off road & drift buggy project build

Printable View

19-07-11, 22:19
sideways_madness

off road & drift buggy project build

i've always wanted a go kart for mainly some off roading, sliding and general arsing about, so i decided to start making one at the end of last year but done some work on it and then kind off left it like this as the back shed wasn't finished and weather was crap.

http://i76.photobucket.com/albums/j5...s/IMG_0014.jpg
http://i76.photobucket.com/albums/j5...s/IMG_0019.jpg
so a month or so ago i took back into it as i wanted it finished for the summer and for the winter when the snow comes. that and i want to start building my drift car so need to get this finished first to clear some space in the garage. got the shed finished so better working conditions, jus need to get the lights and all into it now.

some more pics:
winter caused some surface rust

http://i76.photobucket.com/albums/j5...s/IMG_0174.jpg
http://i76.photobucket.com/albums/j5...s/IMG_0177.jpg
http://i76.photobucket.com/albums/j5...s/IMG_0178.jpg
http://i76.photobucket.com/albums/j5...s/IMG_0175.jpg

Some work trying out back suspension

http://i76.photobucket.com/albums/j5...s/IMG_0622.jpg

And the front, had a fiesta steering rack in it at the start one that I had cut up and re-centered it so that the travel to each side was the same as the rack had to be shortened to leave the ends of it in line with the pivot point of the upper and lower wish bones. But the fiesta one had too many turns from side to side so went with a sierra one which is about 2.5 or so.

http://i76.photobucket.com/albums/j5...s/IMG_0623.jpg
19-07-11, 22:24
sideways_madness

Got good few of the extra added in, plenty of cutting and grinding, but it's starting to take shape now so jus need to look unto the wiring end of things. Need to buy switches and stuff to get it wired up and make some sort of dash panel.
http://i76.photobucket.com/albums/j5...s/IMG_0657.jpg
http://i76.photobucket.com/albums/j5...s/IMG_0658.jpg
And the gear change lever
http://i76.photobucket.com/albums/j5...s/IMG_0648.jpg

I then moved it over to the other side of the shed so that I could get it sandblasted, to get all the surface rust off. Messy job but made a good job of it.
http://i76.photobucket.com/albums/j5...s/2c0daffc.jpg
http://i76.photobucket.com/albums/j5...s/4984f9ff.jpg
http://i76.photobucket.com/albums/j5...s/2d357f17.jpg

I gave it a coat or red oxide primer to keep it from rusting as I still have brackets to weld on for petrol tank, radiator, exhaust, floor panel and few other bars.
http://i76.photobucket.com/albums/j5...s/e17256f4.jpg
http://i76.photobucket.com/albums/j5...s/4a5222bd.jpg

http://i76.photobucket.com/albums/j5...s/cfe961db.jpg
http://i76.photobucket.com/albums/j5...s/260d0dff.jpg
http://i76.photobucket.com/albums/j5...s/f5765876.jpg
http://i76.photobucket.com/albums/j5...s/7e8302c8.jpg
http://i76.photobucket.com/albums/j5...s/950484cf.jpg
19-07-11, 22:26
sideways_madness

i'd say some of you will like this one lol....

My home made hydro handbrake
http://i76.photobucket.com/albums/j5...s/56b7e911.jpg
19-07-11, 22:31
sideways_madness

and as it is at the min, still plenty to do,
make/buy a petrol tank
buy water hose for rad piping
make a dash panel
get clocks switches etc
finish gear linkage lever
make rear brake setup
design and make front hubs to replace heavy fiesta ones
sheet off sides and front
weld on strengthening gussets
make mud guards

http://i76.photobucket.com/albums/j5...s/e3fb882f.jpg
http://i76.photobucket.com/albums/j5...s/6ff1aa0f.jpg
19-07-11, 22:34
sideways_madness

all comments welcome good or bad:afro:
19-07-11, 22:41
ger15

Some serious fabrication there lad,looks like it will be a really cool buggy what are you using to power it ?
19-07-11, 22:42
Robbie Daly Ps13

Serious work right there......! Did u have another base to work from....! What engine u using.....! Some man hours gone into her....!
19-07-11, 22:50
SIMO

savage work there lad, looks class. Will be followin this thread.good luck with rest of build!!!
19-07-11, 22:53
sideways_madness

cheers lads, i have a 400cc gsxf suzuki bandit engine in it, its actually sharp enough but just not what i want, so i have a 919 fireblade lined up for it now jus need to get a few pound gathered up and go get it.

