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Old 12-08-2010, 02:21 AM   69 links from elsewhere to this Post. Click to view. #1 (permalink)
Tom

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Default Tom's Buggy Build

Hey everyone,

Well i have been thinking about building a go kart / Buggy for a while and decided to go for it. I originally wanted a fast shifter kart, after watching many of the videos on youtube, i saw that many people were putting full size super bike engines into them which made me think "i need a BIG motor ." after countless hours of searching and modeling in 3D Max i came up with a super nice 1000cc shifter kart model.

my past model:


But after many thoughts about where i was going to go with it being so low to the ground and noisy for that matter i decided to scrap that idea. So after a couple of nights searching for some type of go kart which could go both on and off road, and still be stable at high speeds i bumped into David (daaboots) buggy. David's buggy looked perfect for the conditions i was to use the go kart for. So I sent him an message about dimensions etc of his buggy and replied back with all i needed to know.

this is just a rough draft of what my buggy is going to look like (David’s buggy is at the start of the video just to give Youtube viewers some visualization what the buggy would look like in the real world, the 3d model is on about 45 seconds into the video)


He advised me to check out this forum and post my build if ever i was to start building, so here it goes...


(5th December 2010)
Ok well last Sunday I found a neat little engine, the CBR600rr. The last owner was a Motorcycle mechanic who wanted a more powerful bike so he sold me his CBR600RR engine. The engine i bought only had 7000km on the clock, and looks in pristine condition (pictures do not do it justice).
















(6th December 2010)
I did not get much done as planned; I cleaned out the airbox, and gave everything a good clean. I wanted to mount my engine on a stand so I was able to work on the engine as the engine does not have any exhaust, radiator, or any electrics hooked up to it, but did not manage to find anything to stand the engine onto. I also transported the engine to school, so in my two mechanics classes i am able to work on it pretty much everyday.

(7th December 2010)
Well today was not the best of days.. I came to pick up the engine and the carb fell off the engine as the hose clamps were loose. So now I have to start from square one and take off the airbox to get to the hose clamps to tie them down. I did not manage to get my engine on a engine stand as all the one's in the shop are for car/truck engines... so i have decided to start building the frame and from there I can mount the engine and put everything on while the engine is on the frame. I also got done building plans for the lower part of my go kart frame, I don't know if it will work out, but mostly the frame is designed around David’s buggy, except mine is obviously larger as I have a larger engine which is actually causing me problems of where to mount stuff. I am also thinking of going independent suspension in the rear part of the frame instead of the live axle. I also changed how the engine was fastened to the swing arm, so now the engine actually sits in the frame not on the swing arm which could cause major problems for me as my engine is obviously allot heavier compared to a 250cc dirt bike motor.

(8th December 2010)
Today I got 28 foot of 1 inch square tubing; I went a little too small wall thickness I think as when I hold the tubing from each end and sway the tubing up and down the tubing does bend quite a bit, but I think once I have lots of reinforcement around the frame it will be fine, I don’t think I will be jumping it (although I will add support just incase). The reinforcement is pretty much just for the torque the engine puts out. Today I also cut out the middle of my frame, not much as I had to replace and line up my band saw as I was cutting about 20 degrees to the left. I think tomorrow should go much more smooth as I have everything set up to cut, weld, and admire.

(9th December 2010)
Well today I got all the cutting of base done, and tacked everything up. I had some advise of my mechanics teacher that 3 inch length in between front A arms (the space in-between the arms) were just to small and would snap on a little impact from the front, so I have extended my frame 6 inches to compensate for this and to overall make my arms stronger... I do have pictures, but they will come tomorrow as I left my camera at school.













(10TH december 2010)
Ok so today I got done cutting the frame support, did not manage to get the engine mounts in but everything is cut and ready to be welded. In the pictures it shows the frame with many of the frame missing because I forgot to shoot some pictures before I shut down for the day.







(13th december 2010)

Ok so not much done today, got a whole bunch cut, but my friend (also my welder) did not turn up so I have a lot to catch up on as far as welding goes. I did not take any pictures as I forgot my camera and also couldn't really show much as nothing was welded to the base.

(14th December 2010)

I finally got some welding action in today! Although it was for only an hour, I did not need to cut anything and so it all went somewhat smooth. As you can see from the pictures, I have the engine mounted (although I did rush it and is off 1.5 inches from the centre, it will be an easy fix) and also got done some welding of the frame, check it out…









(15th December 2010)

Ok well today did not go so well, I must of made a dosen mistakes rushing to get the frame done… today was one of the days where I wish I would have done nothing… just 1 step forward two steps back…










(16th December 2010)
I got every thing straightened out today. Im' very happy with my progress so far, i took the engine back out to weld the underside of my frame. The frame is pretty much how it was yesterday except everything is straight and ready for the second section (round tubing) to go on.

