ST2 LT In Progress - Help me overcome its flaws :)

[ErwinBnl]

Hey there,

I've downloaded the CAD drawnings that TrollBro posted but I think that there are several things wrong?

Like:
Everything is in one drawning? There are several plate thicknesses?
Every component is placed far from each other? This will use a big sheet of unnessasairy metal?

And then, I have an problem.. the Buggy building plans from Badland uses plates with an thickness of 1/8", 5/16" and 3/16". If I calculate this to our metric system, it will never work? The plates would not fit together because of the several problems that this will cause?

Or is it just me?

[skmergen]

Great work. I also started building a badlandbuggy. It is a ST3. You can see my works here Buggy Ýmalatý .
I would like to open a thread but I could only able to work for 2 days for 1 month because of my work schedule. So if Daniel let me I would like to write my questions here.
My question is in fact related with others projects also. Did any one put a R1100GS engine it its buggy? I think it is oil cooled engine and I am concerning if it is enough in low speed off-road conditions.
By the way I make the bottom chassis with 40x40x4 mm. hollow section and upper chassis with Ø33,7x3,25 pipe. I also draw most of the plates in the plans with ACAD by myself in metric form in order to avoid mistakes. And I cut them with laser cutting machine. If anybody needs I cant sent CAD file via email. Thanks.

[Daniel Dk]

Originally Posted by ErwinBnl

Hey there,

I've downloaded the CAD drawnings that TrollBro posted but I think that there are several things wrong?

Like:
Everything is in one drawning? There are several plate thicknesses?
Every component is placed far from each other? This will use a big sheet of unnessasairy metal?

And then, I have an problem.. the Buggy building plans from Badland uses plates with an thickness of 1/8", 5/16" and 3/16". If I calculate this to our metric system, it will never work? The plates would not fit together because of the several problems that this will cause?

Or is it just me?

Hi Erwin

It's not just you! unless you draw all the tabs etc. to the same thickness as your material it will not fit togheter. I used autocad to draw all the parts from the hardcopy plans - it'll take you a few hours but it is worth it - when i got the parts back everything fitted together perfectly like a jigzzaw puzzle! it was worth every minute spent!

To make it easier for the laser-cutting guys - draw a sheet of parts for each plate thickness - i used 5 and 8 mm plates... also give them a call and ask them how close you can place the parts - i spaced mine 2mm apart

oh and they typically cannot cut holes with a diameter smaller than the plate thickness...

[Daniel Dk]

Originally Posted by skmergen

Great work. I also started building a badlandbuggy. It is a ST3. You can see my works here Buggy Ýmalatý .
I would like to open a thread but I could only able to work for 2 days for 1 month because of my work schedule. So if Daniel let me I would like to write my questions here.
My question is in fact related with others projects also. Did any one put a R1100GS engine it its buggy? I think it is oil cooled engine and I am concerning if it is enough in low speed off-road conditions.
By the way I make the bottom chassis with 40x40x4 mm. hollow section and upper chassis with Ø33,7x3,25 pipe. I also draw most of the plates in the plans with ACAD by myself in metric form in order to avoid mistakes. And I cut them with laser cutting machine. If anybody needs I cant sent CAD file via email. Thanks.

Hi Skmergen

Shure you can post your questions here - but remember i'm also a newbie

As for materials i used colddrawn precision steel tubing ø35x2 and 40X40x1.5 square tubing. for the a-arms i used Ø35x2.5 and ø28x2.5 - since the thing haven't been run yet i do not know if these thicknesses are heavy enough...

[Daniel Dk]

man - just had another look at those pictures those welds look rough! It's not that bad IRL....

[ErwinBnl]

Hey Daniel!

Last week i finally started my ST2 project but i don't have got my iron yet.. I started with drawning all the bends on a piece of wood and I bought my differential and driving axles.

I will start my own topic in just an hour or so haha.

Now i'm doing some research of how I could build my driveline the most efficiënt and strong.
That's a bit hard for me because I'm just an (ICT) student and don't really have any experience haha.

