View Full Version : Mini shark resto-mod project

04-16-2014, 10:26 AM
Figured I'd help give K-Fab a bit more of a reason to set up a kid's buggy project section .... he needs more to do since winter decided to stick around for the spring and summer over his way :eek:

Anywho, this is in projects in progress since my daughter keeps growing and making me rebuild it to match ... kids get bigger --who knew?

Backstory is that when my daughter was 5, i got my old yerf 3203, and she looooved riding along on it... of course, i pretty much destroyed it along the way and she was sad that it was always being chopped up and worked on. I missed that happy squeal of a mini speed freak, so something had to be done.

So about 4 months before her 7th birthday, I found an ad on CL for a 50cc weewhaker powered Hammerhead mini shark that needed an engine and front tire. from the pics, it looked good, so i made a couple hour trip to get it --at night ... in the rain ... Ummm don't buy anything at night, in the rain based on pics with lots of leaves covering most of the subject ....

What i thought would be a pretty quick and dirty rebuild with a 3 hp rototiller briggs on the back turned into 4 months of 7-day a week, 10 -14 hour days/nights of garage thrashing, with me having to keep everything hidden from view in the garage.

So here's what rolled in on the truck at 2 am .... Due to a computer swap, i can't find the original overall picture of it, so these show some of the worst areas

http://i995.photobucket.com/albums/af79/x-bird/a1_zps69a970fe.jpg (http://s995.photobucket.com/user/x-bird/media/a1_zps69a970fe.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a3_zps87b1fedf.jpg (http://s995.photobucket.com/user/x-bird/media/a3_zps87b1fedf.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a2_zps800f0911.jpg (http://s995.photobucket.com/user/x-bird/media/a2_zps800f0911.jpg.html)

Pretty much the entire bottom frame was rotten, suspension all around was junk and it was going to be too small really quickly. Fortunately, the same seller also ponied up the front suspension and rear swingarm, including tires etc from a Baja 90cc atv for a not too painful price, and worked near me, so that softened the blow when he dropped them off just about at my door.

Within days the cutting began and a buddy with a chassis shop up the road bent up some tubing for me. Goal wa to lengthen and strength the chassis, get rid of the ridiculous little tires and put a better powerplant on it. the tiller engine turned out to be a smoker, so I decided to graft on my yerf's swingarm and 6.5hp Tec/TAV setup.

http://i995.photobucket.com/albums/af79/x-bird/a0_zpsbbae1644.jpg (http://s995.photobucket.com/user/x-bird/media/a0_zpsbbae1644.jpg.html)

Floor out
http://i995.photobucket.com/albums/af79/x-bird/a00_zps757d73ac.jpg (http://s995.photobucket.com/user/x-bird/media/a00_zps757d73ac.jpg.html)

bottom tubing chopped
http://i995.photobucket.com/albums/af79/x-bird/a4_zps7273a664.jpg (http://s995.photobucket.com/user/x-bird/media/a4_zps7273a664.jpg.html)

04-16-2014, 10:34 AM
http://i995.photobucket.com/albums/af79/x-bird/a6_zps080fb2d4.jpg (http://s995.photobucket.com/user/x-bird/media/a6_zps080fb2d4.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a5_zpsd58835aa.jpg (http://s995.photobucket.com/user/x-bird/media/a5_zpsd58835aa.jpg.html)

Materials and $s were in short supply,(did this right through christmas) so i had to reuse as much as possible
http://i995.photobucket.com/albums/af79/x-bird/a7_zps3a95d6c8.jpg (http://s995.photobucket.com/user/x-bird/media/a7_zps3a95d6c8.jpg.html)

Lengthening provided the added bonus of kicking up the sides a bit higher because of the built/bent in frame caster/rake.

http://i995.photobucket.com/albums/af79/x-bird/a8_zpsaddcbd26.jpg (http://s995.photobucket.com/user/x-bird/media/a8_zpsaddcbd26.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a9_zpsb084c804.jpg (http://s995.photobucket.com/user/x-bird/media/a9_zpsb084c804.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a10_zps08ddd5cf.jpg (http://s995.photobucket.com/user/x-bird/media/a10_zps08ddd5cf.jpg.html)

My little one kept asking me why all the time i spent in the garage resulted in nothing really getting done with the yerf ... I was scavenging it for parts for hers! On the flip side, all i had to do was remind the other half that all the noise, dirt and time was for the little one and not me [smilie=cool.gif] and the complaints usually ended pretty quickly ....

