PDA

View Full Version : Mini 1275 to FJ 1200



FJ1200Buggy
12-28-2012, 06:53 AM
Buggy with Mini1275 engine(1968)

http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20120707_164936_zps1c56f040.jpg

Mini 1275 cc Buggy off road - YouTube (http://www.youtube.com/watch?v=5BujFcUNIek)

Mini 1275 cc buggy offroad 1 - YouTube (http://www.youtube.com/watch?v=H16CyDLOgXc)

Mini 1275 buggy Q4Q 2011 (up) - YouTube (http://www.youtube.com/watch?v=A1dlj5ygfB4)

http://www.youtube.com/watch?v=-hucnE8YoOw

Now:

http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20121202_122507_zps01a3dd10.jpg

Mini diff with sprocket-for the FJ1200 engine

http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20121228_151415_zps9790be1d.jpg

Any ideas to close the openings in the diff?

fabdaddy55
12-28-2012, 01:29 PM
make little 1/8 plates a bit bigger than the hole and weld them up
then drill and tap a hole in 1 of the plates for a grease zerk
then put a half a tube of grease in it

FJ1200Buggy
12-28-2012, 11:35 PM
Thanks, but can I weld on cast iron?

millbilly
12-29-2012, 12:08 AM
I would think it is cast steel... Cast steel you can weld easy. Cast iron.....Is something else. Can you get one to try welding on?? Warm it up, weld and cool down slowly.

E7018 or allstate 275. Mig, Hard wire E60. I think that's the number. Or a S.S. rod or wire.
.

FJ1200Buggy
12-29-2012, 02:23 AM
Thanks, I was also thinking of using a large cv boot.;)

fabdaddy55
12-29-2012, 03:27 PM
my diff is the same as yours and yes you can weld to that housing. I think a CVboot would not keep the grease where you want it.
centrafugal forces will throw the grease out the holes and into the boot,imo

FJ1200Buggy
12-29-2012, 11:34 PM
Good point, do you also have a Mini diff?
What engine do you have?
Thanks

nutz4sand
12-29-2012, 11:43 PM
What amazes me is those bearings on the diff holding the pull. Do you have them bolted "flat" so that they are being pulled on sideways or are they mounted so that under load the bottom is being compressed by the pull of the engine?

I have seen them both ways and as said above the abuse they will take amazes me.

Neat buggy. I am going to go watch the videos now but the net here is kinda slow tonight so may be a bit....

FJ1200Buggy
12-30-2012, 01:43 AM
I am going to bolt them flat onto(on top of) the chassis, so the engine will pull on their bolts, do you think there could be problems?

nutz4sand
12-30-2012, 01:48 AM
I doubt there will be issues as I said I have seen those kinda bearings take crazy abuse but myself I would want the flats of the bottoms being pulled right towards the engine just to feel better behind the wheel. I hate to build a problem into something if I can help it.

Also I will point out if you look for the user Nikken on this site there are not many harder than him on a buggy (This guy get airplane kinda airtime) and he has a jackshaft setup with these bearings like this. BUT he does have a geardown AFTER the bearings so that does make it easier on them.

FJ1200Buggy
12-30-2012, 02:26 AM
Nicken has more power and i think weight, so those bearings should work. I wish I had his suspension, another problem I have is that I only have rear brakes.....and they are drums.[smilie=tr_rip.gif]

FJ1200Buggy
01-06-2013, 01:01 PM
I put a soft-drink bottle over the diff and heated it with a blowtorch, it shrank and molded perfectly around the housing without leaks, hope it lasts[smilie=jumping.gif]http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20130104_201443_zpscf24dea3.jpg

custom39
01-06-2013, 02:32 PM
Now that is thinking out of the box!!!

The diff gets very hot so it probably will melt....see what others say, I like when things like this work!

you may want to shrink a few more bottles on top of what you did...help with the heat the diff will create....

FJ1200Buggy
01-06-2013, 02:51 PM
Thanks, it could but at least it costs nothing and it cant do any damage. What causes the diff to become hot? Is it the chain? I don't think I will get another bottle over, I struggled to get that one over after many failed attempts and I don't think it will help.
We will just have to wait and see.

ironknot
01-06-2013, 05:37 PM
Good thinking. I have seen an article in a magazine a while back that showed a diff covered similarly in fibre glass. May solve the heat issue.

