable it is or isn't. It still has a longer wheelbase and lower center of gravity than an atv and I've climbed plenty steep hills on my king quad without flipping and it has triple the displacement.


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  #19  
Old 11-30-2016, 05:49 PM
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Shock tabs tacked up. Hopefully I'll be able to fully weld it tomorrow. Have had a lot of homework and projects this week.
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  #20  
Old 12-02-2016, 09:41 AM
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I have to relocate the steering rack, and set to shock ride height next. Have more parts on the way. Should be able to get brakes and driveline finished when I get everything, leaving only the steering setup and fine tuning to be done before the build off ends.

I'm hoping I can make it happen, but my next 2 weeks are going to be majorly busy with project due dates, and finals the second week.
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