Starting new Mini-Buggy project

[frankMFG]

Hi all!
New to this forum but I'm very in depth of planning out this project. I'm going to custom build the the rollcage out of 1.5 inch tubing and the frame will be 2 inch square tubing. I'm pretty stacked in the tool department as i have access to just about everything. It will be a 2 seater. I will be using complete A-Arm, spindle, hub, and spring assemblies from a yamaha blaster/banshee/warrior. I will go to the local scrap yard for a rack and pinion assembly for steering. For the back I will be doing a independent rear suspension set up using 88s10Durango's idea (seen here: http://diygokarts.com/vb/showthread.php?t=3911&highlight=rear+independent+suspension&page=4 ) which is 2 drivers side CV axles. I am going to get a 600cc crotch rocket engine. I will have 2 brake pedals, one for front and one for back (obviously) For the brakes, throttle, and clutch i will try a linkage set-up as i am more fond of linkages/
What does everyone think? Changes, questions, concerns are welcome! Let me know if its good and i will start building!

 

[DCProductions]

Welcome to the forum!

Two brake pedals or two master cylinders?
Excellent engine choice! That is the max I would put in anything still considered a kart.
Classic front suspension setup (make sure to take care of bump steer).
Rear suspension... tldr

 

[number 37]

1.5 and 2" is way too big. Big = heavy (and expensive). Heavy = wear and tear on other components (and necessitates more expensive components) ie clutch system, suspension, motor etc

most full sized rock crawler buggies with hot v8's only use 1.75 tubing, and the race ones often use 1.5"

Good luck with your project and keep us updated!

 

[frankMFG]

Thanks for the replies! Yes DCProductions i will be using 2 brake pedals so i can do sick burnouts but also have rear stopping power for power slides and what not. and number 37, thanks for that info, i thought it might seem a little big. So i'll get some 1". It's no big deal really, my welder/metal supplier lives down the road and i work for him sometimes. Thats how i know how to weld. Anyways! I'll probably do a diamond plate floor, sides, and roof. Possibly put a cheap sterio in?? Basically to have some insane fun on the farm and trails, but also to advertise in the parades. (Who doesn't want to go to a place after they see the buisness on a go kart!?!?) I'll keep you guys posted!!

 

[frankMFG]

Hey guys, here is my basic frame and rollbar design.

 

[number 37]

might want to do your brake pedals like on a tractor.

B = Left brake
C = Right brake
A = bar that flips down to lock both pedals together (to use both brakes at one time)

Works really great on sharp turns etc.

You'll also have to have a diff of some type in your rear axle that splits the axle, so when one side brakes, the other can coast

 

[theo]

! 1/2" tube would be ok, but you need to do a lot more designing in where your frame tubing is to go for strength and where your suspension is to attach. It takes a lot of work to do a buggy frame so get back to the design table.

 

[frankMFG]

theo, please keep in mind that that is a 1 minute MS Paint mock up, if you saw my drafting table you would think it was ok. Its more in depth. number 37, my set up would be B) Front Brakes C) Rear Brakes.
Might go pick up the pipe today, what should the thickness of the pipe be? 1/8?

 

[number 37]

I gotcha.

I immediately thought of cutting brakes lol.

 

[frankMFG]

Just wanted to give you guys an update! Working out the bugs in my front a-arm design. I'm going for medium travel. Not to long but not too short! I can have 2 a-arms of equal lengths and that would work, correct?

Also still needing to know what tubing thickness to get! 0.125?

 

[redsox985]

Yes, .125 at the most. It can get quite heavy quickly and isn't always needed. Proper engineering/support can be more valuable than more heft.

 

[88s10Durango]

Good start Frank , I`m using 1 1/4" x 1 1/4" x .100 wall thickness tubing on my kart , the longest pieces so far on mine have no flex , wouldn`t think you`de need the .125 thickness . Theo is very good with his frames , and knows what he`s talking about .

 

[frankMFG]

Hey s10, how did you connect your 2 drivers side CV axles and get the sprocket on it? Thats the trouble i'm running into now.

 

[fowler]

best is to use 930cvs from a porshe ( i think bmw might use them as well
they have the advantage of being able to bolt to hubs

also u will want to set up a way to jion the two pedals
yes u will want front and rear, left and right is just destied to fail
seperate brakes makes better control (i rekon u worked that out already)
u could use a bar like 37 said but make it so u press the rear brake a little then the front start to press (basically give the back slightly firmer brakeing)

with 600cc sharp coners wont be an issue just give it more throttle

 

[frankMFG]

Hey fowler, did some research, turns out that VW Beetle CV axles are the same as the Porsche 930, only cheaper I have to take a few loads of scrap iron (farm machinery and what not) to the local auto salvage so i'll ask them what they have.

 

[wingnut]

Hey fowler, did some research, turns out that VW Beetle CV axles are the same as the Porsche 930, only cheaper I have to take a few loads of scrap iron (farm machinery and what not) to the local auto salvage so i'll ask them what they have.

Might want to continue your research here:

http://www.blindchickenracing.com/How_to/CVJoints_Axles/cv_joints_101.htm

 

[frankMFG]

Hey thanks wingnut. I am wondering how to put a sprocket on the cv joints. Any how-to on that subject?

 

[88s10Durango]

Hi Frank , I haven`t connected a sprocket yet but my plan is to make a small jackshaft , mount the sprocket , brake rotor , V-belt pulley , and a small Honda Civic ring gear on the shaft , then make 2 hubs to mount on the ends of the Jackshaft to bolt my CV axles to . heres a pick of the Edge Piranha with the same idea for the mounting of the CV axles .
If you use those PTO shafts you`ll need the yokes they bolt to to mount up to your jackshaft

 

[Rustydog2010]

I think the main advantage with 930 CVs is the amount of travel you can get before they start to bind up. If your not after huge travel, you should be right.

 

[fowler]

arrr right VW not BMWs
that makes sense as a porshe is just a flash beetle from why back

i reckon the easyest way to connect the shafts would be to make a conversion kit like this one http://www.edgebuggyforums.com/viewtopic.php?f=7&t=9934

the shaft in this is a pto shaft from a tractor

this way u can have a sprcoket and brake disc in the axle