Edit: Could use the bottle as a mould?

custom39
01-06-2013, 09:45 PM
Ironot is thinking out of the box!!! great idea!!!

FJ1200Buggy
01-06-2013, 11:11 PM
Good thinking. I have seen an article in a magazine a while back that showed a diff covered similarly in fibre glass. May solve the heat issue.

Edit: Could use the bottle as a mould?

Thats a good idea, if the bottle doesnt work i will try it.
Thanks

FJ1200Buggy
01-13-2013, 11:53 AM
Buggy with the fj1200 engine http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20130113_155705_zps8bd9803b.jpg
http://i1285.photobucket.com/albums/a587/Erik_Steynberg/20130113_155625_zpsa0e84a83.jpg
Unfortunately I didnt take pics during the process, all that still needs to be done is the axles, exhaust, wiring, radiator mounts and some other small things. Hopefully it will be fully running by next weekend, I will upload some more photos later.
It doesn't have reverse yet but later on I will use a starter for reverse.

FJ1200Buggy
01-17-2013, 11:34 AM
Tuesday when I went to get quotes for the exhaust manifold I loosened the ropes at the first place and forgot to fasten them after deciding on another place,I went around the first corner and......[smilie=tr_oops.gif] luckily some bystanders helped me to get it back on the trailer.I received it today and fired up the engine, I will post a video shortly [smilie=jumping.gif][smilie=ecstatic.gif}

FJ1200Buggy
01-17-2013, 12:52 PM
FJ1200 buggy first (actually second) start. - YouTube (http://www.youtube.com/watch?v=Xgtxdh1h8QM&feature=youtu.be)
Now it just needs a good service and cleaning, does anyone know why that cloud of black smoke appeared?
Thanks

FJ1200Buggy
02-16-2013, 10:20 AM
...

FJ1200Buggy
02-16-2013, 10:44 AM
I connected the axles today and temporarily the wires and took it for a spin, the power is incredible[smilie=ecstatic.gi: and it is very responsive but, for some reason the rev counter isn't working,does anyone have any ideas?
Thanks

Chikin
02-17-2013, 08:28 AM
It's a slow weekend for responces. It's a holiday weekend here in he states. Presidents' Day.

I don't know the answer but give it a few for people to return.

FJ1200Buggy
02-22-2013, 12:19 AM
So nobody knows about the tach, it also seems that the battery isnt charging?

FJ1200Buggy
04-07-2013, 11:18 AM
I sorted out the issues with the battery, but after riding on the farm the 2 middle cylinders lost their spark, I cleaned all the connections but still, no luck.

Chikin
04-07-2013, 11:27 AM
Maybe bad plugs??

custom39
04-07-2013, 07:13 PM
If you lost the middle 2 cly....you probably lost a coil, fj1200 1 and 4 share a coil 2 and 3 share a coil....first check and make sure you have a good ground to the body of the coil (you can run a wire from the mounting post directly to a good engine ground). next I would swap the wiring on the 2 coils, after you do that you should lose cly 1 and 4...if so bad coil, most of the time it is due to grounding.... but have had the coils go bad too.

BTW....the grounding problem can also affect your tach...[smilie=whistle.gif]

Chikin
04-07-2013, 07:42 PM
Oh yeah.... What he said! Ha

FJ1200Buggy
04-08-2013, 04:56 AM
Thanks, I will try that as soon as I have time.

FJ1200Buggy
06-18-2013, 06:10 AM
I finaly got the time, or the courage to test the other coil, both work but the middle one wont fire when connected. After a short while of testing both the coil that doesn't fire as well as the ic-ignitor get a bit warm.
Thanks, Erik.

FJ1200Buggy
08-09-2013, 09:30 AM
I got an idea for reversing, probably a dumb one:D
It was a dumb one.....

Chikin
08-09-2013, 09:52 AM
Yeah that will not work. It will cause major issues and the motor is only made to cycle one way. Forward!

