View Full Version : Protolite SS 630R 2 seat model

11-03-2015, 07:55 PM
We have been working on a new model for the rental buggy industry
Thought it is about time to share
This is a light weight 2 seat model and more budget friendly than our high HP race models
Using a 21HP Honda Vtwin CVT clutch and a lower hp version reverse gear box from RPM
Cutting out all the bells and whistles on this model to make it affordable yet should be fun.

1 1/4" tub chassis
dual a arm suspension front and rear with approx 11" travel
Honda GX630 V twin motor, but room to fit more power
RPM gear box we are using can handle 100 hp,,,, plus
CVT clutch to make it universal and women and children can drive it :D
Weight currently scales out at 465lbs with steel wheel and we expect it to be 625 to 650lbs
This model is lean mean and clean
25" tires on 12" wheels
top speed we are gunning for is 45 to 50 mph but low end torque
hope to start testing in the next week,,, waiting on the motor to finish up

with the lower HP we are using modified Rhino axles coupled up to the 930 flanges on the RPM gear box and
after this build I am building a personal model for my kids to do some trail riding :D
pics to follow

11-03-2015, 08:03 PM
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pics are not the best,,,, just from my phone but you get the jist of it

11-03-2015, 08:04 PM
sorry K,,,,,,,, pics are too big
outa time but I will fix tomorrow

re sized now :-)

11-04-2015, 04:17 AM
Looks pretty cool to me!


11-04-2015, 05:10 AM
Looks great! I really like this simplified version.
What CVT belt are you using? is it longer than a typical sled setup? Reason I ask is the cylinder on the Vtwin on the gearbox side can get really close, usually you need a longer belt to space that type of engine far enough away from the gearbox.

11-04-2015, 05:11 AM
Looks pretty cool to me too. I imagine this will sell pretty good being cheaper.

11-04-2015, 05:51 AM
Thanks Guys
motor should be here today or tomorrow so hope to be test driving it with in a week,,,hopefully only a few days.
weather is still nice here in Michigan

Jerm, I am using Cv-tech clutches and a 41 3/4" long belt
same one as a RZR 570
the longest CV-tech belt is 40 3/8
should give me plenty of clearance

11-04-2015, 10:57 AM
I like it.

Will plans be available for this as well?

What's the story on the low HP RPM? I saw it on your site last week and it took until yesterday for me to realize what I was reading. LOL.

11-04-2015, 11:14 AM
Thanks Bull

plans, yes ,,,eventually
Need to finish the build and test short term and longer term first.
I hate it when some people sell plans to a buggy that was never even built.
puts it on the customer to find any problems,,,,,,

after testing,,,we will have a whole new line of parts,Frame, rolling chassis, A arms front and rear wheel kits drive axles, engine cradles, CVT clutches, etc for 100hp or less machines

low HP RPM gear box,,,, don't know the full scoop other than RPM says they are able to use more cost effective internal parts rated at 100hp than the parts needed to hold up to 300hp

11-04-2015, 12:26 PM
I'm curious as to how a relatively stock V-twin ~21 22hp range engine performs - I am working on a design for a lightweight (400lbs) reverse trike and 70mph top speed is one of my design targets. I figure I can achieve it with a slightly warmed up version of the GX670, but stock would be ideal! Also, I really like that protolite buggy design!

11-04-2015, 02:00 PM
Nice looking ride Jodi!

Lol on the pix. Thanks for downsizing them.

11-04-2015, 03:38 PM
Nice Job Jody, what prompted the design? Were you contracted by a company to design this buggy for them?

11-04-2015, 04:51 PM
Thanks Guys,

Kfab your pet peeve is alot,,,, mine is Jodi with an i
thats a girls name LOL
just messin, story of the life of a guy with a girls name LOL

Ninja, I have had several lower horse power designs in the works for the past couple of months.
One being a quad engine dual arm version of the MXT,,,, thats about 70% complete on the computer
but switched up to this because I was contracted by a rental company for a 2 seat design using this motor and cvt clutch and reverse gear box.
Their specs are a two seat buggy with top speed of 45 mph on this model,,,, and a budget model ,,, good ride but no need for long travel with durability
I cant tell you how many hours I have into design and research around durable budget friendly parts for this model.
but will be worth it in the long run,,, super happy with the simplicity I designed into the build for manufacturing,,, yet strong and durable.
I would not be scared to put a GSXR 600 (103hp) in this model and it would,,,, will rock
I may build one for the family,,, my son is now 15 1/2 and ready to shift gears and take chics for rides around the track :-)

this 2 seat model is using budget coil over shock , but they can be upgraded along with engine and many other things,,, so you can get in at a entry level and add upgrades as your need and budget changes

really looking forward to testing this V twin model, gear box is 13:1 so should hit the specs of my customers low end power with a top speed of 45

