New Shredder Build

**Byronnn** · 09-26-2014 02:22 AM

Hi guys,
I'm going to be building a 2 seater buggy over the next few years. I've decided to go with a Rorty, either an R82 or an R16 Shotgun because it looks like they're some of the best plans around and make some really good buggies. I haven't done any metal fab before so I'll be learning as I go and leaning on my brother in law for guidance (and tools!) as he's a millwright with a lot of 4x4 building experience and a really cool guy. I live near Vancouver, BC so I'll be building the buggy primarily for dirt and mud trails. I've also found a local autobody shop who seems willing to work with me through the build to get the vehicle through the relevant structural integrity & mechanical inspections so I can drive it on the road. In general I plan to stick directly to the plans to keep things simpler, except where I have to add things like mud flaps and mirrors to make it street legal.

Right now I'm leaning towards the Shotgun (over the R82) because I haven't done any metal fab before and it'd be nice to buy the plates and some of the machined parts instead of having to figure more things out on my first go. The Shotgun is heavier and (I think) more expensive than the R82 so I'm looking for some input from the community here. Even after emailing Crisco and reading several threads I'm having a hard time determining the differences in terms of difficulty of building and the impact of the extra 100kg of the Shotgun on performance. I'd like to keep the cost of the build under 8k so I'll be skipping the RPM gearbox and sourcing some used parts where I can.

So far I've bought a wrecked 2005 Kawasaki zx6r ($800) which is currently blowing fuses and won't start, so the first order of business is to get it going so I can put 140hp into the buggy and sell the remainder to mitigate the cost.

I've also got myself an angle grinder, pipe notcher, drill press, vice, bench grinder, and a Lincoln 180 mig welder. I'll be installing a 220v plug and doing some practice welding as time permits. I'll be using my brother in laws tube bender so it looks like I'm on track to keep the tools under $1000.

It looks like most of the builds here were happening 5-10 years ago so I don't know how many people still read through this forum, but I'll keep this thread updated anyways.

Byron

**Duane** · 09-26-2014 03:08 AM

Welcome to the site Byronnn. Your plan sounds good. The under 8 grand part might be a little optimistic but the 2 year timeline softens that a bit. I look forward to seeing a Rorty design take shape.

**foulplay** · 09-27-2014 03:48 AM

I have a 16. beef up the front arms lowers bend and use at least 3/8 thick plate on spindels section.riped both open . also add bars to the front where the tubes come from front . buggy needs strength to these areas. other wise it is flawless great car, cant say enough . I picked my up in az.done though this site so I can only tell you about the performance . this r16shotgun needed a shakedown , after we finish these repairs,powder coat here we come [.powder coat was not done ]

**NEbuggy** · 10-05-2014 02:41 PM

I too am looking to build a R16 Shotgun. Have you bought the plans yet?

**rowycoracing** · 10-05-2014 11:08 PM

Welcome Byronnn! These buggies are a real blast to drive. You won't regret building one once you get in the drivers seat the first time. Have fun with the build!

**Byronnn** · 10-23-2014 04:20 AM

Hey guys, I've been busy with another project, but I've made a bit of progress. I have a powerhouse!
NEbuggy, I have not yet bought the plans.

I've decided to go with the R16 because it looks like it'll be better in a wet climate (Vancouver, BC area). Can someone confirm that besides the $550 plate kit and $850 CNC kit, the rest of the parts can normally be bought locally? Anyone know how much shipping is to North America for those packages?

I got the ZX6R running today, cycled through the gears and it seems okay besides needing an oil and coolant change. With the akrapovic exhaust and a power commander I think it's around 140 hp, or 7.9 lb/hp for a finished R16! Total cost was $1000.

http://www.youtube.com/watch?v=dMtrQDWH1po

Next steps:
-Get the motor out of the bike
-Do a bunch of practice welding
-Learn my local road regs and work with the autobody shop to figure out how many inspections I'll need along the way to make the vehicle street legal

The next few weeks I'll be tied up finishing my last project, restoration of a 2-stroke moped, currently full of air leaks and untuned:

I'll keep you guys in the loop as I make progress on the Rorty. Thanks for the help so far!