It sounds like it would work in text. But it's the worst possible thing you could do to a motor.

Besides the starter only extends with the natural starting motion. It would not start or engage if ran in reverse.

FJ1200Buggy
09-15-2013, 07:35 AM
I fried my cdi and coils and replaced them with ones from a Fj1100.
I put in extra fuses between the cdi and coils to protect them and started the engine. As soon as I revved the engine the fuses as well as the main fuse blew, I replaced all the fuses but now it doesn't have spark at all.:eek:
Any advice? Thanks.

FJ1200Buggy
04-28-2014, 04:31 PM
Got my Dyna ignition system a few weeks ago and completed the wiring over the weekend, took it to a trail sunday for some testing then this happened, had to drive like that for a few k's to get to the trailer, hit a bump that I didnt see and bent the sideshaft:(
http://photos-3.dropbox.com/t/0/AAChjX1fcmWbHlzGbhH9Z1SdsAamfT7VLw82mZo7JZiy4Q/12/128453478/jpeg/640x480/3/1401282000/0/2/20140427_141917.jpg/AkjP4KLEpwYXcw-l9WZhVbfMeZMbZlLUYzV06SARFyA
http://photos-4.dropbox.com/t/0/AAD8FMFohobD3Ngmjx9rBZk05m5A4Lz-aV6emfTZrcKjBw/12/128453478/jpeg/640x480/3/1401282000/0/2/20140427_141859.jpg/XeafYGBEIF8jMVqPLzrGEbvNcVOGQWnCxGBOBb6d-LYhttp://photos-3.dropbox.com/t/0/AADAKtbZlUuMXPCqo0T4KZRzJ-wRocYKpyVRBbJIRknefg/12/128453478/jpeg/640x480/3/1401282000/0/2/20140427_141850.jpg/mZIZwYpanaddBlgZdOZkRA8JC6LMevLOWhWB72DnwzI

Xbird
04-28-2014, 06:23 PM
never seen a shock go like that--did the shaft tear through the outer body? would almost seem like the piston locked up in it.

Martinm210
04-28-2014, 09:49 PM
impressive! maybe one of the eyelet bushings was seized causing it to torque in travel. I've seen a few atv style shocks loose movement at the eyelet.

Time for a pair of new shocks. Perhaps some monroes or fox air?

Lug-Nuts
04-29-2014, 02:10 AM
i hope you get this bad boy running. Cant wait to see it go!

FJ1200Buggy
04-29-2014, 05:35 AM
never seen a shock go like that--did the shaft tear through the outer body? would almost seem like the piston locked up in it.
I think it had a stop at the bottom of the shaft that broke off and the shaft popped out.


impressive! maybe one of the eyelet bushings was seized causing it to torque in travel. I've seen a few atv style shocks loose movement at the eyelet.

Time for a pair of new shocks. Perhaps some monroes or fox air?

I wanted Fox, but they are going to be too expensive...think I will get Monroes.


i hope you get this bad boy running. Cant wait to see it go!
I know, I started this "quick engine swap" in December 2012, its about time to get things done!

Those shocks are actually made for trucks to enhance loading capacity...so Im glad they're gone actually, they were very hard.

FJ1200Buggy
04-29-2014, 02:03 PM
I decided to get a pair of Monroe Max-airs (MA758), looks like people on the forum have had success with them.
I also need a new voltage regulator, so now I have to choose between that or suspension for this month....

Xbird
04-29-2014, 03:52 PM
2 words ... limiting straps!
;)

Martinm210
04-30-2014, 12:58 AM
if you can get back tontesting with the shocks I'd start there. Whatever gets you in the dirt sooner..:)

FJ1200Buggy
04-30-2014, 03:03 PM
Where can I get reliable info on the Monroe shocks? Every website I find has different info on extended and collapsed lengths and on weather the shocks have 2 eyelets or not.

Martinm210
04-30-2014, 05:51 PM
I would PM the folks in this thread:
http://www.minibuggy.net/forum/suspension-wheels-tires/19524-shredder-2-shocks.html

No pesonal experience but Someone did post the exact model in a thread not too long ago.

