First time buggy maker - Help please

[Arc4771]

Hi. I've recently enrolled in an engineering course and I wanted to start my own one man buggy project. I was hoping to build a basic, one seater buggy with a 196cc engine. I have some basic welding, hand and power tool skills, as well as some thermal cutting and fabrication skills. I also have access to a lathe if I need one.

Basically, here is a picture of a buggy that I would sort of like to replicate: http://www.yukongifts.com/wp-content/uploads/2014/01/honda-odyssey-go-kart-frame-look-907.jpg

And the engine that I was thinking of using:

·Air cooled, 4-stroke, OHV25 inclined single cylinder
·6.5hp gasoline/petrol engine
·Max Power Output: 6.5hp/3600rpm
·Displacement: 196cc
·Bore*Stroke (mm): 68*54
·Compression ratio: 8:5:1
·Max Torque [kg.m(n.m)/rpm] : 1.35(13.2)/2500
·Ignition system: Transistor Electric / Inductive Firing
·Starting system: Recoil
·Fuel Tank Capacity: 3.6L
·Oil capacity: 0.6L
·Fuel consumption: 230g/hp.h (313g/kw.h)
·Air cleaner: Semi dry, dual filter
·Shaft Diameter: 19mm
·Shaft Length: 58mm
·Shaft rotation: Anti-clockwise (from output)
·Weight: 16kg

Would anyone have any tips, hints or advice in building my own buggy? I would also really appreciate if someone could hook me up with a link to some plans that match the buggy in the picture that I posted. Feel free to throw any advice at me, as I don't want to waste any money.

EDIT: In the plans I'd like a clear list of the materials needed for the frame and what not.

 

[landuse]

Welcome. That buggy looks like a Honda Oddysey to me. Bighead had quite a few threads on Ody refurbishing. You could have a look at those.

I have reservations though about you using a 6.5HP engine in a buggy. It might not be enough to power you as a buggy should be powered

 

[Arc4771]

Ok mate, how horsepower do you recommend for one guy? keep in mind I only weigh about 64-65 kilograms. If you could find a buggy on a budget plan to link me too, that would be fantastic.

 

[landuse]

Ok mate, how horsepower do you recommend for one guy? keep in mind I only weigh about 64-65 kilograms.

With a buggy, you are going to have a lot of weight. A buggy is larger than your average yard kart. I would suggest at least 11HP. Odyssey's usually used a 250cc 2 stroke engine. This will give you some idea of the power you might need. A 11 or 13HP engine would be fine though. The clutch for it would be a lot more expensive than one for the 6.5HP engine though. You would have to get a comet 40 series torque converter for the larger engine, where you could have used a 30 series for the smaller 6.5HP engine

Have you got a decent budget for this build?

 

[Arc4771]

Have you got a decent budget for this build?

I do have some steady funds but I'm planning to make it as I go over quite a period of time, it's a Saturday afternoon hobby for me at the moment, so I'd pay as I go and therefore can spend hundreds over an extended period of time. Would you have a total plan that you could suggest? something including a list of materials, tools, machines and the required steps? I'm struggling to find a complete plan for such a project myself, but I'm still looking around.

 

[landuse]

I do have some steady funds but I'm planning to make it as I go over quite a period of time, it's a Saturday afternoon hobby for me at the moment, so I'd pay as I go and therefore can spend hundreds over an extended period of time. Would you have a total plan that you could suggest? something including a list of materials, tools, machines and the required steps? I'm struggling to find a complete plan for such a project myself, but I'm still looking around.

You will probably have to buy some plans like from Badland buggies or spiderkarts or Edge. This will give you some idea of what you are in for. I do not think anyone will be able to give you a breakdown on what to do etc.

 

[Arc4771]

Alright mate, will have a look at what I can find, thanks for your help.

 

[landuse]

Alright mate, will have a look at what I can find, thanks for your help.

Edge is an Aussie product. In Perth

 

[fowler]

I don't know why there isn't plans for the oddy yet

They were so famous and still popular
Honda must still have the copy rights sealed up very well

Edge is the way to go for plans

 

[OzFab]

That does look like an ody but, just that...

I have reservations though about you using a 6.5HP engine in a buggy.

Waaay underpowered, start looking for a small road bike, 250-500cc; in the long run, a bike will be cheaper than buying a large industrial engine ($300-$600) & a torque converter ($300-$450 complete); you can pick up a bike for as little as $200-$300 & you end up with engine, trans, chain, sprockets, engine cradle, brakes, electricals, etc...

 

[Poboy kartman]

Also....it's going to help a lot along the way if we know where you are at mate......I could take a guess...but it's always better to fill out your profile. ....at least your location. ......

BTW......Welcome to the forum. .....

 

[OzFab]

He's an Aussie, mate...

 

[Poboy kartman]

Yeah.....That would have been my guess. ....but unless he includes mate in ever post.....it's still easier to look at upp right corner. ......

Just saying. ......

 

[OzFab]

 

[Arc4771]

Profile updated.

Also, I see that quite a few people use the frames and engines from old ATV's when fabricating their buggy, but I'm not sure if it would be better to find an old Honda ATV for parts and then use that, or if I should buy a brand new Atomik (cheap chinese brand, known to fall apart). The upside of using Atomik parts, would be that I would eventually have to replace them with better (working, lol) parts and that would improve my servicing knowledge early on, which is good personal development. On the other side of it, I don't know too much about ATV's and I fear if I go used that I'll end up buying a ****ter that will conk out two months into driving and I'll have to fork out for another one. Inexperience for you.