nay no base to work from i have wanted one of these since i was about 8 years old so had a full design done in my head lol. i was gonna draw it up 1st but just went and made it instead so far its turned out alrite. looked at plenty of pics of different ones online just.
19-07-11, 22:56
sideways_madness

all the fabrication of it has been good practice for when i go to build a drift car when i have this finished.
when i get this buggy finished i'll prob take it to some of the drift practice days at bishops court if its allowed as i seen another lad had one up at it.
21-07-11, 19:10
Robbie Daly Ps13

What did u bend the bars with and what sort of tubing did u use...!
22-07-11, 09:11
sideways_madness

Quote:

Originally Posted by Robbie Daly Ps13

What did u bend the bars with and what sort of tubing did u use...!

i used an ordinary 12ton pipe bender like this one
http://www.tool-net.co.uk/data/tools/CHV12.jpg

the pipeing on the main cage is about 32mm outside wall with about 2.5 - 3mm tubing, its all i could get around here, i wanted seamless T45 but as its not going to be used in compitition i wasnt bothered, all the arms and outside bars are made from 32mm x 1.5mm tubing really light stuff so it will bend if hit to absorbe some of the impact ie trees in a forest.
22-07-11, 09:20
Robbie Daly Ps13

Did it not crimple any of the bars as it looks like u have a very sevear bend on a few of them....!
22-07-11, 09:39
sideways_madness

Last nite I went to look at a 919cc fireblade engine, measured it all up and it looks like it'll just about fit in so when I get paid I'll go and get it I think. It's been sitting for a year or two so will need to give it a once over and check and oil everything up, there's only 17k on it so should be good enough, will make some difference over the wee 400 engine.
I'll need to see about getting a sprocket for the font with splines to suit the blade shaft and my new 508 x ring chain as I don't want to have to buy them again. Might have to make one up if I can't get one? I'll see when I get to that point
22-07-11, 09:47
sideways_madness

Quote:

Originally Posted by Robbie Daly Ps13

Did it not crimple any of the bars as it looks like u have a very sevear bend on a few of them....!

Yea I learned from the first main hoop I tried bending, it just collapsed straight away, so what I do now is don't bend steel on a cold day! If it is keep space heater in front of pipe bender so it just warms pipe slightly, then I shim both sides of the tubing in the die so that it has nowhere to move or start flattening , and it works the best,
I had started drawing a pipe bender that clamps the pipe and pulls it around a die rather than pushing the die into one point on a pipe, so need to finish drawing that and make one up as it will be a far better job. Works a bit like the way a proper pipe bending machine would work.
15-09-11, 13:46
sideways_madness

Have the fireblade engine bought, fitted and running, not getting much time at it these days but getting there bit by bit.
15-09-11, 13:48
sideways_madness

I'll get some more pics of it up next time I get back at it, need to get the exhaust made for it which is a bit awkward.
15-09-11, 13:56
PeterT

I want videos :D
15-09-11, 15:21
sideways_madness

Quote:

Originally Posted by PeterT

I want videos :D

I'll get videos up when I get it driving, good bit to do to it yet, few things I want to change on it after testing it with the 400cc engine, need to buy some Rose joints and alloy radiator too.
15-09-11, 15:54
Noel

nice work fair play
15-09-11, 16:06
babyeater690

savage work lad cant wait to see this finished serious work
23-10-11, 14:36
sideways_madness

Another bit of a well needed up date...
i had it up and running with the 400 engine and it just didnt have enough go for the sideways action or to scare me enough lol
so out it came and i have now replaced it with a 919cc honda fireblade, which has about twice the horsepower.
still a few things left to get sorted before i strip it down and paint it.
Brakes now sorted all round, got new custom braided brake hoses made and have them fitted.
Gear lever linkage sorted now to work with the fireblade engine.
Dash now made and fitted, still some clocks and switches to be added.
Front suspension modified for more lock, jus need to modify shock set up.
Clutch and throttle cables, linkages and brackets sorted
replaced the cloth bucket seat with a leather bucket seat.
Chain and sprocket set up now suited to fireblade.
Waiting on a petrol tank and alloy radiator.
Made a start on paneling the sides.
Got a set of magnesium revolutions - really light.

http://i76.photobucket.com/albums/j5...s/8987ab9a.jpg
http://i76.photobucket.com/albums/j5...s/6fc7d706.jpg
http://i76.photobucket.com/albums/j5...s/f457cd3a.jpg

all thoughts and suggestions welcome
29-10-11, 19:01
flatout

great work, looks like its going to be fun
14-11-12, 14:43
sideways_madness

i forgot i had this build thread on here, i must update it
14-11-12, 14:50
sideways_madness

