Dune buggy project

[Wild_Alaskan]

I'm retiring the lifan at the end of the summer and making a buggy. The rest of the Chinese parts on the lifan break too much and I'm tired of working on it, not to mention the suspension holds me back a lot. so I am going to make a custom buggy and use the motor out of it.

I've got the cabin and roll cage basically completed already and will try and get the front and rear suspension and a-arms done before I leave for school so when I get back I can simply drop the motor in.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0028.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0029.jpg

[Weldangrind]

It looks like you had lots of rectangular tube laying around; I hadn't thought of that as buggy frame material. Having a shifter buggy sounds like great fun, and you'll be able to use it in the snow.

Any plans for the title on the old frame?

[FastDoc]

I have my feet propped up and I'm comfortable with a fresh bag of popcorn to follow this thread. :P

I assume you are planning chain drive to a solid axle?

I'm wondering about weight. Looks like it could get heavy in a hurry.

Do you have and wind/weather protection planned?

I respect the level you brought your Lifan to. You broke a record of some sort there. :D

I don't blame you for resting that project and moving on to another. :wink:

[Wild_Alaskan]

Im planing on doing front and rear independent suspension using cv axels and such off of some old four wheelers I'm currently trying to buy

As far as weather protection it would be very easy to bolt a sheet of plexiglass on the front of it if needed for wind/roost protection. I've got some shocks in the mail, and my 4 point harness just got here.

[SpudRider]

Thanks for sharing this great project with us, WA! :D I'm subscribed. ;)

Spud :)

[FastDoc]

Sounds like an Oddesy killer, or in more modern terms, a RZR chaser! :P

[Wild_Alaskan]

Nice just got two 4x4 quad front ends. seem to both be 1993 honda fourtrax 300s. these should work great for my steering parts as well as a-arm pivots, cv joints hubs and wheels! pics coming soon.

[MICRider]

Nice just got two 4x4 quad front ends. seem to both be 1993 honda fourtrax 300s. these should work great for my steering parts as well as a-arm pivots, cv joints hubs and wheels! pics coming soon.

Sweet! Looking forward to the pics :D

[Weldangrind]

That sounds like it will have a fancy independant front end. I would have gone the hillbilly route and installed small block Chev valve springs in homemade spindles.

[Wild_Alaskan]

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/080502_105600.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/080502_122700.jpg

There are the two four wheelers, and also the shocks I will be using for the front

[FastDoc]

I am following this thread with a fresh bowl of popcorn. :D

[katoranger]

Did you get the whole ATV? I may be needing some parts.

[Wild_Alaskan]

i got basically two almost complete ones except for the rear axels and tires,

[katoranger]

I didn't bid high enough. Will keep looking. I like the 300 size atv.

[Wild_Alaskan]

Got one of the lower a-arms and mounts basically done besides reinforcing and shock mount

from the frame to the pivot point is 30.5 inches, should give me a lot of room for travel :lol:

(rear view)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/081602_210500.jpg

[Weldangrind]

30.5 inches! 8O I can't wait to see articulation pics.

[SpudRider]

Thanks for the update, WA. :)

Spud :)

[katoranger]

I forsee pics of big air.

[SpudRider]

I forsee pics of big air.
:lol:

I bet you're correct, Allen. ;)

Spud :)

[Wild_Alaskan]

here are some articulation pics!

got the upper one tacked together slipped the wheel on and took some pictures before i take it down and finish welding it

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/suspensiontravel1.png

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/suspesiontravel2.png

[katoranger]

What will you be using for suspension?

[Wild_Alaskan]

for the front I will be using the shocks in the picture on the last page. 14" eye to eye, hopefully stiff enough to support over a foot of travel.

[Weldangrind]

That looks like nearly the entire diameter of the wheel in travel! Awesome!

[Wild_Alaskan]

mhm and thats a 20" tire for reference :D

[SpudRider]

That looks like nearly the entire diameter of the wheel in travel! Awesome!
You need suspension travel if you are going to catch big air! :lol: Nice job, WA. :)

Spud :)

[Wild_Alaskan]

Got the other side finished up today.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0037.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0038.jpg

[FastDoc]

Now what will you do for your winter project?? Drive this bad boy I bet! :D

[Wild_Alaskan]

I wish! but i have to go back to school in 3 days so this project will go on hold for 8 months :(

[katoranger]

Will we get a Christmas break update?