(17th December 2010)
Just a little cleanup today, I installed the rear tubular section of where the engine sits inside, it’s kind of hard to explain but I will get some pictures up soon. I also started to bend tubing for my frame, this is actually really hard to be honest, I have had to cut the tube into sections just so I could fit it into my machine.


more to come....

Last edited by Tom; 12-19-2010 at 04:31 PM..
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Old 12-08-2010, 07:36 AM   #2 (permalink)

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Default Re: Tom's Buggy Build

Welcome to MBN Tom
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Old 12-08-2010, 08:55 AM   #3 (permalink)

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Default Re: Tom's Buggy Build

Hey Tom!

Welcome to MBN indeed.. nice that you started your own threat. The story is also very clear to me.
Have fun and keep us posted on progress.. I'm already curious about your build.

Could you show us some of your 3D models? If you have questions.. ask! There are a lot of experienced (buggy) engineers on this forum that usually have an answer. Better than you need to change things afterwards..

Erwin
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Old 12-08-2010, 12:08 PM   #4 (permalink)

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Default Re: Tom's Buggy Build

These mc engines are so ridiculous in a shifter cart..

I think you should scale it up just enough to justify the power and consider doing a cage and seat belt. like a welter weight mini sprint type thing. 600 cc micro indy would be some sick shiz!! I can't wait to see what you come up with.

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Old 12-08-2010, 01:56 PM   #5 (permalink)

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Default Re: Tom's Buggy Build

Welcome to the site man you have come to the right place to find lots of very useful info. I think you may have to ditch the swingarm idea if you want to do independent rear suspension. The engine has to be sitting on the frame to a rear carrier of some sort then you can use independent suspension. The swing arm is the suspension, and will only allow you to use a solid axle. Unless I didnt understand your post, you may have to remove the swing arm all together.
Good luck on the build, remember have fun and post LOTS of pics.
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Old 12-08-2010, 02:14 PM   #6 (permalink)
Tom

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Default Re: Tom's Buggy Build

@ProtoDie
Thanks for the warm welcome!

@ErwinBnl
Yes I will keep the thread updated, for some idea on my work you can check out my Youtube channel, racingredneck21. I have a bunch of work on there, although my buggy is not the most accurate (only spent a day on it), the shifter kart is more than finished . I will post some HD renders if you would like, once I get home.

@jersdunz
I think I have changed my mind from the shifter kart idea, i am going with more of a low buggy look. I do have many shifter kart tracks around my area, but none which allow 600cc engines .

@dirtreaper
I was thinking of doing a rear swingarm like a motorcycle works. Although i would not just have the two forks coming down to the axle, i would have more of a triangular frame, much like davids custom buggy, just much shorter.
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Old 12-10-2010, 09:27 AM   #7 (permalink)

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Default Re: Tom's Buggy Build

Hey, welcome to the site! Glad to be an inspiration to you! That motor is gonna haul! If you do go with keyed shafts and a swing arm, you'll want to consider using a 1 1/4" or a 1 1/2" shaft with 3/8 keys. There is a build on here where someone used 3/8 keyed shafts - new updates to an old build

Good luck and keep the posts and pictures coming!
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Old 12-10-2010, 11:19 AM   #8 (permalink)
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Default Re: Tom's Buggy Build

Thanks David, im glad you found my thread alright. I will not be making my swingarm till later next week as i want the majority of my framework done before i start on that, but thank you for the tips, i will keep that in mind

i actually have another question for you, i have seen the way you mounted your engine by those engine brackets, did you make those? if so how? as i want to get my engine in the buggy either today or monday.

Last edited by Tom; 12-10-2010 at 11:42 AM..
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Old 12-10-2010, 01:47 PM   #9 (permalink)

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Default Re: Tom's Buggy Build

Hey Tom,

The front mount was the original mount off the motorcycle. I made the rear mounts.

David

Quote:
Originally Posted by Tom View Post
Thanks David, im glad you found my thread alright. I will not be making my swingarm till later next week as i want the majority of my framework done before i start on that, but thank you for the tips, i will keep that in mind

i actually have another question for you, i have seen the way you mounted your engine by those engine brackets, did you make those? if so how? as i want to get my engine in the buggy either today or monday.
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Old 12-10-2010, 02:15 PM   #10 (permalink)
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Default Re: Tom's Buggy Build

Ah ok, too bad i do not have the originals for my motor, i guess i will just have too make some brackets from square tubing.

whats the dimensions are the inside of the swingarm, from inside tubing to inside tubing? (where the sprocket and disc brake go)
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