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Beelzeboss
12-06-2008, 03:35 AM
Hi,
Just finished high school and have a 4 month holiday in which to do nothing (besides work a bit :rolleyes:) so I decided to build a buggy. I went for the Sidewinder because the supplier is here in Australia, it looks easier and less costly to build than a Piranha, as well as taking less time, it's not likely I'm going to race it so I don't need the power of a Busa or ZX-14, and I liked the look of it.

Here are some progress pics:

Frame
http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/612083.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/612085.jpg

Front swingarms (second set [smilie=rant.gif])
http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/3011083.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/3011082.jpg

Rear swingarm (all bracing changed from 20x20x1.6 to 30x30x2.5 for extra strength)
http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/3011084.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/3011085.jpg


The buggy is extended 180mm for me, 6'4", and that has created a couple of issues but most have been worked out. I have also finished the pedals and pedal boxes, and almost finished modifying the rack and pinion.

Questions, comments and criticism welcome.

Andrew

tone
12-06-2008, 04:23 AM
hi

there are clubs you can race at if you get the urge
more pics

cheers

K-fab
12-06-2008, 08:01 AM
The work looks nice.

Second set - :rolleyes:
been there, done that! [smilie=wbounce.gif]

Gene
12-06-2008, 10:34 AM
Nice work and a great first project. Keep posting so first-timers see that they can succeed!

Beelzeboss
12-17-2008, 04:12 AM
Thanks very much for the comments. I have made a bit more progress and have pics.

Frame (have since fully welded it and added a couple more bars to the front, but these pics are fairly recent)

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1012081.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1412081.jpg

I also now have a powerplant. 2007 Suzuki GS-500F twin cylinder with only 9,500 km's (5,900 miles).

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/BikePic.jpg

Front forks were quite damaged :eek:

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1212083.jpg

Some shots of the engine out of the frame with carbs, exhaust, oil cooler (broken in crash), and electrics removed

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/NakedEngine1.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/NakedEngine2.jpg

The engine is SO chunky. I was attracted to it by the price, the bulletproof reliability and a reasonable amount of power. I will be running car tyres and rims to save money so excessive power is not required, as traction will already be a problem. That's fine by me because what I enjoy most is powersliding and drifting!

Andrew

NWOff-Roader
12-17-2008, 05:33 AM
Your project looks good, a very clean build for sure. Keep it up!

yummi
12-17-2008, 06:32 AM
Hi Beelze, welcome to the site.

I am always amazed at the number of young guys here who do such a good job. Looking forward to watching the progress of your build.

Beelzeboss
12-19-2008, 02:40 AM
OK, I have done a bit more since the last update. HAVE PICS!

Close up of the bars which I added to the front of the frame:

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912088.jpg

Put on the rear suspension mounts:

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/19120811.jpg

Cut the frame ("God I hope this works...")

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912086.jpg

Then welded it back together 20mm downwards. Othersie the HUGE Suzuki engine won't fit!

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/19120810.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912089.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912082.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912083.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912081.jpg

I also bought two shocks from a yamaha XT-550. Unfortunately the designer of the Edge buggies says that I will have to upgrade the springs in them to make them work properly. I will see how it goes.

Andrew

TutTech
12-19-2008, 11:11 AM
Looks like your doing really well.
The buggy is coming together nicely and I like how you are problem solving and working out
ideas ahead of time to make the buggy work out. Like lowering the engine and beefing up the
back end.
Really good and like others have said I wish I could have built something so well just out of high school. Looks like your fits are going together very well. Nice. It's looking great.

I would like to make a suggestion that may or may not help you but it's input and free
so if you use it great if not no worries. On your welds something I do is make more of a circle
going around in a puddle until my joint is welded in. Go around and make a dime shape circle
and then drop down about half way through the dime sized circle you just made and make another
circle. Do this until you finish welding your entire joint.
It make for a very strong weld and mostly a very clean weld.
Something to give a try on. Maybe grab a couple pieces of old tubes and try it.
Also it looks like you can go a little slower on your welds? Hard to say I am not there and the tube
could be to thin and you could burn through it I am just guessing and trying to give input.