[Wild_Alaskan]

possibly, haven't planned out travels for then yet

[Wild_Alaskan]

More updates coming soon. The new motor just shipped :twisted:

[Weldangrind]

New motor? I thought the 400 was going in the buggy.

[Wild_Alaskan]

That was the original plan, but i think with the extra weight of the entire buggy and operating in sand a little more power would be a good thing :wink:

[SpudRider]

Dont tease us! :? What motor did you order? :P

Spud :)

[FastDoc]

Gotta say more power is always better. :P

[MICRider]

I'm guessing... Snowmobile engine! Those thing's are beast! (But have no transmission)

[Wild_Alaskan]

Ok so i got a part of it :wink:

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/carbs.jpg

[Weldangrind]

I'm guessing Keihin CV carbs, so is it a Honda? A Hawk, maybe?

[katoranger]

I'm guessing Keihin CV carbs, so is it a Honda? A Hawk, maybe?

I was thinking the same thing.

[FastDoc]

I am trying to remember what type of carbs come on a Banshee.... :lol:

[Wild_Alaskan]

Well it got here today! so here is another teaser pic

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/P1010163.jpg
























And maybe some real pictures :P

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/P1010162.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/P1010165.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/P1010164.jpg

Anyone guess now?

[FastDoc]

EX500

[katoranger]

Must be. A 250 would be stepping down. Only 2 cylinders. Thought he would go bigger. :(

[Wild_Alaskan]

Fastdoc wins :D


more info on it:
http://www.motorcyclespecs.co.za/model/kawasaki/kawasaki_gpz500s_96.htm

[katoranger]

60hp at 9800rpm. Not bad.

[FastDoc]

Do I win a ride on it? :P

6 Speed will allow low final drive gearing while still pulling a fast top end. That will get you into the power right off the line for climbing and mud/sand etc. :D

Are you using the radiator for the same bike or making your own from something else?

EX/GPz/Ninja 500's used to be very popular race bikes. They even had their own class when I raced at Sears Point (now Infineon Raceway) in California. Good bike. Solid performing engine. 8)

[Wild_Alaskan]

Finished making most of the main wiring harness for it today and put all the parts I had for it together to show the general concept of it.


http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0050-1.jpg

And here is what the stock harness for this bike looks like.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Ex500D_wiring_diagram.png

[FastDoc]

Looks like a lot of electrons to me! Can't wait! :D

[katoranger]

Sounds like your home for Christmas.

[Wild_Alaskan]

I wish, I just have the motor components in Montana for now since shipping a motor to Alaska is nearly impossible through mail.

I have to split the motor in to <100lb pieces an then I can air freight it for fairly cheap.

[Wild_Alaskan]

here are some pics of the rear shocks, both are from crf250s should allow for plenty of travel even with the heavy motor in the back.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Snapshot_20121221_zpsa3ca3dee.jpg

[FastDoc]

Cool. KYB's? :D

[SpudRider]

Indeed, those are nice shock absorbers. :)

Spud :)

[Wild_Alaskan]

Showa I believe, adjustable compression rebound ect.

[Weldangrind]

Excellent idea! I never thought of mono shocks paired up to suspend a buggy motor. I've got a smaller buggy project here, and I might do something similar.

[Wild_Alaskan]

MY rear setup will be similar to this guys setup

http://youtu.be/8MzQgRn68Kc

Mine will be lower with less travel obviously, since my a-arms are shorter cause mine need s to fit in street lanes to get local street legality. I think he was going for 3.5 feet travel in his buggy. mine would be more like 1-1.5 ft.

[Weldangrind]

Very entertaining video! His accent places him somewhere in the Canadian prairies, and my guess is Manitoba.

What a lot of work to get the buggy out of the shop!

[Wild_Alaskan]

Some updates on parts I picked up in montana. Ive got most the motor parts here but an waiting on one box that is still in the mail. to answer fastdocs question I will be using a stock radiator and fan for the bike It only came with one radiator so if it needs more cooling I will add another.