Also, i'm happy to be able to borrow an tube bender of an good friend of my but I don't know if he has the correct jig for my tube diameter. I'm going to use 35mm for the main chassis and I can't find jigs from that size on the Internet and I don't know if my friend has it.
You also used 35mm, did you have a jig?

Tip for you: Please post new reply's when you have got updates on your buggy instead of edit the first post of you. People won't notice it

Good luck with your build and I will follow it very closely.

Thanks for all your help so far with my issues.

And really.. your buggy lookes awesome! With that tires and rimms.. great!

Greetings from The Netherlands,
Erwin

[wyattboche]

Isn't the Suzuki on side of the motor suppose to be level to the chassis? Thats what I was told when installing mine. Also might wanta bring the motor down to the chassis a bit. Wouldn't that bring the center of gravity down on the buggy?

[Daniel Dk]

Originally Posted by ErwinBnl

Hey Daniel!

Last week i finally started my ST2 project but i don't have got my iron yet.. I started with drawning all the bends on a piece of wood and I bought my differential and driving axles.

I will start my own topic in just an hour or so haha.

Now i'm doing some research of how I could build my driveline the most efficiënt and strong.
That's a bit hard for me because I'm just an (ICT) student and don't really have any experience haha.

Also, i'm happy to be able to borrow an tube bender of an good friend of my but I don't know if he has the correct jig for my tube diameter. I'm going to use 35mm for the main chassis and I can't find jigs from that size on the Internet and I don't know if my friend has it.
You also used 35mm, did you have a jig?

Tip for you: Please post new reply's when you have got updates on your buggy instead of edit the first post of you. People won't notice it

Good luck with your build and I will follow it very closely.

Thanks for all your help so far with my issues.

And really.. your buggy lookes awesome! With that tires and rimms.. great!

Greetings from The Netherlands,
Erwin

Hi Erwin


Thanks for the kind words!


If by jig you mean the correct tube bending die - then yes i had 35mm die... it is an absolute necessity to use the correct die. Also DO NOT use a pipe-kinker like this:


I tried every trick in the book to make these work (Like sand in the pipe and heating it up) and failed trhe tube would either split or kink... These benders (kinkers) are only to be used for heavy-walled pipe...


On the other hand: these machines work beautyfully! Tube Bending Machinery, Pipe Benders, Tubing Notchers, Bead Rollers Be prepared to spend a fortune though . Luckily i had the die and bender availerble!


Oh - And good luck with your new buggy!

[Daniel Dk]

Originally Posted by wyattboche

Isn't the Suzuki on side of the motor suppose to be level to the chassis? Thats what I was told when installing mine. Also might wanta bring the motor down to the chassis a bit. Wouldn't that bring the center of gravity down on the buggy?

Hi Wyattboche


Short answers - YES and YES

Because it is a v-twin the front cylinder sticks out a long way pushing the seat forward, tilting the engine ever so slightly also made routing the chain a lot easier and gave me som much needed clearance between the chain and engine block.

I've been reading up on various suzuki boards and the general concensius is that the sv1000 does not like to be wheelied. However since i'm only tilting the engine about 10 degrees and not vertical like a wheelie - and i plan to add a little extra oil to keep the level above normal range, i think i will be allright...


Regarding COG. - Yes i would have loved to bring the engine further down but it is impossible because of the limited space down there. I flirted with the idear to extend the back of the cart to make enough room, but it needed a whopping 12 inches to fit in front of the drive unit... Its all about compromises i guess

[Daniel Dk]

Hi Erwin

Did another post as you suggested - thanks!

Did a little more on the Cart

Heres the rear drive:



Mounted the caliper(used one of the front calipers from the suzuki sv1000), disk, and sprocket in the box:


added bushings and a-rms all the way around :


I need to make the rear a-arms longer.. the buggy looks a little wierd with such a narrow rear axle. These a-arms are made to fit the driveshafts from the porsche 924 - i need longer driveshafts and a-arms but i need to find a source...