11-04-2015, 05:21 PM
Thanks Guys,

Kfab your pet peeve is alot,,,, mine is Jodi with an i
thats a girls name LOL
just messin, story of the life of a guy with a girls name LOL
I can totally understand. I've always questioned the spelling. It seems I'd seen it spelled with an i in a post long ago and I took that as the way.

My apologies, Jody! [smilie=peace.gif]

I have a cousin named Dana and he's had hell with it all his life. Knew a Karol too...

11-04-2015, 05:25 PM
Just say Dana, like the axles :D

11-04-2015, 05:44 PM
LOL no worries K fab

I was in a bar at a concert a few months back making conversation with some new friends in line for a beverage
They asked my name , I told them Jody
in line next to us a huge 6' 5" bulk of a guy says "whats your name?"
I repeated Jody , whats yous?
he laughs and says "Ashley , its a f**king curse isnt it bro"
we high fived and had some beers LOL

11-04-2015, 07:17 PM
Hey, glad to hear you got a contract to drive the new design! That is great news. I can't tell you how many times I see a Polaris rental place give someone a 15 minute video of how to drive on the dunes and cut them loose with a 900 or 1000. They would be better suited with something a little more beginner friendly like the design you have. I have also seen really low powered rentals that go nowhere. Looks like you have something in between.

11-04-2015, 07:55 PM
Yep very nice

11-05-2015, 05:27 PM
Nice work Jodi... ur, I mean Jody LOL.. When someone thinks it's Jodi, just tell them to replace the "o" with an "e", and to bow down to the Buggy Fab Master!! [smilie=gun_gun.gif]

Hopefully this design makes you some bank, keep living the dream man!!!

11-06-2015, 05:40 PM
Thanks MrB LOL :D

more progress, engine cradle, motor mount, battery mount ,clutches, Reverse shift lever and cable,,,, in

fuel cell and exhaust probably done tonight.
first test drive tomorrow or Sunday if all continues well :D

nuff talk,,,, I know all you guys care about are pics lol

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11-06-2015, 06:26 PM
Great engine/trans package! Maintenance free and bullet proof!

Do you mind if I ask what clutches your using? I like the looks of the driven.

Cant wait to see how this performs.

11-06-2015, 07:31 PM
Thanks Bull
CV-tech clutches
belt matches rzr 570 41 3/4 long

min ratio 3:1 Max achievable 0.45:1

11-07-2015, 09:58 AM
Compliments again on the very well thought out dual A-arm setup around the trans.

I've always wondered if a guy could take a motocross bike set of forks and make a strut assembly (much stiffer springs obviously in the fork tubes). Not having to place that upper control arm you could squeeze everything even tighter. I'm sure there would be a few specialty pieces on each end to catch the fork tube - but starting with some nice aluminum Polaris struts would provide axle parts that all slip together AND brakes!

Just a thought!

11-07-2015, 12:50 PM
Nice work as always

do you have a price point in mind for the kit or finished model

11-07-2015, 06:45 PM
Thanks Guys

not sure on that,never looked at the strut design up close
but if Polaris is doing it, seems like it should work
does that work like a single lower a arm with the bearings / hub built into the lower arm?
if so the camber change is real big and only the inner joint needs to pivot

Hoping to be able to produce these full turnkey for 13K,,, least thats the goal
after testing we will offer them frame, kits, rolling chassis,,, all the parts will be available to build as you go

11-08-2015, 08:53 AM

11-08-2015, 05:48 PM
Got to take her our for a test drive today :-)
Tested good, custom exhaust with super trapp style disc muffler sounds great
V twin is deep and throaty but not too loud.
Motor sounds bigger than it is,,, nice rumble
Low end power is nice, spins the tires and can slide it sideways in the corners
on the .19 mile sandy dirt track
hit top speed of 36mph on the track , but feels faster and handles good
scrub off speed in the corners , so it should top out 40-45 in a straight away where ,, how intended
power is is fun and will be good for trails, general fun and for sure an awesome rental unit
going to scale out for final weight tomorrow
should be 650lbs or less I expect

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11-09-2015, 07:55 AM
Glad to see it is running well!