**N8ball** · 10-26-2014 01:02 PM

Originally Posted by Byronnn

Hi guys,
I'd like to keep the cost of the build under 8k so I'll be skipping the RPM gearbox and sourcing some used parts where I can.

So far I've bought a wrecked 2005 Kawasaki zx6r ($800) which is currently blowing fuses and won't start, so the first order of business is to get it going so I can put 140hp into the buggy and sell the remainder to mitigate the cost.

It looks like most of the builds here were happening 5-10 years ago so I don't know how many people still read through this forum, but I'll keep this thread updated anyways.

Byron

Byron,

I started an R16 build a few years back and it'll get done someday. Still looking for a round tuit. I have a sweet 4 seat buggy right now so I am not in a big rush. Nice work on getting the motor going. I think your hp numbers and your budget are overly optimistic, but don't let that discourage you. I am for sure going to read every post of your build so don't skimp on the updates. Keep up the good work.

**NEbuggy** · 10-29-2014 07:42 PM

Originally Posted by Byronnn

Hey guys, I've been busy with another project, but I've made a bit of progress. I have a powerhouse!
NEbuggy, I have not yet bought the plans.

I've decided to go with the R16 because it looks like it'll be better in a wet climate (Vancouver, BC area). Can someone confirm that besides the $550 plate kit and $850 CNC kit, the rest of the parts can normally be bought locally? Anyone know how much shipping is to North America for those packages?

As far as i can tell you should be able to get the rest of the parts from a local supplier. I have been trying to contact the Rorty guys about some questions I have but i havnt been able to get through to them. I am thinking that just buying the plans would be the best way to answer most of my questions.

I got the ZX6R running today, cycled through the gears and it seems okay besides needing an oil and coolant change. With the akrapovic exhaust and a power commander I think it's around 140 hp, or 7.9 lb/hp for a finished R16! Total cost was $1000.

-Get the motor out of the bike
-Do a bunch of practice welding
-Learn my local road regs and work with the autobody shop to figure out how many inspections I'll need along the way to make the vehicle street legal

Im kind of in the same boat as you. I have some fabrication experience and this will be my first build. I dont have my motor picked out and purchased yet tho but i guess im trying to figure out as much as i can about this buggy before i invest alot of time and money into it.

Originally Posted by N8ball

Byron,

I started an R16 build a few years back and it'll get done someday. Still looking for a round tuit. I have a sweet 4 seat buggy right now so I am not in a big rush. Nice work on getting the motor going. I think your hp numbers and your budget are overly optimistic, but don't let that discourage you.

I agree with the budget comment for sure. Ive researched for quite awhile and i expect to spend about 20k on my R16 build, but I will be spending a few grand on tools that i will need to complete the project such as a good pipe bender and a welder but i also plan to span it out over 2-3 years so that should help with the money issue lol

Anyways, good luck man and im looking forward to following your build so I can have some help along the way.

**NEbuggy** · 10-29-2014 07:43 PM

i obviously am not well vetted in the forums department lol

**Byronnn** · 01-04-2015 01:06 AM

Hey guys, I've made some minor progress on this project. I've decided to build a modifed Shredder II buggy instead of a rorty, primarily due to the width, cost and complexity of the builds. Most trails around here (coastal BC, Canada) won't fit an 83 inch vehicle, so I'm better off building the shredder, which is around a foot narrower.

My new plan is to put big tires and shocks on a shredder build and modify the drivetrain to handle the 130ish HP of the ZX6R engine.

Also, after talking to some local autobody guys, it'd be MUCH cheaper and simpler to buy a utility trailer to tow my buggy than try to get it insured for road use, so I'm going to go that route.

Unfortunately this will make the build less interesting for the rest of you to watch! But I think it's the best option for my first build, and I can always make a Rorty as my second build if I'm still interested.

Perhaps a moderator can move this topic to the Shredder build subforum?

Here's the engine ready to be put into something new:

I'm in the process of selling some of the leftover parts, I think I'll be able to get the cost of the engine down to a couple hundred.