FJ1200Buggy
05-03-2014, 06:17 PM
Im struggling to order the shocks from ebay, but I at least got the voltage regulator, it charges the battery at the correct voltage but here's my problem:30846
Hopefully someone can help me.

FJ1200Buggy
05-21-2014, 06:33 AM
My shocks should arrive this week or next week:D Is it possible that those wires in the post above got hot because I had 2 deadish batteries connected and the alternator had to work too hard to charge them? (18 and 70 amp batteries)

K-fab
05-21-2014, 09:34 PM
It's possible... But...

Odd that the supply to regulator are getting that hot. Guess you can always see how it works with a good battery.

FJ1200Buggy
05-25-2014, 10:45 AM
WOW, just went onto badlandbuggy website, started suspecting that my buggy is a sabretooth, then found a picture of it on their website!! :eek:
30877
Anyway, heres a picture of the new shocks.

https://www.dropbox.com/s/8wd8vw0n0kuwl3c/20140525_114729.jpg?dl=0

It now has way more travel than it had with those stiff coil-overs.

K-fab
05-25-2014, 12:25 PM
Would you like me to drop this over into a Sabretooth forum? I'd be glad to make one for you.

FJ1200Buggy
05-25-2014, 12:43 PM
That would be great.
Thanks.

K-fab
05-25-2014, 09:00 PM
Done! :)

FJ1200Buggy
05-28-2014, 09:08 AM
Thanks K-fab!

I just ordered a Trail-tech Vapor through E-bay :D Its going to be awesome to have a speedo and a tach that actually works.
I will also need to move the mufflers closer to the engine, at full droop the shocks press against them.

daaboots
06-05-2014, 03:08 PM
Nice clean looking buggy!

FJ1200Buggy
10-15-2014, 04:46 AM
Thanks Daboots.
Progress on this thing is really slow, but I am going to get it in top condition before the end of the year.
I set it on fire a while ago :eek:

http://www.youtube.com/watch?v=fB9NB6OEczc&list=UUt8xUzeOmiP9By4LQkIT8sw
After a good carb clean its running like never before.
I am busy putting Monroe shocks at the front, will post some pictures later.

Xbird
10-15-2014, 11:12 PM
Had quite a bit of burn time going there! :eek: Glad it didn't get far ... something tells me you got an earful moments after that vid ends ;)

FJ1200Buggy
10-16-2014, 07:05 AM
Yes, that was right after I fitted the new Dynatek system, luckily no damage whatsoever.
My mother was actually quite calm.:p

I have a few free hours, Im going to try and get the shocks done.

FJ1200Buggy
10-16-2014, 02:48 PM
The shocks are in.....looks like it can be rock crawler now.:cool::D

FJ1200Buggy
10-18-2014, 03:45 AM
I have a strange charging problem, when the engine runs, the volts go up to 13.8V, but the battery doesn't charge :confused:

Hambam
10-18-2014, 04:04 AM
If your getting 13.8v I would imagine it is a battery problem (but I'm no sparkie). Try a different battery or charging the one you have, then you'll know if its a charging system problem or a battery problem at the very least.

FJ1200Buggy
10-18-2014, 04:12 AM
The battery is brand new and has been checked, so I don't know.
Tested again, volts don't go up anymore and the voltage regulator rectifier gets extremely hot.

FJ1200Buggy
12-12-2014, 11:36 AM
Im busy fitting a car alternator now, its going to run with a pulley from the oem alternator.
Does anyone know what the engine rpm to alternator rpm ratio is?
I need to choose the right size pulley....
Thanks, Erik.

K-fab
12-12-2014, 12:23 PM
You can go one to one with that. Most (good) alternators can spin upwards of 15K+ and be fine (recalling a conversation w/bdkw1)

FJ1200Buggy
12-12-2014, 01:08 PM
I tested it now and it is 1:1 so its going to spin at 9000rpm max

K-fab
12-13-2014, 12:03 AM
You should be just fine with that. [smilie=thumbs_up.g:

FJ1200Buggy
04-01-2015, 07:25 AM
I made an air suspension control system, going to try and install everything today.