I picked up some front hubs from the two wheel drive version of the quad that wont require modding cv spindles to hold them on. I got a set of 12 inch rims that will fit and a set of paddle tires that fit them as well as a a set of knobbies for use on streets and trails, or can be transfered to the front for more braking and steering traction in the dunes. I also have a set that is worn at about 50 percent that came with one of the quads that will be used as fronts fr the most part.

I also got some 1.5" diameter harley exhaust cores. I will be wrapping them in packing (unlike standard harleys) and making two mufflers for the dual exhaust.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0131_zps5a56cbad.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0131_zps5a56cbad.jpg.html)

Front and rear suspension comparison
Edit: Decided not to use the Smaller shocks due to horrible damping action, seals, and stickiness when actuated without the coil.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0132_zps20dd2723.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0132_zps20dd2723.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0133_zps99b31cd7.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0133_zps99b31cd7.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0134_zps27a915b4.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0134_zps27a915b4.jpg.html)


I also got a new helmet camera made by astak, Its similar to a gopro but with lots more features and a low price. :wink:

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0129_zpsbf4b2fc7.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0129_zpsbf4b2fc7.jpg.html)

[SpudRider]

That's a nice bunch of goodies! :) Where did you get the exhaust baffles? What are their measurements, and how much did they cost? I might be able to use that baffle on the stock muffler of my XR650L. ;)

Spud :)

[Wild_Alaskan]

they are 19.3 inches long 3.3 inches across at the wide ends and the perforated tube is 1.5" outside diameter. It is stamp perforated instead of drilled so inside diameter will be less.

I got them used off of ebay the listing stated this:

This is a set of 1.5 inch baffles for Rush slip on mufflers, they fit 95 to 13 touring. I looked them up on the Rush website and I think the part number is 155012DB. I know what mufflers they came out of , 3.5 inch slash down touring mufflers. Nothing wrong with them, My buddy was just trying different sizes in his dresser to get optimal power. Thanks for looking!!

[SpudRider]

Thanks for the information, WA. :)

Spud :)

[Wild_Alaskan]

More progress on the buggy, got the front end just about sorted out suspension wise. will have 14"" of travel total. Still have some work to do on reinforcing the a-arms and fabbing the right side suspension mounts.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0139_zpsd88b6308.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0139_zpsd88b6308.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0140_zps424a4ba4.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0140_zps424a4ba4.jpg.html)

[Weldangrind]

I can't wait to see this buggy in action!

[Wild_Alaskan]

Got the engine put together with fresh rings and gaskets, motor will be ready to mount when I get some all-thread and finish fabricating tabs. Tested the electric starter and it works very good.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0141_zps76b88bcc.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0141_zps76b88bcc.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0143_zpsa953a199.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0143_zpsa953a199.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0146_zps0a6dba19.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0146_zps0a6dba19.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0147_zpsb20aab78.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0147_zpsb20aab78.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0148_zps4bfbc0ac.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0148_zps4bfbc0ac.jpg.html)

[SpudRider]

Thanks for posting the update, WA! The engine looks good. :tup:

[Weldangrind]

Extra points for displaying it on the kitchen table. I can't tell the difference between Cinnamon Toast Crunch and the much cheaper Cinnamon Toasters from Walmart.

[SpudRider]

Extra points for displaying it on the kitchen table. I can't tell the difference between Cinnamon Toast Crunch and the much cheaper Cinnamon Toasters from Walmart.
:lmao:

Your sharp wit always brightens my day, Brother Weld! :D

[FastDoc]

I get the cereal in a bag which I assume is a similar generic. I like it fine.

[FastDoc]

I'm a cheap (frugal?) bastard. More $ for the Husky/KTM fund ;-)

[katoranger]

I buy the bag of kid feed too.

[SpudRider]

I was disgusted to discover the knockoff raisin bran I bought from my local grocery store the last trip was more expensive than Kellogg's Raisin Bran! :grr: I almost always check the price per ounce before I buy a generic product, but they fooled me this one time. :wtf: Never again! >:(

[FastDoc]

God help the guy who rips off Spud on his Raisin Bran.

[SpudRider]

God help the guy who rips off Spud on his Raisin Bran.
Amen! :lol:

I also fear for the woman who takes FastDoc in divorce proceedings. ;)

[FastDoc]

Amen! :lol:

I also fear for the woman who takes FastDoc in divorce proceedings. ;)

There will never be another of those.