Anyways awesome job and I hope you don't mind me trying to give you input as I wish people would have helped me out instead of telling me my stuff sucked at your age and that I can't do it.

Keep us posted and don't give up your doing great!
Keep the pics coming.

;):)

klr700sidewinderbuggy
12-24-2008, 04:29 PM
Heres my edge sidewinder ! im new to the forums here and thought id share

Gene
12-24-2008, 06:29 PM
Now Beelzeboss is drooling!

klr700sidewinderbuggy
12-24-2008, 09:28 PM
.....

Gundog
12-24-2008, 11:35 PM
OK, I have done a bit more since the last update. HAVE PICS!

Close up of the bars which I added to the front of the frame:

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912088.jpg

Put on the rear suspension mounts:

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/19120811.jpg

Cut the frame ("God I hope this works...")

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912086.jpg

Then welded it back together 20mm downwards. Othersie the HUGE Suzuki engine won't fit!

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/19120810.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912089.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912082.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912083.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/1912081.jpg

I also bought two shocks from a yamaha XT-550. Unfortunately the designer of the Edge buggies says that I will have to upgrade the springs in them to make them work properly. I will see how it goes.

Andrew

Just a suggestion but I would consider grinding the weld down on the sides where you made that drop in the tube and fish plate it with some 1/8" plate or strap overlapping that joint . That will make your joint much stronger than a butt weld connection.

Mike

Beelzeboss
12-25-2008, 01:53 AM
TutTech and Mike, that is very good advice from both of you.
Keep in mind that my welding has become a lot better since doing those frame welds, I might even grind off and re-do a couple of them.
KLR700 that is one hell of a Sidewinder. If you have any pictures of the build progress I would love to see them in your own build thread.

Well, I have a small update. I have done 2.5 of the 4 engine mounts. I need to get some bolts to do the front and rear mounts because they need to be removable so that I can get the engine in and out.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512084.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512085.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512083.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512082.jpg

All mounts have these machined washers (made on the lathe) so that if it needs to be moved slightly I can machine a slightly thicker/thinner washer to move the engine.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512086.jpg

Here is a picture of the frame as it is now

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512087.jpg

And Rocky likes to think he has helped a bit :D

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2512081.jpg

klr700sidewinderbuggy
12-26-2008, 05:03 PM
not trying to take yours over, just showing a few things you could see to replicate or what not. I removed the pics and what not. good luck on the build.

Beelzeboss
12-26-2008, 08:01 PM
KLR700 I'm sorry if I came across as "GET OUT OF MY THREAD!", I wasn't meant to. You can leave the pics there if you want, I actually have a copy of that last pic of your beefed up swingarm on my computer for reference :) Yours really is a sensational looking buggy and it would be great if you could post many pics of it in the finished rides section. It looks like great fun.

klr700sidewinderbuggy
12-26-2008, 09:31 PM
KLR700 I'm sorry if I came across as "GET OUT OF MY THREAD!", I wasn't meant to. You can leave the pics there if you want, I actually have a copy of that last pic of your beefed up swingarm on my computer for reference :) Yours really is a sensational looking buggy and it would be great if you could post many pics of it in the finished rides section. It looks like great fun.

