View Full Version : Protodie- XTC buggy, chop, cut ,rebuild

07-21-2011, 07:50 PM
Most of my projects are all new design & build from the ground up.

This log is about a customers buggy that we chop cut rebuilt.

Customer brought us a XTC 2 seat buggy that he wanted us to redesign & build to put our GSXR 1000 / RPM gear box engine cradle, A arms , Fox shocks, rear wheel kits ,,,etc...

This buggy had very little travel,,,,and the front A arms are scary small:IMO

Here is the buggy before

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/281386_244093138942243_205230589495165_920545_7554 954_n.jpg

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284106_244093512275539_205230589495165_920546_1753 959_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/285379_244094095608814_205230589495165_920547_6275 862_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/281240_244094742275416_205230589495165_920549_6216 726_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/284396_244094815608742_205230589495165_920550_8128 516_n.jpg

07-21-2011, 07:56 PM
So I brought it in to the shop & started re-creating the chassis in 3D CAD to start the design process.

Once I have all the main chassis points re-created in CAD, then I merge in our existing designs and components, E cradle RPM, A arms, suspension,,,etc.

currently working on the rear only

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284905_244095395608684_205230589495165_920552_6470 72_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283924_244095725608651_205230589495165_920555_6959 065_n.jpg

07-21-2011, 08:01 PM
Got the rear designed,,,,,,,,,,,,time to start cutting.
Kinda fun for a change,,,since I normally build from scratch

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/284325_244096602275230_205230589495165_920559_2486 372_n.jpg

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284132_244097388941818_205230589495165_920560_4808 616_n.jpg

http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/285095_244098018941755_205230589495165_920561_3836 0_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/281868_244098068941750_205230589495165_920562_2796 22_n.jpg

07-21-2011, 08:04 PM
Customer very happy with the rear design & work,,,,,,,,,,,,,so we move on to the front and start to design

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284243_244098102275080_205230589495165_920563_2242 170_n.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284644_244098138941743_205230589495165_920564_7456 776_n.jpg

07-21-2011, 08:13 PM
He's gonna be really happy when it's done.He'll be totally amazed at the difference won't he!

07-21-2011, 08:14 PM
Thats one hell of a shop you have....... All I can say is "Jealous!!"

One day I will be to that level.... one day

07-21-2011, 08:14 PM
I like the buggy and LOVE your shop!

Nice job.

07-21-2011, 08:21 PM
Thanks Guys :D

He stops in every week & ,yes is very happy.

This buggy will be lighter than ours, as it is mostly just for dunes & not racing,,,,,,,,,,,,,only with the same parts & performance so it should scream quite nicely in the dunes.

alright ,,,,,,,,,,,,,,,design done, start cutting off all the front components and grinding

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283227_244098232275067_205230589495165_920566_3013 50_n.jpg

he wanted to keep his fuel cell. There is room for one of ours later if needed

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/281424_244098272275063_205230589495165_920567_4457 433_n.jpg

07-21-2011, 08:30 PM
Front has 17" of travel and uses our single seat lower A arm. Upper A arm had to be lengthened to achieve proper suspension geometry & performance.

Rack was extended and extra guide & supports were added to achieve zero bump steer.

Using shock mock up tubes set for full droop and full compresion.

This allows me to use the shock to control the limits of suspension

http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/283140_244098318941725_205230589495165_920568_5668 528_n.jpg

http://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284196_244099435608280_205230589495165_920571_1948 469_n.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/284549_244100538941503_205230589495165_920576_6775 3_n.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/283903_244093068942250_205230589495165_920544_5631 401_n.jpg

07-21-2011, 08:32 PM
Nice Work Jody!

MC@ Performance Fab
07-21-2011, 09:49 PM
Your really going to try running full droop at that much angle?

07-22-2011, 05:12 AM

try was a long time ago on earlier buggies.

yes, while it looks extreme and right to the limit,,,,,that's because it is.

same stuff as on our single seat & 2 seat buggies,,,,zero failures, and performs great

07-22-2011, 12:30 PM
Maybe XTC should pay you to redesign their cars. I can't say too little about them.

Nice work Jody!

07-23-2011, 09:02 AM
Those floor drains still crack me up...LOL Looks really good!


07-23-2011, 09:26 AM
Wow, quite a difference in the look and I bet performance too. I wasn't to crazy about the buggy before the mods, the frame just didn't look finnished, but I sure like it now. Great work as always.