I am in the process of perfecting bachelorhood.

[katoranger]

I think I would be living out of the hanger. :D

[SpudRider]

I think I would be living out of the hanger. :D
When I lived in suburban Portland, Oregon, I kept my ultralight trike in a hangar at a small, nearby airport. One of the guys lived in his hangar, and I think he had a nice setup. :D

[FastDoc]

Living in my current hanger would not be too bad, but at the time of the Big D my hanger had no electricity and a dirt floor. Still would have been better than my 5,000 SF home with my ex-wife in it...

[FastDoc]

Proverbs 21:9

'It is better to live in a corner of a roof Than in a house shared with a contentious woman.'

[katoranger]

I spent about a week in a ford escort. Bit cramped. It was nice not having anything.

[culcune]

My wife and I went for an hour and some minute plane ride yesterday evening for her birthday. We flew out of Somerton airport. After the flight, as we were driving by the hangars, there were a few guys hanging out at one. I looked in, and it looked like a man cave! Not sure if the guy lived there, but it could be done...

[FastDoc]

What a great birthday present for your wife!

Yes some of us personalize our hangers, to say the least;-)

This is the sign I have on the man door of my hanger.

http://www.amazon.com/MAULE-MAN-CAVE-Sign-Personalized/dp/B006493F4E

[culcune]

I love the sign! She really enjoyed the flight, and I had a blast. I had never been in anything smaller than a 727. I have 2 sources of video, and plenty of stills of the flight; due to my lack of success posting pictures or video, however, here on CR, it will take several months to do so! LOL

[Wild_Alaskan]

First rear a-arm is in place. The lower part of the other one is also ready for mounting. I hung the tire on the end of it to show size, should be able to get 16" of travel. Starting to look like a buggy now!

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0150_zps9eb8003c.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0150_zps9eb8003c.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0151_zpsa13ed70e.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0151_zpsa13ed70e.jpg.html)

[SpudRider]

It's looking good, WA! :tup:

[Weldangrind]

16" of travel! What a cool project. :tup:

[Culley_Bristol]

Just came across this thread and read it from start to finish!

I have always wanted to build a buggy out of box section but thought it'd be too heavy and cumbersome unless it had something over 500cc powering it.

Would love to see this thing in action.. HURRY UP! :D

[Wild_Alaskan]

this stuff is pretty high gauge stuff its not all that much heavier than the 3/4" id 1/8" wall tube ive been using for support

[Culley_Bristol]

I see..

Have you had much experience in this kind of thing? Are you following a plan or just doing as you go?

I used to have a cheap little 2 seater 250cc buggy but because of the sh*t laws in the UK there wasnt a single place i could use if off road for over 45 miles so ended up selling it for a road bike. (Which ironically was stolen and found burnt out after the little scumbags had abused it off road)

But anyway, like i said, i cant wait to see this in action.

Good on ya buddy.

Culley..

[Wild_Alaskan]

I basically just make it up as I go along, all the drawings are in my head ;)

[bogieboy]

I basically just make it up as I go along, all the drawings are in my head ;)

precisly how i built my gocart....LOL lots of folks said i was :crazy: for not having a formal blueprint.... i responded i do...i just dont have a hard copy...its all in my head, and i can already see the finished product....LOL to wich the flols that dont think that way just sorta walked away like :hmm: amd im like :hi::hehe:

[Wild_Alaskan]

More progress! Its gotten rainy here again so I have been spending more time in the shop instead of going riding for my spare time. I got my rack and pinion mounted, tie rods created and steering shaft set up for the most part. one of the rear a-arms are nearly completed, part of the rear cage is installed

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0154_zpsed0bf733.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0154_zpsed0bf733.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0155_zpsc1f40cff.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0155_zpsc1f40cff.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0156_zps267f65fb.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0156_zps267f65fb.jpg.html)

[Weldangrind]

What is the rack out of?

[Wild_Alaskan]

this is the rack i have in it, a perfect spread end load rack and pinion. Got it lined up just right and there is no detectable bump steer to the naked eye and the steering setup is extremely tight, no slop at all

http://www.ebay.com/itm/290438881075?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

[SpudRider]

Nice work, and good progress. :tup:

[katoranger]

Will this be finished this summer or you going to make us wait a whole winter for updates.:D

[Wild_Alaskan]

I will be in alaska until november so it should be done before i go back. Today i think i am going to work on testing the engine

[Weldangrind]

Bumpsteer was going to be my next question.

