Mini Buggy Build Log

[jman231994]

Update Time

Had a pretty unproductive week, but the last two days have gone pretty well

Was driving home 2 days ago and saw something that looked a bit like a seat, knew I'd regret it if I didn't have a look so I went back and found this

It's cover is pretty stuffed but I'm not too bad with a sewing machine so I'm confident I can get it looking decent again

Then, last night I stumbled across someone selling a quad frame on a Facebook group, it happened to have a 250cc engine in it...$50 later and I've got this

Engine seems to be in good condition won't know for sure til tomorrow though, should go well though


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[firemanjim]

You LUCKY sonuva ... SCORE! Man,endless possibilities with that engine. Got ideas already? If not, I can loan you a few...... lol

 

[jman231994]

You LUCKY sonuva ... SCORE! Man,endless possibilities with that engine. Got ideas already? If not, I can loan you a few...... lol

Haha my only idea so far is that I need to get it done quicker so I can get out on the dunes haha

Loan me those ideas need as much as I can get for this beast haha


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[firemanjim]

Well, you are already on the right track ,so I wont side track you..... Put that 250 on the buggy and keep working. Youre doing an excellent job already. Are you still gonna do the swingarm set up for the back? Seems that quad has all you need to put the Aarm set up into/onto your buggy. Just sayin.... you got parts for a full suspension build, front n back......
If the 250 is running, sell the 110 to get rear shock money..... Do yall have swap meets over there? Good place to find good parts cheap.....

 

[OzFab]

You LUCKY sonuva ... SCORE!

What he said :toetap05:

Seems that quad has all you need to put the Aarm set up into/onto your buggy.

Clean up & mount those suckers on the front. With a bit of skill, you could even extend them...

 

[jman231994]

Haha yea I actually forgot about that, I got some shocks off fallenleopard the other day, just some Chinese ones but they seem alright

I don't think I'll do front suspension just yet, if I do I want to narrow the front end so I can get as much arm length as possible and I really can't be screwed after just building it lol, it's definitely on the list of things to do one afternoon though and I'll definitely be keeping all the bits off the quad that seem good for that haha. I'll need another pair of shocks too, probably do it as soon as I come across them, I don't mind the extra work when that comes around. I hate finishing things cause then there's nothing to do haha so I'll leave myself some upgrades for the future

I got most of the electrics with the quad too so I'm all set to put in key ignition with a neutral light and some headlights

If the 250 is running, sell the 110 to get rear shock money..... Do yall have swap meets over there? Good place to find good parts cheap.....

Probably will keep the 110 and put it on my kart so there's something for my friends to drive with this, what exactly is a swap meet? Pretty sure we have them but as far as I know they're just generic household items and stuff. I've never been to one so I don't really know though haha


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[firemanjim]

In the states, car buffs/parts hoarders get together at car shows and stuff, to sell used parts. Almost every car show/event will have a swap meet. In California, they have like 2 annual.giant swap meets where people from all over come to sell/buy hard to find used/oem parts..... great place to find the hard to find....

 

[jman231994]

Hmm I'll keep that in mind and try and find one around here, sounds like fun looking around


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[jman231994]

I THINK MY ENGINE HAS REVERSE!!!!!!

I knew if it was a quad engine it would but I thought the engine had been replaced cause it looked cleaner than everything else...But now I'm not so sure anymore cause the reverse light seemed to be connected


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[OzFab]

The gear arrangement should be stamped into the casing near the shifter...

 

[jman231994]

The gear arrangement should be stamped into the casing near the shifter...

I thought it would be too but couldn't see anything It's just a Chinese Honda clone, I think they normally just have a sticker saying it.

Anyway, I'll pop the side cover off and turn it over to see what happens.


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[OzFab]

It's just a Chinese Honda clone, I think they normally just have a sticker saying it.

Yeah, that sounds about right...

 

[jman231994]

Ok now I need some advice. I've been designing the swingarm and have come up with two designs but I cant pick one/not sure if theyre any good.