07-23-2011, 12:50 PM
Really shows what great skills you have to take another companies car and retro fit it and re build it to turn out so well.
Great work.. looks cool. I look forward to seeing it perform. Post back pics after it goes out so we can see it running.

Nicely done.

oh hey you mind posting the new specs.. length width wheelbase info?

07-23-2011, 07:41 PM
Impressive. I'm also wishing one day I can get to that level.

07-24-2011, 01:26 PM
Thanks guys,

Customer picked it up Friday and is very happy. He does not plan on having it done until sometime next year,,,,,which is too bad.
I hate seeing things go,,,unfinished.

wheel base is 96"
front track width is 72"
Rear is 70"

overall length 124"

on to the next project

07-24-2011, 07:56 PM
Great work!

05-09-2012, 03:28 PM
Bringing this thread back from the dead...

The rear removable section you have there. Was the made in house by you or purchased out? I am putting the exact same engine in my triple-E and want the same setup as you have going there. Looking for ideas on how to adapt it to the smaller chassis I have. Only differnece is that I planned on using a carrier instead of a trans.

05-09-2012, 04:05 PM
Wow, nice rebuild....missed this one and what a transformation!

05-09-2012, 04:26 PM
Thanks :)

We designed and manufacture the engine cradles,,,and all the parts

Live axle engine cradle & engine cradle for the RPM reverse gear box are available

width outside of tires ends up 64-68" wide depending on wheels

parts are available here

here are some complete assembled pics

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/468055_418605604824328_205230589495165_1508353_169 481755_o.jpg

http://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/467301_418605824824306_205230589495165_1508355_659 115452_o.jpg

http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/414614_418605941490961_205230589495165_1508356_497 321370_o.jpg

http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/461475_418606114824277_205230589495165_1508358_173 0362452_o.jpg

05-09-2012, 05:24 PM
geez... i missed this one too. fantastic job Jody!

05-09-2012, 06:11 PM
Very nice products! Thank you for the pics, gives me a better idea of size now.

General Lee Stupid
08-25-2012, 10:34 PM
Nice build. Im hoping to do very similar to mine here soon.

09-10-2016, 05:37 PM
so I had to dig deep to find this old thread.

I did a major overhaul on this XTC buggy 5 years ago and customer was going to finish it himself.

5 years later,,, he brings it back same as it left my shop.
now we get to finish it , powder coat , body , spoiler,,,,make it bad azz

I see most of the pic links are dead now, so I will re post the transformation

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/284106_244093512275539_1753959_n.jpg?oh=a6d37cc596 0dd7ff2d1c342f04940d2a&oe=587F6A9B

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/285379_244094095608814_6275862_n.jpg?oh=a55b5e146b a1999bb67e2247049d0543&oe=58781C19

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/281240_244094742275416_6216726_n.jpg?oh=83f72dfce8 3b2bdcc94fe358f5ee8298&oe=58759FA3

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/284325_244096602275230_2486372_n.jpg?oh=1988b69d5f 50bf95a2829ceabcf53839&oe=5841ADDE

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/285095_244098018941755_38360_n.jpg?oh=a51ba1be1b65 e0937bb39918e8e22b4d&oe=5876A948

https://scontent-sjc2-1.xx.fbcdn.net/v/t1.0-9/283227_244098232275067_301350_n.jpg?oh=13624e93607 ed81832c373e682305e03&oe=5878D303


These were 5 years ago,,,,,,, now pics from the past week,,, phone pics, some are blurry

https://scontent-sjc2-1.xx.fbcdn.net/t31.0-8/14305434_1252859028065644_1673784087734929505_o.jp g

https://scontent-sjc2-1.xx.fbcdn.net/t31.0-8/14310577_1252859228065624_9099322710612569222_o.jp g

https://scontent-sjc2-1.xx.fbcdn.net/t31.0-8/14249939_1252859331398947_2866047212336573981_o.jp g

https://scontent-sjc2-1.xx.fbcdn.net/t31.0-8/14241508_1252859454732268_5050732241315291864_o.jp g

https://scontent-sjc2-1.xx.fbcdn.net/t31.0-8/14231893_1252859554732258_3777767599545037978_o.jp g

09-13-2016, 05:49 AM
Now this is the kind of thread resurrection I like, Jody! Can't wait to see it run. Did the customer do the bodywork? He made it his own, if so.

09-13-2016, 11:28 AM
Ahhh, he brought it back! Well. I guess he took it to the right place. Looks really cool too. I like the chassis angles, it looks fast just sitting there.