04-16-2014, 10:42 AM
Since i was more than intimately familiar with the yerf swingarm, having fixed and braced cracks all over the silly thing, i chose to use it as an engine mount, narrowed it, added new side tubing and welded the 90cc quad swingarm to it.

The quad frame mounts matched my original modified yerf mounts, (3/4 bolts through bronze bushings) so i cut the rear bar out and welded that in the mini shark and the two basically bolted together.

http://i995.photobucket.com/albums/af79/x-bird/a12_zpsacbc6179.jpg (http://s995.photobucket.com/user/x-bird/media/a12_zpsacbc6179.jpg.html)

The swingarm went in upside-down, which means i have to periodically check that the primary hub nuts don't unwind, but this allows the hub to pivot and provide chain tension adjustment in the right direction.

Up front, the atv arms went in parallel, mounted on 1" angle iron welded to the frame sides--nice easy method and the rack got moved a bit forward to provide front steer. yerf mechanical shocks (same at the rear) went in using old golf ball picker frame tubing.

http://i995.photobucket.com/albums/af79/x-bird/a13_zps338b1adc.jpg (http://s995.photobucket.com/user/x-bird/media/a13_zps338b1adc.jpg.html)

A roller! The lengthening also shows amount wise in the additional length i had to plug into the upper cage.
http://i995.photobucket.com/albums/af79/x-bird/a14_zpsc22fe1ec.jpg (http://s995.photobucket.com/user/x-bird/media/a14_zpsc22fe1ec.jpg.html)

04-16-2014, 10:49 AM
Seat frame was made from golf club sales display racks and old honda cvcc seat sliders. I reused the original padding and two seat configuration with it's awesome lap belts (don't ever do that to your kids!) Doing that config kept the steering and pedals in their original off center locations.
http://i995.photobucket.com/albums/af79/x-bird/a20_zps0de2bb31.jpg (http://s995.photobucket.com/user/x-bird/media/a20_zps0de2bb31.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a15_zps3f6e2db8.jpg (http://s995.photobucket.com/user/x-bird/media/a15_zps3f6e2db8.jpg.html)

Found it easier to spray it before adding the final floor pans, which i made full length. why they build these things with open floor areas is beyond me

http://i995.photobucket.com/albums/af79/x-bird/a16_zps69232f75.jpg (http://s995.photobucket.com/user/x-bird/media/a16_zps69232f75.jpg.html)

Skittles n bits ....
http://i995.photobucket.com/albums/af79/x-bird/a17_zpsdfc31096.jpg (http://s995.photobucket.com/user/x-bird/media/a17_zpsdfc31096.jpg.html)

Brakes were yerf spiderbox master and caliper (about the only new part that went on this thing) with home made bracket and solid rod linkage to the pedal
http://i995.photobucket.com/albums/af79/x-bird/a18_zps9e59cf40.jpg (http://s995.photobucket.com/user/x-bird/media/a18_zps9e59cf40.jpg.html)

Rear fenders are another golf club display rack piece (PING) (I use the same panels as front fenders on mine)

http://i995.photobucket.com/albums/af79/x-bird/a19_zpsc6168cb9.jpg (http://s995.photobucket.com/user/x-bird/media/a19_zpsc6168cb9.jpg.html)

