David's 250 Micro Burst

**daaboots** · 12-04-2012 06:53 PM

Well, here we go again. I built my very first buggy a few years back, and it turned out ok. Just ok though. Over the years, I quickly learned what could have been done better. Since then, I built a buggy for my wife and it turned out much better than mine. I then registered for ATV plates, found some insurance, and bought Ontario ATV trail passes so we could drive our buggies on the trails. My buggy is in really rough shape though - cracks in the frame, engine running bad, no reverse, and things just constantly breaking.

Time for take two

I spent some time in Sketchup modeling my buggy and came up with a few improvements along the way. It will still be single A-Arm in the front but I've added single A-Arm in the rear and reverse. It will still be powered by my Yamaha SR250.

Here is the original build if you're interested https://www.minibuggy.net/forum/proje...tom-buggy.html

I wanted to give it a name, so I came up with Micro Burst - small but potent! I like it

My Sketchup drawings:

I'm starting my build at the rear working with the Polaris FNR and my engine. I want to get this just right. After looking at the FNR, I came up with an idea - I could extend the output shafts and use the FNR as a center spool as well. The shaft was 0.980 - darn, not quite 1". So after a lot of though, I decided just assemble the shaft with the bearings and then weld the shaft extenders. So now if the bearings go, I'll need to cut and re-weld. Not the best, but oh well.

Once welded, it was back to the lathe to turn the extenders true.

Next I'll be cutting them to the exact length and adding the key ways for the U-Joints. Stay tuned...

**n1kogr** · 12-04-2012 07:51 PM

nice i will be watching this one. Will you be salvaging many parts form your first buggy for this build?

**daaboots** · 12-05-2012 07:01 AM

Originally Posted by n1kogr

nice i will be watching this one. Will you be salvaging many parts form your first buggy for this build?

My plan is to use as much as possible from the first build - front shocks, rack, brakes, steering wheel, seat, wheels, etc. So aside from some rear shocks, I should have all the parts I need.

**daaboots** · 12-07-2012 08:25 AM

Made some progress on the rear plates for the suspension mounts points and rear spool.

And this is just a quick mock up of what it will look like. The Polaris FNR will be mounted in between the two plates with bearings on the end of the shafts. I still need to cut the shafts to the correct length and add the keyway slots.

Finally, some videos of my Excello mill in action.

Excello cutting steel - YouTube

Excello mill cutting a slot - YouTube

Bearing support brackets are next.

**custom39** · 12-07-2012 10:57 AM

looking good!

**TONYCYB** · 12-07-2012 01:45 PM

very cool

**daaboots** · 12-08-2012 03:37 PM

Having a decent set of plans this time around makes work really easy. I made the bearing brackets today and then placed the FNR and engine in place for a quick mock up.

**lillert** · 12-10-2012 08:26 AM

Nice work! I'm looking forward to see your solution on mounting the axles

**nutnbolt2002** · 12-10-2012 08:29 AM

Are you keeping with the single a arm Dave? Thats a great idea you have there.

**daaboots** · 12-10-2012 10:14 AM

Thanks guys. Yup, I'm staying with single A Arms. Double would be nice, but I'm happy with the front single A-Arms on my current buggy and single arms in the rear will be a nice upgrade from my current design. Plus, I only need to purchase 2 U joints, and the axles will just use 1/4 key ways. Simple and cheap