That's a cool rack. What kind of bushings do you plan to use between the rack ends and the tie rods?

[Wild_Alaskan]

It is an end load rack and pinion so the ends do not pivot they are designed to take all the load internally.

[Wild_Alaskan]

I think I misunderstood your question, there will be heim joints at each end of the rack, and the stock honda ball joints at the hub

[Weldangrind]

The tie rods still must articulate up and down as the control arms move; they have to pivot at the rack. Are you just using rod ends for that?

[Wild_Alaskan]

yes

[Weldangrind]

Have you considered using poly bushings to take some of the shock? I just installed some two-piece poly bushings on Mrs. Weldangrind's '01 Intrepid, and they're nicely made Napa units (the original bushings were rubber and wasted in 75000 miles). Perhaps you'd benefit from some DOM tube to support two piece poly bushings slathered in moly grease. The bushings I bought were dirt cheap and easy to get.

[Wild_Alaskan]

I cant imagine having too much shock issues, the other buggy Ive driven was relatively unaffected by impacts and pot holes. im sure the low pressure atv tires have a lot to do with it.

[Wild_Alaskan]

Got the cooling system plumed, and started on the rear shock mounts,

Made a couple adjustments and the total travel in the rear will be 17.5 inches at the wheel and the shock completely bottomed out.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0157_zps058610d1.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0157_zps058610d1.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0158_zps0f27fc4e.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0158_zps0f27fc4e.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0159_zps526c8f31.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0159_zps526c8f31.jpg.html)

[Weldangrind]

The rad looks safe up there. I'm looking forward to seeing the suspension completed.

[SpudRider]

That's very nice work. :tup:

[Wild_Alaskan]

Lots more updates! Got the floor in, the seat put on proper mounts, moved some front shock mount supports back to have room for the new pedal system, and got more reinforcing done on the rear end.

Seat belt is going in soon as well as the right front shock and the shift lever.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0163_zps81e08a3a.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0163_zps81e08a3a.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0164_zps4c67efc3.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0164_zps4c67efc3.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0165_zpsbb068c07.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0165_zpsbb068c07.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0166_zps094b6b41.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0166_zps094b6b41.jpg.html)

[SpudRider]

It looks good, WA! :tup: I see the CRF250X sitting outside, in the sunlight. ;)

[Wild_Alaskan]

right next to its replacement, the cr250 ;)

[SpudRider]

I'm loving my CRF250X. :tup: I like the smooth, wide power band of the 4-stroke engines, and I insist on having an electric starter. ;)

http://i442.photobucket.com/albums/qq146/spudrider/RR%20Jam/rbampoxcrf003_zps6c7d2fda.jpg (http://s442.photobucket.com/user/spudrider/media/RR%20Jam/rbampoxcrf003_zps6c7d2fda.jpg.html)

[Weldangrind]

WA, do you have a tubing notcher, or are you grinding those fishmouth joints by hand?

[Wild_Alaskan]

all by hand

[Weldangrind]

Wow, that's a lot of work. I use one like this, and it's very handy: http://www.ebay.ca/itm/KART-FRAME-MINI-BIKE-ROLLCAGE-PIPE-TUBE-TUBING-NOTCHER-/360711035498?pt=Motors_Automotive_Tools&hash=item53fc0d9a6a&vxp=mtr

[Wild_Alaskan]

probably would have been a good investment :)

[Wild_Alaskan]

sorry for the long while without updates, work has been keeping me very busy lately. I have worked on the buggy a bit, I've got all the shocks mounted up the front brake lines and master cylinder are setup. The carbs have filters and I got another set of large rims and tires for the rear for street use. Ill post some pictures tomorrow if I have time

[Wild_Alaskan]

I have decided to re-do some of the parts for the rear end, The crf shocks are not strong enough for the amount of travel I want to get out of the rear. I will be upgrading the rear end to 14" travel nitrogen spring fox shocks. These will have the added benefit of reducing the stress in the frame considerably. I will also be going with a 10mm larger 35mm axel for strength and to prevent some fabrication issues associated with the smaller drive axel.