I also need advice on what size metal to use and the like. (25mm or 20mm rhs?)
And also I'm going to need a jackshaft mounted at the back of each of these to get the chain under the motor/low enough, so if you have any design ideas for that let me know

The first image is just a straightforward basic swingarm, I'm not overly keen on that design just because I'd like the engine to be as level as possible when its in its normal position, but it is easy to design the jackshaft mounts. This one would just be using pillow blocks

The second image is more what I prefer, I'll trim the shock position so the upper side is sitting flat in a normal loaded state, keeping the engine pretty level, and still giving me a bit better ground clearance. Bearings would just be flanges, and the two cross pieces would be moved to clear the chain, I just put them there to show the general idea.

Keep in mind both have the engine on the swingarm, not really in my budget to run the engine on a seperate platform with another jackshaft

Thanks Guys

 

[landuse]

The second idea would be good for keepng the engine level, but it would be slightly harder to mount the jackshaft without more structure to mount it to (if you know what I mean).

 

[jman231994]

The second idea would be good for keepng the engine level, but it would be slightly harder to mount the jackshaft without more structure to mount it to (if you know what I mean).

Yea thats my main concern really with that setup, I might be able to make some sort of overhead jackshaft for it....hang on I'll design it and post a pic



EDIT: Here we go, I was thinking make some arms like this to support a jackshaft between the two ends, I'd have some plates for bearings off the ends obviously.



Also I have no idea where the main bearing flanges went lol, they just dissappeared

Edit edit : lol

I forgot the picture

 

[jman231994]

Heres the pic sorry

If I get some other advice on this design by the morning I'll start building it tomorrow

And the engine does definitely have reverse, just took the side cover off and turned it over then. Weirdly the flywheel side of the engine is in oil, dont know if many bike engines are like that, just found it a bit odd

 

[fowler]

to get the chain forward of the engine there is no need for a jack shaft

but u need two drive gears and some basic measureing skils

get the original drive gear thats splined to the output shaft and use it for the spline

then get some thick walled tube and weld it the sprocket
efectivly maeing an output shaft spacer
then run it though a bearing and weld or spline anogther gear to it to run the chain

the flywheel may well have a little oil in it
my guess u have a starter generator
oil to lube the teeth

but maybe watch the oil level once running

 

[jman231994]

to get the chain forward of the engine there is no need for a jack shaft

but u need two drive gears and some basic measureing skils

get the original drive gear thats splined to the output shaft and use it for the spline

then get some thick walled tube and weld it the sprocket
efectivly maeing an output shaft spacer
then run it though a bearing and weld or spline anogther gear to it to run the chain

the flywheel may well have a little oil in it
my guess u have a starter generator
oil to lube the teeth

but maybe watch the oil level once running

Thanks Fowler, I've been wondering for ages how I could do something like that and never came up with anything

So how do I hold it on the output shaft? Cause I won't be able to use the locking bracket thing it's meant to use, right?

And by starter generator you mean the starter is also the alternator yea? If so, then nah it's on a freewheel so it can't be, that and it has a charging coil in the stator plate. It's set up basically the same as most small pit bike motors which run it dry. Though I'm not complaining, surely it's a good thing for all the starter gearing

I was just worried the crank seals were shot but there's definitely a passage for the oil to go through


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[fowler]

u an use locking collars on each side of the bearing

it might float a little on the spline
but its not tight with the locking plate is it

edit

actually take a pic of the shaft
i remember on my cm250 u could put the lock collar on either side of the sproket
it would just meant the sprocket is riding further out on the shaft

edit 2nd time lol

i was wondering how u would be able to get away with not welding the spacer output gear on
but u cant use a solid keyed shaft as it must slide over the engine ouput

so revised of above will save on head acres and machineing (hopefully)

get the oem sprocket with splines
weld it to a tube that fits over the eng output
get keyed shaft that fits inside the tube
weld it it
put keyed shaft though
lock collar
bearing
lock collar
output sprocket
chain and so on

 

[qtband]

Earlier you said you weren't going with a front suspension. The quad frame looks to have the A-arms on it. You can swap the mounting points and the A-arms to your buggy pretty easily. Just something else for you to think about.