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    GVouvakos ST3 Build
    #1
    Senior Member gvouvakos's Avatar
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    Hello everybody!

    After reading hundreds of posts and other people's builds, finally my own topic!

    Last summer i decided to start building my own buggy. Due to lack of money and time I never started one. One year ago, I registered myself in minibuggy.net, bought the st3 plans from Badland buggy and started reading other people's builds and searching for parts.

    A little bit about myself.

    My name is Giorgos (same as George) and I live in the small island, Cyprus. I am 17 years old and I have been fabricating and welding since i was 13. At the university i will be studying civil engineering.

    I have just ordered the steel tubing and hope to get them in the next couple of days. I ordered 35mm OD tubing for the main structure, 40mm square tubing for the chassis and 27mm for the suspension arms and diagonal reinforcement.

    I am very lucky because i have free access to professional mig tig arc welders, professional blade saws, laser cutter, bench drill and lathe. I want to fabricate most parts myself in order to save money. However, the only thing that will cost me a lot are the air shocks. The shipping alone is 220 dollars + 800 for the shocks and another 17% VAT

    I do not have the engine yet, but i have called an insurance company in my area and i will go to the place where they store their crashed motorcycles. I will get a v-twin engine, 600cc and use a homemade gear reduction box to have good acceleration

    The buggy will be driven in mountain trails so i do not want high speed but high torque.

    I have not yet decided about the drive line, but most probably i will use tractor u-joints with trailing arms and homemade hubs. I really liked TTGInc's speed reduction box so i will make something similar.

    With the help of God , this weekend i will start welding the chassis and main frame. Then start the front suspension and steering system. I hope to give it a test run in less than 3-4 months. I am so so excited and i can wait to get started.

    I hope that you will follow my build

    Greetings from Cyprus
    Giorgos
    Last edited by gvouvakos; 07-19-2012 at 06:42 AM.
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    Re: GVouvakos ST3 Build
    #2
    Junior Member samram13's Avatar
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    good luck George, glad your with us
    keep the wheels underneath you. it wont hurt so much when you come down...
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    Re: GVouvakos ST3 Build
    #3
    Senior Member gvouvakos's Avatar
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    There was a small update in my build. Today I tacked the chassis together. And cut the tubes for the front A-arms. On monday i will go to a shop to have my tube bend. And hopefully start the main frame. Can someone suggest me a good place to buy my bushings from ?


    Last edited by gvouvakos; 08-03-2012 at 02:11 PM.
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    Re: GVouvakos ST3 Build
    #4
    Senior Member gvouvakos's Avatar
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    Front A-arms are now fully welded

    Last edited by gvouvakos; 07-15-2012 at 01:20 PM.
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    Re: GVouvakos ST3 Build
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    Senior Member ErwinBnl's Avatar
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    Hey!

    Nice to see you have started your own build! The start is made...

    Funny to see that the first 2 rows of your topic starting post are the same as my topic haha


    Good luck and keep the photo updates coming!

    Erwin
    I'm building my personal Badland's ST2 Long Travel
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    Re: GVouvakos ST3 Build
    #6
    Senior Member gvouvakos's Avatar
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    Erwin. You got me . I had no idea how to start my topic so I "borrowed" the 2 first lines from your topic. I hope you do not have copyright laws.

    No wait. It is not exactly the same. I have added a small phrase " and other people's builds"
    Last edited by gvouvakos; 07-15-2012 at 01:23 PM.
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    Re: GVouvakos ST3 Build
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    Senior Member gvouvakos's Avatar
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    Hi. I finally got my bended tubes so i was able to continue with the frame. I finished tack welding the frame. Tomorrow finish the reinforcing and finish all the welds. I also got my laser cut plates for the front uprights, A-arm mounts and shock mounts.








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    Re: GVouvakos ST3 Build
    #8
    Senior Member gvouvakos's Avatar
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    God my rod ends today. 5/8 teflon lined with reducers.

    Damn it. I am now missing one of the lower shock mounts. i have no idea if i got 8 from the laser cut shop but now i have 7.




    And paint the frame with primer.
    Last edited by gvouvakos; 07-19-2012 at 07:20 AM.
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    Re: GVouvakos ST3 Build
    #9
    Senior Member gvouvakos's Avatar
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    Front uprights fully welded. Tomorrow i will go shopping for sanding discs, and grind them. I got a teflon rod to make my bushings. I hope by tomorrow have my bushings ready so i can assemble the front end

    Last edited by gvouvakos; 07-19-2012 at 11:29 AM.
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    Re: GVouvakos ST3 Build
    #10
    Senior Member gvouvakos's Avatar
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    I was able to make my bushings on a lathe and threats on my axles

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