The Beefcake Buggy Build

[MrBracket]

I started a buggy build last October, I was going to enter the build off last year but got a late start... Plus, it's proving to take a little longer than the contest would allow anyhow...

Today I read the Big CC in a kart thread, http://www.diygokarts.com/vb/showthread.php?t=25081 and decided I should start a thread here for what I'm building. I started a thread on minibuggy.net when I began the project if you want a long read...

My goal is to build a fun, safe, 2 seat buggy that has enough power to climb sand dunes yet still fit on trails in the woods near my home.

I'm using a 1997 Honda CBR1100xx Blackbird engine that puts out about 120HP. It's a 4 cylinder water cooled street bike engine. Not an engine you could strap onto a yard kart without serious re-engineering..

To date, I have the frame tacked together and have the engine and suspension mounted. I even started the engine in the frame for the first time a couple weeks ago. I hope to have it move under it's own power within a couple weeks!!

Enough words, here are some pics.....

http://www.moto-mule.com/mini-buggy/minibuggy-01.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-08.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-15.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-18.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-26.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-30.jpg

 

[OzFab]

I don't think that thread applies to this particular build, it's directed more at those attempting to put the same engine on a 50lb go kart frame

Great work so far, keep them pics coming (with a few explanatory words...)

Welcome to the forum

 

[rmm727]

Gotta love laser cut parts...What was the rear end you narrowed for under there?

 

[landuse]

Welcome to the forum. This looks like it is going to be a great build

 

[MrBracket]

I wish I had a laser!!! All the brackets on my build are cut on a small cnc plasma table that I built a few years back.

The rear axle is a Dana 44 that was narrowed from the factory for a forklift application. I found a company that had several that have been sitting on a pallet since 1979, now that's New Old Stock!!! Picked it up for $180 and it has 5.38:1 gears in it with an open differential.

Here are some more pics:

http://www.moto-mule.com/mini-buggy/minibuggy-32.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-42.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-51.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-55.jpg
My oldest boy modeling for me.

http://www.moto-mule.com/mini-buggy/minibuggy-56.jpg
My youngest, showing where he belongs.

http://www.moto-mule.com/mini-buggy/minibuggy-59.jpg

 

[MrBracket]

Here are some more pics:

http://www.moto-mule.com/mini-buggy/minibuggy-60.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-61.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-62.jpg

My youngest thinking he's gonna steal the drivers seat!!

http://www.moto-mule.com/mini-buggy/minibuggy-64.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-79.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-78.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-81.jpg

 

[2SlickNick]

Great build and wow.... such progress. Definitely subscribing to this thread.

 

[MrBracket]

Thanks for kind words. As mentioned above, the design goal for this buggy is to have the power to climb tall dunes yet fit on tight wooded trails. Originally I wanted to keep it at 50" wide, but it seemed too top heavy at that width. It's 58" wide now, I'll still have to be careful turning a speed, but at least I'll fit on many of the trails near my home.
The rear axle houses 5.38:1 gears plus I have a jackshaft that reduces the gearing almost another 2:1, for a total reduction of about 9:1. With the 31" tall rear tires that should put me at about 4mph in 1st gear at 2,000rpm. I want to be able to putt around in the woods without burning up the clutch. This low gearing means that in 6th gear at 10,000rpm I'll "only" be able to go 62mph (which is fast enough for me!!!)

http://www.moto-mule.com/mini-buggy/minibuggy-87.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-99.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-102.jpg

http://www.moto-mule.com/mini-buggy/minibuggy-104.jpg

The last picture is the reverse gearbox that I'm using in the drivetrain. Now this thread is up to date to where I'm at currently.

Here's a video of the engine running:
http://www.youtube.com/watch?v=418tLm02vEQ

 

[gman3850]

i think i just had a mangasm. so sweet. Wish i had the tools and skill to build something like this

 

[redlinemotorsportts]

Thats hot ****.... LOL, man awesome work. one of them things were your looking at it saying "GIMMIE GIMMIE"

 

[rmm727]

Got a link for the reverse gearbox?

 

[landuse]

Great build!

 

[MrBracket]

Here is a link for the reverse gearbox:
http://www.roadstercycle.com/Reverse%20gearbox%20for%20motorcycles.htm

landuse, I see you've edited my posts to change the way the pictures show up. Is this something you'd prefer that I do from now on? Do the thumbnails automatically show up? Thanks in advance for the info.

 

[landuse]

Here is a link for the reverse gearbox:
http://www.roadstercycle.com/Reverse%20gearbox%20for%20motorcycles.htm

landuse, I see you've edited my posts to change the way the pictures show up. Is this something you'd prefer that I do from now on? Do the thumbnails automatically show up? Thanks in advance for the info.

Thanks. We have found that most people prefer thumbnails due to the forum being global with varying browser speeds and bandwidth issues. The main reason is that thumbnails are uploaded to the server and can then be viewed forever. If the pics are just links to a photo album, the pics are lost when the album is deleted or rearranged. The thread then becomes useless with broken links.

You can click on the Go Advanced button when wanting to post, then the Manage Attachments button. You can then copy and paste your links into the spaces provided for URLs and then upload

 

[MrBracket]

I picked up a little something this morning.....

http://www.moto-mule.com/mini-buggy/minibuggy-105.jpg

With a little luck, this beast of a buggy might move under it's own power this weekend!!

 

[Poboy kartman]

Awesome job. .....love it! !!!!

 

[MrBracket]

http://www.moto-mule.com/mini-buggy/minibuggy-106.jpg

On the far left of the picture you can see the chain coming down from the engine, it's rolling around a sprocket sitting between two pillow block bearings. Connected to that via the u-joint is the reverse gearbox. In the center of the pic you can see the driveline that connects the reverse gearbox to the rear axle.

 

[landuse]

Nice

 

[MrBracket]

This morning it moved under it's own power for the first time!!!!

https://www.youtube.com/watch?v=dRPn4CSss9c

 

[Hambone]

Man that's awesome! Great work!

Did it leave marks on the pavement when you went to park it??