04-16-2014, 10:54 AM
And finally, the money shots .... I put the seat in at about 4-am the night before her birthday! Didn't i say quick and dirty at some point ... 4 months later ... :D

http://i995.photobucket.com/albums/af79/x-bird/a21_zps8d45d9ba.jpg (http://s995.photobucket.com/user/x-bird/media/a21_zps8d45d9ba.jpg.html)

http://i995.photobucket.com/albums/af79/x-bird/a22_zpsf1ae0984.jpg (http://s995.photobucket.com/user/x-bird/media/a22_zpsf1ae0984.jpg.html)

I dubbed it "The Dog Shark" she calls it the sunchaser ... I like her name better. ;)

Presently, she's now a tall 9 year old and I just completed conversion to single seat by putting in a booster set, moving the pedals and relocating the steering on center (had to hand cut/file in a buttload of rack teeth) and raising it. As soon as i get a new set of Crow harnesses, she can ride again. end of this year, or over the winter, it gets a new, taller cage and she might get another 2-3 years out of it .... dang kids and growth, go figger!

04-16-2014, 11:06 AM
Your resto looks great , Wild colors ya choose . In my world I call projects like those "Makein hamburger out of horse sh$t " And it looks like ya fixed up a hell of a berger :D

04-16-2014, 11:19 AM
That's killer. Perfect little ride for a little girl. My youngest would have loved it - heck, she loved the Briggs once she was old enough.

Yea, yea... kid's section... Okay, it's done. :p

04-17-2014, 09:06 AM
:) awesome job on the resto!!

04-18-2014, 10:37 AM
Thanks guys, this was one of those projects that became a true labor of love. I can't find the energy to work as long or as late into the night on mine as i did with this one. Word of advice for those building a buggy for their kids--build in plenty of room for future expansion of the seating, controls and cage dimensions.

Spent last week and part of this week getting it ready for the season, she wants to run in one of the kids races at Line Mtn. this year, so i'm stoked for that. Just a fun race ... individual timed flat loop with everything from barbie jeeps to alcohol go carts and mini quads.

Her seating and controls were offset, i never liked how close to the side she was.

http://i995.photobucket.com/albums/af79/x-bird/kaw1524_zps0ddf2ce3.jpg (http://s995.photobucket.com/user/x-bird/media/kaw1524_zps0ddf2ce3.jpg.html)

The old seat also had her helmet in the front slope of the bars so i took it out and modded a booster car seat for it. sets further back and lower, still have another 2 inches i can move it back when needed. I did the seat at the end of last season, controls were still offset and lets just say it wasn't too comfortable to drive. Steering wheel was also in her lap.

Had to chop through the center for the steering rod, reconnected with tubing chunks. I intend to put a new set of shocks (my foxes from a polaris 600 sled--shock go boom thread) when i do that, the shock mounts will get a bridge tube that also has short drop tubes to the bars i cut.

Re-cutting the rack tube and teeth was probably the hardest part of the changes. Did it in the past with mine, so it only took a day or so of cutting and filing new teeth.

http://i995.photobucket.com/albums/af79/x-bird/overall_zpsbd431a44.jpg (http://s995.photobucket.com/user/x-bird/media/overall_zpsbd431a44.jpg.html)

The pedal setup on these little things is actually pretty nice. provides 3 different position to move through by undoing one end bolt and the cable stop. I switch from a rod on the brake since it wasn't long enough and would have needed a bend in it to reach the new inboard position. Pedals presently set in the middle position, so there's another 2 inches to the front they can move.

http://i995.photobucket.com/albums/af79/x-bird/pedals_zpsbaf70dd6.jpg (http://s995.photobucket.com/user/x-bird/media/pedals_zpsbaf70dd6.jpg.html)

4-points are ordered an on their way. I should get at least a year out of this round of work.

Now, for K-Fab, ... it's lonely in here, need some more kid's buggies moved in to keep her company [smilie=wbounce.gif]

04-18-2014, 11:01 AM
LOL - yea, I know. Everyone that has a kid's buggy build needs to pm me and tell me so I can move the threads. The only ones that I'll leave out will be Protodie's stuff, since he has his own section for them.

04-18-2014, 11:40 AM
Nice job X-bird.

05-29-2014, 09:17 PM
very unique! i love it. great work!