2013 - pvc buggy

[Doc Sprocket]

Very nice! I'm sure you will enjoy the heck out of it. Mine oughta be in my grubby little hands in 1-2 weeks. I'm STOKED!

 

[freqster]

I will be welding up some parts for the buggy soon, but I have family coming for a visit soon, so I've been on hold with the buggy build. I need to hurry up and build, because the more down time I have, the more I Change/add to the design. Its killing me not being able to make progress.

 

[OzFab]

... & there you have a hertz donut

I pretty much have the same dilemma but, it's only four days... I'm getting the DTs just thinking about it...

 

[rinkydink]

I hope it works out for you because i would like to build one. That is cool!

 

[freqster]

I feel bad for not getting more done, but I have a lot of steps to do before I can make any progress. So here is what has been done since my last update:

I got my welder set up on a rolling kart, and I got some shielding gas for it.

Today I got some steel flat bar, square tube, and flat plate for the engine cage that will mount in the buggy.

And I ordered the rear bearings I plan on using.

And finally, I set up my grandfathers old Harbor Freight Horizontal band saw that I plan on using for most of my metal cuts. I need to clean it up some because I doubt it was ever set up properly or maintained in the last 20 or so years that he had it. Its funny looking at this band saw and comparing it to the one you can get at harbor freight today. There isn't a lot of difference between them besides the color, and a few new safety features on the newer ones. I guess not a lot has changed with horizontal band saws in the last few decades.

 

[freqster]

Very nice! I'm sure you will enjoy the heck out of it. Mine oughta be in my grubby little hands in 1-2 weeks. I'm STOKED!

I'm curious if you got your welder yet, and how it's working out for ya?

 

[freqster]

This weekend I was finally able to get some work done on the PVC buggy.

I started to mock up the "Motor Cage" with my 1" square tubing when I discovered that my little ATV motor really isn't designed to be mounted on a flat plate. The bottom of the motor only has about 3"x 5" of flat surface where the bolt holes are, and I wanted to be able to have some room to slide it for aligning to the chain, axle, ect. So I decided to mount the motor like it was mounted in the quad, which is basically hanging from the frame. So I had to make a few changes to my design. It is probably for the best because my new design uses less tubing, and I am trying to keep the weight down as much as possible.

I have seen a few posts where people are using ATV motors in go karts, but I cant find any detail on how they mounted the motor and left room for adjustment. If anyone has any links to some custom mounts for ATV motors, I would like to check them out.

Here are a few pics of my old design, the new design, and what I have done so far.

 

[Doc Sprocket]

I'm curious if you got your welder yet, and how it's working out for ya?

Absolutely freaking dynamite! I am in love! Problem is, I've been working a lot of overtime lately, and haven't put much time on it at all. So far, I've done a couple of test zaps, and built a header for my clone- simply welding a pipe to a flange. I really want to play!

Regarding your ATV/Bike engine question-

You can simply make up a spring loaded (or manual if you like) chain tensioner, and not have to worry about adjustable engine mounts.

 

[freqster]

Absolutely freaking dynamite! I am in love! Problem is, I've been working a lot of overtime lately, and haven't put much time on it at all. So far, I've done a couple of test zaps, and built a header for my clone- simply welding a pipe to a flange. I really want to play!

Regarding your ATV/Bike engine question-

You can simply make up a spring loaded (or manual if you like) chain tensioner, and not have to worry about adjustable engine mounts.

I really like my new welder. It allows even a hack like me to weld something together.

I could use the tensioner on a chain. I forgot about that option. I will see how it goes as I make progress.

 

[Doc Sprocket]

Good stuff. A thought I've had that may work for you- a spring loaded serpentine belt tensioner from an automotive engine. In your case, you probably don't want an old grimy one, but who-knows- you may have a nice one laying around...

 

[n1kogr]

looks good

 

[freqster]

Made a little bit of progress today. Got the motor mounts done. Still need to drill the slots in them for bolting them to the frame.

 

[freqster]

Since I have a lot of the motor cage done, I am second guessing the weight issue. I sure hope this little 110cc motor is up to the task. I may have to gear it really low. There is always the option of finding a bigger motor with the same features, (electric start, automatic with reverse) and put that in. I will have to keep a look out for a good deal on one.

 

[B.M.800]

Is it just a single speed engine? Does it have a TC?

 

[freqster]

Is it just a single speed engine? Does it have a TC?

Well, sort of. The motor is an automatic. Forward, Neutral, Reverse.

I will use it now because I really don't want to spend too much more money on the project.

 

[freqster]

looks good

Thanks n1kogr, I am making it up as I go, so we will see how it turns out!

 

[B.M.800]

Well, sort of. The motor is an automatic. Forward, Neutral, Reverse.

I will use it now because I really don't want to spend too much more money on the project.

I see. Well, HERE is a DIY 2 speed gearbox that might work out for you if you decide to.
I would like to build one one of these days.

 

[freqster]

I see. Well, HERE is a DIY 2 speed gearbox that might work out for you if you decide to.
I would like to build one one of these days.

Thats a neat little gear box. I will put that in my favorites.

I did a little bit of work on the buggy this weekend. I mounted the pillow blocks and the differential I planned on using. I need to extend one of the differential axles, so I took it apart to investigate how hard it would be and I found that it has a splined shaft for the bevel gear. NUTS! So I have a few ideas on how to extend the axle, the first being to replace the splined bevel gear with a keyed bevel gear so I can just modify the end of the extended axle with a flat, rather then trying to cut splines into it. If that doesn't work, I may either weld an extension on to the existing axle, or just replace the axle and weld the bevel gear on to it.

I will put together some pictures tomorrow.

 

[freqster]

As promised, here are a few pictures of my differential / axle extension problem, and some pictures of a few of the many parts that are on order as of today.

In the third pic, you can see the splined shaft and bevel gear, with the new axle beside it. In the 4th pic you can see the bevel gear that I hope to use on the extended axle. I can machine the end of the new axle to fit the new bevel gear much easier then trying to spline the end of the new axle. I had some difficulties trying to find the sizes of the gears. I am crossing my fingers and hoping that the new bevel gear is right size. It should be here by the end of this week.

The pillow block bearings, split collars, and sprockets are for the jack shaft.

I ordered some parts to use on my bicycle wheels that should be here soon too. I found a way to adapt the bicycle wheels to a 3/4" axle. I will do a post about it in the future.

 

[freqster]

Well, I am still working on the motor cage. For the last few weeks, I only get to work on the buggy one day a week so the updates are few and far between.

Tonight, I added another bearing support in the motor cage. After reading more about the differential I am using, I discovered that its best to use a set of bearings close to the differential, and a set father away close to the wheels. I don't have the room for 4, so I am just adding one more. I will be putting some bearings in the end caps of the PVC so that should help with the support a little.

I started to fab my wheels. I am still on the look out for some nice motorcycle wheels, but for now I am just welding up what I have. I am putting dual wheels on the back so I am just welding two rims together at the hubs, and putting the bore hubs on the ends. I also welded the disc for the brakes to a hub. The caliper from the little quad I have is no good, so i have to find a source for brakes. Anyone got any good suggestions on where I might find a brake kit?