The strut in the rear would just connect to the lower control arm with a ball joint - giving it all degrees of freedom. A toe link would be the only other piece needed if using a polaris style strut unit - but if a person were to build their own, a king pin on the lower control arm would eliminate the yaw movement. I'll have to make a sketch :)

11-09-2015, 08:04 AM
Looks clean, should work out good for a rental.
Do you know what the gear ratio's are on that CVT ? I tried to look it up just for comparison from the comet 780 series but couldn't find anything spacific

11-09-2015, 08:45 AM
Glad to see it is running well!

The strut in the rear would just connect to the lower control arm with a ball joint - giving it all degrees of freedom. A toe link would be the only other piece needed if using a polaris style strut unit - but if a person were to build their own, a king pin on the lower control arm would eliminate the yaw movement. I'll have to make a sketch :)

I am curious about this concept, look forward to the sketch.:D

11-09-2015, 09:40 AM
Fair enough - Here is my sketch (looking directly at the back of a buggy). Imagine the shock being a fork from a motocross bike (one of the shocks that make up a set of forks). It is captured at both ends rigidly by clamps similar to what you would find on a triple tree. This is basically a McPherson style strut if I'm not mistaken, just built with tasty high performance off road parts!


11-09-2015, 09:43 AM

here are the clutch ratios
min ratio 3:1 Max achievable 0.45:1

gear box is 13:1

11-09-2015, 10:27 AM
Hey Dain254, I see what you are getting at with the sketch. the Coyote I have mounts the shock at the hub, but uses a Heim joint for attachment at both ends and has upper and lower arms. Its basically a scaled up version of the Honda Pilot.

Not sure how the sketch above would work with only the lower control arm.....

11-09-2015, 11:07 AM
It would work exactly like a McPherson strut - except without the need for a steering link because a kingpin would be used to connect to the bottom arm instead of a ball. Here is a link with an example of a basic McPherson. In this design, there is no heim or flexible joint between the hub carrier - they are fixed together.

Front Suspensions - HowStuffWorks (http://auto.howstuffworks.com/car-suspension4.htm)
page 4 of that

11-09-2015, 12:13 PM
Gotcha, yes that should work

probably more for a one off build and not production though because there are more shocks than struts available brand new
with this design you would probably need to find used ones on Ebay , unless you wanted to buy new ones from Polaris

11-09-2015, 12:25 PM
Definitely - would be difficult to source these specialty struts for a production run - didn't mean to take over your thread with a bunch of long travel strut nonsense :cool:

11-09-2015, 12:47 PM
LOL, all good and buggy discussions :D
now if you were trying to sell Tupperware or sharing dog grooming tips

11-09-2015, 01:43 PM
I get the concept now, interesting option and not the same as the Coyote. Having said that, no reason why it wouldn't work.

11-09-2015, 04:52 PM

here are the clutch ratios
min ratio 3:1 Max achievable 0.45:1

gear box is 13:1

Ok thanks
Looks like the ratio is pretty close

11-10-2015, 06:47 PM
more testing today :D
springs were too soft on first test drive a couple days ago
ordered up to some good ones,,,,, love the ride now,,, really good and smooth over the rough stuff
power is smooth and fun with quick acceleration.
Handling is awesome and easy to control and drive
This will be a great trail buggy and in between other builds, will build one to keep here for the family

buggy weighs in at 704lbs with fuel battery and everything complete minus body panels.
they should weigh less than 10 lbs
was hoping for 650, but heck,,,that is pretty light for a 2 seat buggy with a 100lb engine and 40lb gear box

weight is 62% rear and 38% front

couple of little things to wrap up and then off to powder coat this week

11-10-2015, 06:57 PM
Great job Jodi/y , I want one! Or two actually.

11-10-2015, 11:21 PM
Bull, you said many times NJ was a NO Fun State!!! You moving West??

11-11-2015, 08:13 AM
Bull, you said many times NJ was a NO Fun State!!! You moving West??
We're working on him! [smilie=boogie.gif]

11-26-2015, 10:09 AM
Happy Thanksgiving MBN

Buggy is done,,,,,,and fun!

build pics to go with your turkey today

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11-26-2015, 10:11 AM
That looks awesome!!


11-26-2015, 10:45 AM
Very clean and professional work! Does it get a CVT cover of some sort?

