Dirtbox Venom mini-buggy, 40+ horsepower!

[mysteryboy28]

Building another buggy for a customer, thought I'd have you guys follow the build. Decided to name the buggy the Dirtbox Venom (Dirtbox being my company name).

This is based on the cool PGO Bug Racer, which I've adapted to my own style and shop capabilities. The Bug Racer retails for around $13,000, mine sells for $4500 with independent rear suspension and reverse, powered usually by a 440cc or larger snowmobile engine, or if the customer prefers, with a motorcycle or ATV engine.

Polished up a bunch of 1 1/4" steel tubing. Using some heavy guage tube for the bottom of the frame (at least .15" thickness), and some medium guage tube for the rest of the buggy. It'll be solid! Good thing it'll have plenty of power...

Got a start on the bottom of the frame, and the roof hoop.

Imagine my demo buggy (pictured), slightly longer, with independent rear suspension, some sheet metal panels on the lower sides and front to keep the tree branches and mud out, and the engine compartment more boxed in...

Ignore the honky fenders. Like my giant tube bending tower?

 

[mysteryboy28]

Bought several items for the buggy, including some 25 inch Yamaha Grizzly tires. I'll need to get some different front rims, as these ones are a 110mmx4 bolt pattern, which is impossible to find axle stubs and bearings for that will work for what I want (I need 156mmx4, 110mm is intended for 4-wheel drive quads and rear axles). This buggy will have front and rear brakes, so I need compatible front hubs with brake rotors.

I haven't decided if I'm going to use quad spindles, as they aren't designed with Ackerman geometry to assist with proper steering (inner tire turning in a smaller radius when you turn, so that one tire doesn't drag). Quad spindles have the advantage of everything bolting right up, but having to extend the steering arm affects the integrity of the spindle (not as strong as the original steering arm). Probably going to fabricate my own buggy spindles, called "uprights", using quad hubs with brake rotors, and the axle stub and bearings.

Some pics of what I've ordered, mostly off eBay:

 

[mysteryboy28]

I had bought a 95 Yamaha VMax XT 500 snowmobile the other day for this build, drove 3 hours away to pick it up - but it ended up having low compression, and needed some other work to get top performace. Kinda sad, because it had reverse. Only spent $200 on it, plus the $50 bucks in gas, turned around and sold it 2 days later for $500.

It was also liquid cooled, which i DON'T want, due to the added complication of running hoses and using a radiator (one more thing to block the rear-view mirror, besides the gas tank). I prefer the fan-cooled sled motors. Although, given the limited availability of sleds in that price range, I might have to be less picky...

 

[OzFab]

Like my giant tube bending tower?

You do know those benders can be used horizontally. The manufacturers won't suggest it but I've done it

 

[fowler]

Ha I thought they were designed to run horizontal

Water cooled is far better
A radiator is very easy to add
Its just 4 extra bolts and 2 hoses
A water cooled engine will run better in a range of temperatures and u don't have to worry about air flow
Should help marketing to a larger market

for example an air cooled engine will not work in Australia ( hot climate)
U can't leave it idle as it will overheat

 

[mysteryboy28]

You do know those benders can be used horizontally. The manufacturers won't suggest it but I've done it

i tried using it horizontally and the oil in it seeped out of the chamber so that is was only pumping air. then it took it a hour or so for the oil to seep back where it belonged, and it finally started working again. sometimes i'll lean it 45 degrees or so, but with big pieces leaning it is a pain in the butt. the tower works out great. filling the long tubes with sand is a challenge though - have to stand on a chair, then tape it off quickly and carefully before the sand falls out.

 

[fowler]

Why not put tape over the ends

It should work horizontal
Maybe the deal is gone

 

[mysteryboy28]

Why not put tape over the ends

um, i said i did that. lol.

 

[Doc Sprocket]

This thing's gonna be a brute- I'm lovin' it!

 

[exenos]

Now, Lets see this get done in under a month and a half. You know how to build it so it should be doable in under a month if you work hard. Also I second the liquid cooled engine, they are much better for a buggy application.

 

[mysteryboy28]

Now, Lets see this get done in under a month and a half. You know how to build it so it should be doable in under a month if you work hard. Also I second the liquid cooled engine, they are much better for a buggy application.

2 weeks, just watch! And yeah, I'm thinking I'll take the liquid cooled plunge if need be.

 

[OzFab]

Sounds like there's a seal gone somewhere. Oh well, have fun with the tower.

Looking good so far...

Edit: 2 weeks? ok, timer's running

 

[mysteryboy28]

Some progress...

bottom front suspension frame, and side cross-braces.

tires!

 

[mysteryboy28]

The saga continues...

My grinder crapped out on me tonight, probably the 6th one to do so. Gotta love Harbor Freight tools!

 

[mysteryboy28]

I am periodically going to post a request for an investor, or donations of tools to help get the business up and running. If you're interested in becoming a part of an American business that provides lots of fun for young and old guys (and gals!) alike - shoot me an email, and we can figure out the details. Thanks!

 

[Nodroz]

Yet another awesome build! Keep up the good work dude!

 

[fowler]

Looks like you are getting there
should get good at pumping them out
Have u made jigs for the common parts
Should save time and make it easy to provide relacemebt parts

If u want a good grinder look at hitachi tools

 

[exenos]

If you don't have a chop saw yet then I would highly recommend getting one along with your new grinder. It helps with the angle cuts and as a bonus one wheel lasts a long time and they're. Cheap in comparison to cut off wheels (12$ per chop saw wheel)

 

[mysteryboy28]

i've got a little 6" chop saw. i love it! you can use the discs on the 4 1/2" grinder after they've worn down too!

hoping i still have the receipt for the grinder, might be more than 90 days old though. going to upgrade to their 6 amp grinder (2 levels up from their el cheapo).

 

[mysteryboy28]

Frame reinforcement day. Celebrate it.