Dirtbox Venom mini-buggy upgrade/rebuild!

[mysteryboy28]

yeah, he's not gonna drive from upstate minnesota to south-central michigan just to work on the buggy for a few hours. lol. we'd be going to kick some sled seller guy's arse!

 

[greaser]

Exactly then maybe work on the buggy for a few lol.

 

[mysteryboy28]

sled has been delivered (what's left of it). the guy forgot the clutch cover/shield, says he'll get it to me soon. the radiator is just a weird long pair of metal things under the tunnel, so i'll be ordering a real radiator.

picked up a little heater dish thingy for propane tanks from lowes today. hopefully it'll get warm enough to heat up my work area in the garage! the itsy-bitsy electric space heater was barely enough to warm up my legs standing right in front of it. i came to lowes prepared with my harbor freight 20% off coupon, and a printout of harbor freight's similar heater dish thingy. good thing i did too, cuz the lady manager chick started spewing about the coupons only being good for tools and items that are almost identical to what harbor freight sells. i was like "here you go", she looked at the printout, saw 15,000 BTU propane dish heater, looked at the box in my kart which said 15,000 BTU dish heater, and got that look on her face like "oh, i guess you got me there". lol.

 

[Doc Sprocket]

Excellent! Hope the heater works out for you. I just picked up a kerosene heater for my garage so that maybe I can get some junk done this winter. Once I clean up my garage!

 

[exenos]

Ya, those "weird long things" are called heat exchangers. Snow gets tossed up onto them to cool the coolant running through them.

 

[mysteryboy28]

i don't think greaser is gonna want to drive around with a big bucket of snow to throw at the "heat exchangers". radiator may be a better choice.

 

[exenos]

Aww, but then he could toss snowballs at any one who's faster than he is.

 

[greaser]

Aww, but then he could toss snowballs at any one who's faster than he is.

I don't think there will be anyone to throw snowballs at then. Get a radiator and fan out of a 4cyl Toyota or honda they are tiny and should work great on the buggy.

 

[greaser]

Honda civic look how cute and tiny it is lol

http://www.corsportusa.com/store/catalog/images/K-RB-000A-EG 640X480 1.JPG

 

[exenos]

Looks like a decent size, It's probably the perfect size because this buggy will have almost as much power as a civic as well.

 

[mysteryboy28]

picked up a set of tires today, the tread is actually pretty great on all 4. since they're a matching set (close enough) i'm gonna swap the front tires out, and sell the ones that are on it now. that'll pay for the the rear rims.

also some pics of the sled pieces, and my new little propane dish heater thing.

 

[exenos]

Are you going to try to try to fit the engine on the current sled frame on the buggy? I'm just asking because that chassis with the belly pan and steering post will bring a few hundred easily. You may need to do a bit of fiddling but I bet it could be done without too much trouble. Move the mounts and put the skidoo secondary on there and your good to go.

 

[mysteryboy28]

yeah, gonna hack out the whole circled section, grind off the excess, and weld it to the frame.

 

[souperman000]

The sled looks more like a jet-ski now

 

[exenos]

Guess I didnt word that right, I was meaning that you should try to re-use the frame that you already have instead of chopping up a good chasis. It would also save you a decent chunk of money.

 

[OzFab]

Cool air filters

 

[mysteryboy28]

so, the motor mount is aluminum on the sled, different than the motor mount on the yamaha sleds i've been using. can't weld aluminum to steel! not the end of the world, as what i'll be doing is bolting the motor mount to a couple of steel rails (lots of little bolts), and weld the rails to the buggy.

got about half of the motor mount hacked out of the sled. leaking coolant all over the place. yay.

 

[mysteryboy28]

got the motor mount hacked out. need to trim it down a bit. positioned the motor and essentials on the mount to study and determine the appropriate amount of trimming.

if you look closely at the bottom "lip" of the mount/frame - that is where i will be drilling several small holes to bolt to some square tubing, which will be welded to the buggy.

i will be cutting, trimming, and reshaping the exaust so that it isn't so dang big and honky, and sticking into the back of the seats. i will do it in a way that it will only minimally shrink the expansion chamber. i've got 82hp to work with, so i think i'm good to trim off a bit for the sake of space compliance.

i also plan to cap off the top of the airbox, and create a new opening in the back of it.

 

[exenos]

DO NOT SHORTEN THE EXPANSION CHAMBER UNLESS YOU KNOW WHAT YOU ARE DOING. Which I can be almost guaranteed that you don't know what you are doing when it comes to expansion chambers. You cannot shorten a chamber. I will write a bit more in a few minutes, but just promise me that you won't chop the pipe untill I get around to it in a few minutes. Your power will go from 80 to 0 in no time flat.

EDIT: Shortening the length of the pipe will result in a shorter and a higher rpm ranger power band, both of which you don't want. The engine will run at another rpm and will feel relatively gutless UNTIL you hit that smaller rpm range where the pipe will work.

What you should do is to do one of two things.

- One is to cut the pipe clean off at a 90 where you want the bend and rotate the pipe then re weld.

- the other option is to cut a v shape halfway into the pipe, then on the other side cut a slit then bend and insert the v cut you just made and welding it in place.

Using either of these methods will keep the effectiveness of the pipe and allow you to change the shape of it.

 

[mysteryboy28]

thanks for the input. can you take my first pic and paint up some suggested cuts for me? i want to significantly shorten the distance that the muffler protrudes forward.