I cleared out the garage a bit and put the wheels on the front and set it down, they are a bit soft but the damping action is smooth enough I cant get it to bottom out hopping on the front of it, I will likely just be getting stiffer springs for the front and keeping the smaller sized shocks for visibility purposes.

I will also be placing a large order of custom motion pro cables pretty soon. :)

http://www.ridefox.com/img/product/offroad/shocks/air-20-main.jpg

Ill try to get the pictures i promised awhile back aswell

[SpudRider]

Thanks for the update, WA. :tup:

[Weldangrind]

Good thinking. I learned from my quad that excessively strong springs will compromise suspension components, like bushings and tie rods.

[Wild_Alaskan]

Final update for the year, the buggy is sitting on its wheels now. the final travel specs for the rear is 19 inches. Stronger springs were installed on the front. the only things left to do are the drive train, cables, electrical, rear brake, seat belt, and some minor reinforcement of the a-arms and frame.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0178_zps48227ab8.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0178_zps48227ab8.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0179_zps22b79d0f.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0179_zps22b79d0f.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0180_zps91880be1.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0180_zps91880be1.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0182_zps37d48cf8.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0182_zps37d48cf8.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0183_zps29aed7d4.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/100_0183_zps29aed7d4.jpg.html)

[Weldangrind]

When it's done, you're going to want to power it with a 1.8L four cylinder, and sell that 400 to me.

[SpudRider]

It looks good. :tup:

[katoranger]

I forsee a larger powerplant after the initial phase. Its looking good. Will we see an update at Christmas time or will you be away yet?

[FastDoc]

Looking good WA, thanks for the update. Nice toi hear from you I hope life/school/work are all going werll for you.

Given the fact that motor is going to be run hard and at low groundspeed I would imagine cooling may be an issue. Are you going to fit a large radiator? Oil cooler? Fan?

[Wild_Alaskan]

i have the stock radiator set up with the stock fan that is going to be running all the time, it is located behind/above the drivers head where it should get good air flow while staying protected

[Wild_Alaskan]

probably no update for christmas, I will be back in town in may next year.

[Wild_Alaskan]

Had to clean the shop today so I moved the buggy out side. Got some pictures that weren't taken in a cramped garage. :)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0188_zps4317c535.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0188_zps4317c535.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0187_zps00266735.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0187_zps00266735.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0186_zpsf7166dd1.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0186_zpsf7166dd1.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0185_zpsa9779208.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0185_zpsa9779208.jpg.html)

[Weldangrind]

Sick! You have mad skills, sir.

[FastDoc]

Very impressive!

Looks like a nice sunny day also :-)

[Wild_Alaskan]

after the last month worth of rain the last two days have been beautiful!

[katoranger]

Will the CV shafts be able to handle all that travel?

[Wild_Alaskan]

Shouldn't be a problem the actual angle of them will be less than when fully extended on the quad they came from, im getting some of the travel by the arms moving past parallel with the buggy so for part of a full stroke they will be angling down, straight, them angling up. The one issue I may have is that I have a 60hp motor putting power through the cvs designed for a 25 hp quad, also I wont be using a differential. I'll see what happens and if things start breaking Ill go to a different design.

[pete]

Got the other side finished up today.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0037.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/100_0038.jpg

kool project......
remineds me of the days spending hours in the shed building/fixing/modding
speedway midgets...

PS..... Perhaps my sheds not that messy after all...

[SpudRider]

Tidiness is greatly overrated.


:lol:

[Wild_Alaskan]

https://www.youtube.com/watch?v=HF76vTWn7pw&feature=youtu.be

[Weldangrind]

I'm looking forward to action vids!

[SpudRider]

X2! :tup:

[2LZ]

Looks straight out of Johnny Quest! That's gonna be FUN!

[katoranger]

The summer returns in Alaska.

[Wild_Alaskan]

will have 15.5 inches of travel in the front and fox shocks also!

https://www.youtube.com/watch?v=-WNj_cFP9iw&feature=youtu.be

[SpudRider]

You work fast! ;) I love the time lapse video. :tup:

[Weldangrind]

15.5"! I can't wait for action video.

[Wild_Alaskan]

just got the first part of the drivetrain back from the machine shop. I will take some pictures soon.