Got a pic of the exhaust sitting in place
http://i76.photobucket.com/albums/j5...s/0fd4f910.jpg
petrol tank and alloy rad
http://i76.photobucket.com/albums/j5...s/cadd5e64.jpg
So made a start on getting it fitted into place, cut some more box section and made the base frame around it.
http://i76.photobucket.com/albums/j5...s/01720c8e.jpg
http://i76.photobucket.com/albums/j5...s/93c52631.jpg
Also cut out a place at shock mount bracket for a tail and brake light. Pass no remarks on welds here, only few blobs to hold it together, gonna weld it up when I have her stripped.
http://i76.photobucket.com/albums/j5...s/6c961079.jpg
14-11-12, 14:50
sideways_madness

Got a bit more done to this,
Fitted fuel tank and fuel pump and made brackets to suit, also made a fuel swirl pot and piped all up. Still need to make a mounting bracket for it.
Also got radiator fitted, just need to make a removable top mount, also got it piped up, just need to make a few clamps to hold the pipes in place.
I got the mudguard brackets made and fitted on one side, to mount the front one I made a plate with mounting holes and welded it to the top of the hub so it will turn with the wheel.
http://i76.photobucket.com/albums/j5...s/8431f571.jpg
http://i76.photobucket.com/albums/j5...s/c04ae761.jpg
http://i76.photobucket.com/albums/j5...s/8e8a091b.jpg http://i76.photobucket.com/albums/j5...s/f54df955.jpg
Never mind the messy garage lol
14-11-12, 14:51
sideways_madness

got back on track with this, stripped it all down so i could get it fully welded up as alot of it was just tacked together, mainly all the brackets.

lining everything up and thinking of what all brackets i needed was the slowest part.
but i should have all welded up soon an ready for a lick of paint.

http://i76.photobucket.com/albums/j5...s/bb8e42df.jpg
http://i76.photobucket.com/albums/j5...s/c98b78a4.jpg

looking forward to a proper test drive:excited:
14-11-12, 14:52
sideways_madness

Frame now painted the nite, bit late on the go but just want it done at this stage to get at other stuff.

http://i76.photobucket.com/albums/j5...s/ec216ec3.jpg

Various mounting brackets an pedals and stuff painted now an all the suspension A-arms are painted too. Might have her going the morrow......I wish.
http://i76.photobucket.com/albums/j5...s/58e130d5.jpg

http://i76.photobucket.com/albums/j5...s/9db48347.jpg

Made a start this evening on getting all assembled back together.

Got the engine in and some of the suspension arms.

http://i76.photobucket.com/albums/j5...s/e29e575d.jpg
http://i76.photobucket.com/albums/j5...s/41d9545e.jpg
http://i76.photobucket.com/albums/j5...s/8fe2bfb3.jpg
http://i76.photobucket.com/albums/j5...s/5b8901cc.jpg
17-11-12, 00:04
sideways_madness

some more pictures

http://i76.photobucket.com/albums/j5...s/a2d86818.jpg
http://i76.photobucket.com/albums/j5...s/e8a8cafd.jpg
http://i76.photobucket.com/albums/j5...s/7858fb59.jpg
http://i76.photobucket.com/albums/j5...s/14bf43ec.jpg

Some from Eglington

http://i76.photobucket.com/albums/j5...s/b24c3ca1.jpg
http://i76.photobucket.com/albums/j5...s/1ee1e720.jpg
17-11-12, 00:05
sideways_madness

Some more action pics from the drifting
the photographers done a good job on the pics
http://i76.photobucket.com/albums/j5...s/d7d31075.jpg
http://i76.photobucket.com/albums/j5...s/69a42f65.jpg
http://i76.photobucket.com/albums/j5...s/b8095b5b.jpg
http://i76.photobucket.com/albums/j5...s/fc434530.jpg
17-11-12, 00:06
sideways_madness

Here's a wee video of her going at a family fun day I was at

http://www.youtube.com/watch?v=VcRt6...e_gdata_player
17-11-12, 00:15
crash&burn

link not working dude,,say theres sum serious fun in this,,,,a well good built too
17-11-12, 00:31
sideways_madness

Try this one maybe?
http://m.youtube.com/watch?v=VcRt6kYDPFs
17-11-12, 00:37
sideways_madness

Quote:

Originally Posted by crash&burn

link not working dude,,say theres sum serious fun in this,,,,a well good built too

Awe it's fun alrite, she's snappy with the short wheel base but can kind of control it with the throttle lol:cool:
17-11-12, 00:38
dermot-r32

Steveys fireblade buggy - YouTube

thats it i think??

serious machine man!!! must be mental to drive!!