11-26-2015, 01:40 PM
Not planning on a cover at this time.
Heat vs dirt debate with belt life
Many say heat is worse than dirt and drill holes or pull the covers off to run cooler.
I personally like to see the belt for quick inspection

11-26-2015, 03:16 PM
About 6 or 7 years ago I talked with a comet engineer about and he emphasized keeping it cool gives you the most significant increase in belt life. I've been running mine without a cover in a pretty dirty environment and it doesn't seem to be showing any wear. I think a shield to keep out the big stuff is all the further I'm going to go with mine... has about 100 hrs on it and still looks like new! Next time I'm in Vegas I'll see if I can make it out to rent one!

11-26-2015, 07:29 PM
I may be in Vegas in a week or so, to see how it tests in that environment:D
Ill update performance,,,,,,,,,if I remember lol

11-26-2015, 07:40 PM
Awesome job ProtoDie!

How many do you have to build?

Any chance we will see a video?

11-26-2015, 09:31 PM
Buggy looks really nice. Could you share the buggy dimensions? What about suspension travel?
Thank you,


11-27-2015, 07:15 AM
Awesome job ProtoDie!

How many do you have to build?

Any chance we will see a video?

hopefully alot
:D:D:D [smilie=haha2.gif] [smilie=poked.gif]

a lot that is,,, just messin with Kfab

they are hoping to have us build 20, we build and ship 5 at a time
we will see, everybody projects big numbers in the beginning
until the orders come in,,, who knows
I do know they will like it

probably no video on this one,, clean and ready to ship.
rainy and crappy weather in Michigan right now

11-27-2015, 07:21 AM
Buggy looks really nice. Could you share the buggy dimensions? What about suspension travel?
Thank you,


Thanks Willy
116" long
62" wide
58" tall

weighs in just over 700lbs

11" travel front and rear

11-29-2015, 05:52 PM
looks fantastic! are those front spindles the same ones you sell on your site or are they a throttled back version?

11-29-2015, 06:46 PM
almost identical, but the spindle is welded in and the upper heims mount is slightly lower
all parts for this model and others will be available in the next couple weeks / months

12-02-2015, 07:40 PM
had a hood designed in,,, customer wanted it left open with no hood
was done and ready to ship,,,,,customer changed their mind and wants the hood back in :D

all good, I like it better with a hood and glad its in.
done again and ready to ship

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12-04-2015, 05:30 PM
sunny and 50 in Michigan today
got it out for a final test drive
top sped with this gear box is 45 mph , right on target
gets up to speed real quick too,,,, not a dog
gear box is 13:1 higher top speeds could be achieved with different gear box ratios is desired,,,, motor seems to have plenty of torque

some outdoor pics, last ones until it is out in Vegas

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12-04-2015, 05:39 PM
oh ya, governor is intact and bone stock motor , probably 3600 rpms
can hit 4000 rpms with pulling a governor spring

another note,,,,,Harbor freight now carries the clone of this motor for around $650 and can add a full 1 year warranty
swap it out if needed every 11 1/2 months :D

clone motors you can probably bypass governor easier than Honda lets you
Honda has a electronic governor after 4000 rpms

4000 rpms would have you at 50 mph

5000 rpms 62 mph

not 100% on the clone governor until I try, but it is that way on the smaller motors

with some upgrades we were hitting 7500 rpms with the 6.5 clone motors,,,,,,,just sayin

12-04-2015, 07:58 PM
quick video
just off my phone, so kinda sucks


12-05-2015, 05:06 AM
Such a cool looking car! Now Silver Lake needs to have you build some of those


For some reason your video is private

12-05-2015, 09:03 AM
Car looks cool, can't get access to the video either.....

12-05-2015, 10:04 AM
Thanks guys,
Ninja , video works when I click on it, not sure why its not working for you

12-05-2015, 11:45 AM
yup, for some reason the video setting was private, made the change to public
try this


12-05-2015, 12:23 PM
Now I see it, cool. All you have to do is wait for the multiple order coming in!:D

12-10-2015, 12:29 PM
I don't know much about the motor, but is it air cooled?