Will do

Beelzeboss
01-21-2009, 02:08 AM
OK, here's an update.
Finished modifying the steering rack. Instead of tacking a bush on one end, I decided to machine a press fit bushing on the lathe to press into the rack. I might have to bore it out a bit more, but at the moment it works perfectly.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2110911.jpg

Rear bearing plates arrived from Edge, so now the rear swingarm is 100% complete except paint

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211092.jpg

520 50 tooth sprocket from a motorcycle shop in Brookvale was $40 new. The guy went through all the 520 50 tooth sprockets to find me the cheapest, AND then he gave me a discount! I think it looks pretty good. The place was called APW motorcycles.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/2110910.jpg

Picked up a seat on ebay. A friend and I bought the pair for $140, and I got the more faded one because I need the reclining lever on the left. It won't fit on the right because of the engine.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211095.jpg

Mounted the oil cooler at the back of the buggy. If I was to do it again I would save some money by using rigid steel pipes, rather than the expensive oil cooler pipes.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211096.jpg

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211097.jpg

Removed the rear brake assembly from the bike

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211099.jpg

Made the suspension pivot pins. The rear one is a bit longer than stock because I made the pivot wider.
Instead of threading the end of the pins I decided to use cotter/split pins through the end of the bars. I also bored out the nuts to weld them on the pins, rather than threading them on. I have since found out that I have to thread the bars. Not a problem, because I can thread over the cotter pin holes.

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211098.jpg

Seat rails without the holes drilled in them

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211094.jpg

Both the wing supports done. It was easier to cut the correct angles than I expected

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211093.jpg

Also, I fitted the front suspension mounts. I had to tack and grind off the top suspension mount like 10 times to get it in the right spot and square to everything. Magnets helped hold it in place but made the arc (during welding) go a little bit strange

http://i231.photobucket.com/albums/ee224/jones_pbkt/Sidewinder/211091.jpg

I hope to have the buggy done by the 1st of feb. It will be close, but I think I can make it, especially if my friend comes over to help.

Andrew

boostinjdm
01-21-2009, 10:22 AM
looks good. I would suggest flipping the oil cooler over so the hoses run out the bottom though. It will help when draining the oil and would look a little cleaner also. just my .02

Beelzeboss
01-21-2009, 03:12 PM
Thanks boostinjdm.
I put it that way up so that the oil doesn't drain out of it when the engine shuts off, if it gets a leak in it or the check valves in the engine fail.
Also, when it is this way up the oil pipes can be completely hidden under the roll bar padding. If it was the other way up I would need much longer pipes to do that because it would need to go all the way to the rear of the frame and then back to the motor. Those pipes aren't cheap!

klr700sidewinderbuggy
01-23-2009, 08:13 PM
Heres my edge sidewinder ! im new to the forums here and thought id share

my swingarm has cracked in all the green lines. the red is where gusset was placed cracks kept following gusset. Would suggest boxing in take more precautins while your welding yours up. now powdercoating it again wont be fun.
http://i187.photobucket.com/albums/x226/airmiller44/sidewinderswingarm.jpg

Beelzeboss
08-26-2009, 05:14 PM
Buggy is pretty much complete. I've taken it apart and painted the frame with this KBS Coatings - Stop Rust - Tank Sealer (http://www.kbs-coatings.com.au/)
Results from the Rustseal were spectacular, but the top coat of "blacktop" looks pretty shoddy up close.

Anyway, a pic of how it looked before disassembly.
http://i231.photobucket.com/albums/ee224/jones_pbkt/9809.jpg

Yes, it's bloody loud!

Gene
08-26-2009, 07:43 PM
Caution! Do Not Use Armrest On Right!

kawonda
08-26-2009, 08:44 PM
Good job. I bet you can't wait to take it out.

Beelzeboss
08-27-2009, 03:52 AM
Caution! Do Not Use Armrest On Right!

LOL! I might have to put a heat shield there... nah!


Good job. I bet you can't wait to take it out.

You have no idea...

Cheers everyone.

buckotom
11-07-2012, 01:49 AM
Gday Beelzeboss
you wouldn't believe it I'm in year 12 at school in Sydney now and building the
exact same buggy but not quite so far through mine yet! haha
just wondering how you lengthend it for your height? was it awfully
hard or just a few simple steps? if it was really hard don't worry about it.. but if it wasn't too hard i wouldn't mind knowing what you did if that's ok?
Cheers