12-10-2015, 01:09 PM
Looks great and sounds mean .. But man dont rev it up in "N" gear that poor input bearing aint gona like it LOL

12-10-2015, 01:25 PM
Looks great and sounds mean .. But man dont rev it up in "N" gear that poor input bearing aint gona like it LOL

I know,,,,, LOL can't help myself [smilie=banghead.gi:

restricted myself to only a couple of times :D

98Blazer, yes it is air cooled
21hp V twin Honda
1" output shaft
electric start
governed at 3600 rpms

nice little motor and kinda surprised at how well it performs and the torque it has coupled up with the Cv-tech clutches and RPM gear box

it shipped out to Vegas last night, but I was able to get a little video footage before it left.

need to put the video together yet,,,, maybe in the next couple of days I will have some video to share

12-10-2015, 11:23 PM

http://www.minibuggy.net/forum/attachments/protodie-buggy-group/32595d1449814964-protolite-ss-630r-2-seat-model-10988527_10155362522725438_1962545776154128591_n.j pg

12-14-2015, 05:56 PM
ok, so I only had limited video footage with the time frame of the build and weather here in Michigan
some of it from my shaky cell phone LOL

you guys are video freaks so figured I'd put it together into something for you

(I usally never get this right the first time)


12-14-2015, 08:01 PM
lets add more power,,,,,,,,185hp :D


12-14-2015, 08:15 PM
I like em both!

Whos the test driver? Jodi?

12-14-2015, 08:31 PM
Thanks bull :-)
That's me driving the new model
The SS1000 video is one of my customers in Georgia
He finished one of our SS frame kits and did a great job of it:D

12-16-2015, 05:00 PM
flying to Vegas in the morning :-)
you guys probably want me to wear a helmet cam and video,,,,,
nope,,,thats evidence LOL

12-16-2015, 05:30 PM
lets add more power,,,,,,,,185hp :D


I like the first video. looks like a smooth little buggy. As for this video I'm quoting... I would swear that was filmed at Stony Lonesome, which is about an hour from my house. where you there testing??

12-22-2015, 05:55 AM
hey Wheels
yes I think it was Stony Lonesome
That was one of my customers playing around, not me

12-27-2015, 01:02 PM
sweet buggies!!!!!!! and congrats!!! on the contract once they see it and drive it they will want more

Old fast guy
11-02-2016, 12:26 PM
I'm interested in this buggy mostly for dunes. And since I would use it mostly for the dunes I would need a little more power. I was thinking of a mid sized snowmobile four stroke. How would that work in this buggy would the chassis handle it. When do you think you might have plans out for it or maybe a frame kit. I like the fact it's lighter than the ss1000. But because it's lighter would it hold up to the adding of power and the added stresses of duning. Thanks Bill

11-02-2016, 04:12 PM
Yes chassis will take more power, no problem
I have looked at the Yamaha Phazer engine for this model, 4 stroke 85 hp
would be a good power plant in this model

I know I will not be releasing plans for this model anytime soon,,,, buried with other work right now

your best bet would be a rolling chassis for this model and then put the power plant of your choosing in it

Old fast guy
11-02-2016, 05:27 PM
That's the engine I was thinking of too. I think it would work great in the dunes. Light weight with good power it should be a good combo. How do you think it would do with the smaller suspension travel compared to your ss1000. I don't really want to blast thru the whoops or go for big air. Just something to have fun with in the dunes and maybe change tires and ride a few trails with. Ya got me interested so are you going to produce a rolling chassis for this soon. I didn't see one on your website the last time I looked and if I did this do you think the smaller rpm box would hold up to the phaser engine. One more ? About what would a roller chassis for this run. Pm me if you like but if it's close to the ss1000 then that might be my best choice maybe with a apex. Thanks for your time Bill

11-02-2016, 06:15 PM
we have many things we produce and build but have not found the time to put on our website yet.
Turnkey this buggy is $15450, I need to update the website for this too.
we added some upgrades to the base model, mostly cosmetic stuff

if you wanted a rolling chassis for this model, guessing it would be somewhere around $7500
I would have to go thru the parts list and fine tune that number to firm it up though

I personally think it would make a great dune machine with that power plant
11" travel is with the existing shocks on there, more travel could be attained with different shocks

low HP RPM gear box we use in this model would hold the 85 hp no problem

Old fast guy
11-07-2016, 01:07 PM
That price sounds good what the chances of getting a unwelded tube kit. And going with the higher quality dom tubing. That would save me some on shipping. Thanks Bill

11-07-2016, 04:40 PM
DOM tubing , yes

unwelded kit, sorry no

we do not offer plans for this model and you would need plans for how to put together an unwelded kit

Old fast guy
11-07-2016, 05:10 PM
Ok thanks it will be a bit but I think I will order a roller when I can thanks Bill