I still have to do the foot pedals again and all the cabling and brakes

[Wild_Alaskan]

Drivetrain pictures

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0022_zps6d192416.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0022_zps6d192416.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0021_zpsbd1266d0.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0021_zpsbd1266d0.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0020_zps628e7a78.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0020_zps628e7a78.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0019_zps4453bb12.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0019_zps4453bb12.jpg.html)

new front suspension coming soon! more castor and travel

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/100_0023_zps626fedaa.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/100_0023_zps626fedaa.jpg.html)

[SpudRider]

That is very nice work. :tup:

[Weldangrind]

How do you stop the shaft from walking in the pillow blocks?

[Wild_Alaskan]

sprocket is from a 88 yamaha warrior rotor is from a 400ex as well as the caliper. everything has been machined very nicely so the is almost no runout anywhere on it.

[Wild_Alaskan]

How do you stop the shaft from walking in the pillow blocks?

the pillowblocks have set screws

[Wild_Alaskan]

https://youtu.be/4WWHfHOb_c4

[katoranger]

That is a teaser. We have been waiting years.

[Weldangrind]

Indeed! Man, the sound in that vid is awesome.

[Wild_Alaskan]

haha sorry guys! there is still a bit of work to be done, the honda rancher drivetrain isn't holding up to the power so it is currently being switched to chevrolet IFS components

[Wild_Alaskan]

ok here is what you hopefully wanted to see :P

https://youtu.be/FUmf6G6DE6w

This one is a virtual reality video, for the best experience view on a modern smart phone with the youtube app and you will be able to look around by moving the phone. you can view on a pc by clicking and dragging the screen.

https://youtu.be/_54y__sZr6E


More to come as the drive train is upgraded!

[culcune]

Haven't seen you here for a while! Maybe you have been here, but posting here only? I just happened to notice your name and think; "the guy who dropped a 400cc in a LIfan enduro!"

[Wild_Alaskan]

Haven't seen you here for a while! Maybe you have been here, but posting here only? I just happened to notice your name and think; "the guy who dropped a 400cc in a LIfan enduro!"

It has been a few years! I haven't done much with chinese bikes since the old 400. I figured there were probably a few people on here that wondered if this project was ever finished, so I figured I should post a few updates now that I once again have some time to work on it.

I am impressed how much it appears the chinese bike scene has changed, don't see much mention of lifan dual sports anymore...

[culcune]

don't see much mention of lifan dual sports anymore...

Lifan is coming back to the US any month now--actually they are back, two of their bikes are EPA certified, but I don't believe any are in dealers, yet.

They are bringing back a boring, but seemingly high quality, 200cc enduro. http://americanlifan.com/

[Wild_Alaskan]

Lifan is coming back to the US any month now--actually they are back, two of their bikes are EPA certified, but I don't believe any are in dealers, yet.

They are bringing back a boring, but seemingly high quality, 200cc enduro. http://americanlifan.com/

interesting looks like they at least completely re did the body, hopefully they got their suspension pivots in the right place too! haha.

[pete]

They should have used the water cooled 6 speed motor
in the duel sport/trail bike....



.

[BlackBike]

Lifan is coming back to the US any month now--actually they are back, two of their bikes are EPA certified, but I don't believe any are in dealers, yet.

They are bringing back a boring, but seemingly high quality, 200cc enduro. http://americanlifan.com/

Yes, I don't "expect" much from this 14 hp 63 mph moto

:doh:

[Weldangrind]

That 360 video was so cool! What camera are you using?

[Wild_Alaskan]

That 360 video was so cool! What camera are you using?

A Samsung Gear 360


so far the new drive train is coming along nicely, I will try and take some pictures today.

[culcune]

That 360 video was so cool! What camera are you using?d

YES!! I just watched it tonight (totally overlooked it the first time) WOW!! How technology has changed!!!

[Wild_Alaskan]

here are the initial mock ups for the rear A-arms

https://lh6.googleusercontent.com/0Xf7-dwLAbcNtkuBJRNqAl-UzE2H2uItBvZYSymvaw6xWJRkjvKH9YoUJvqBSROIV6Ui57taO z1c6cE-z5OS=w1680-h944-rw
https://lh6.googleusercontent.com/SH-8Em5jRHziAkQ35dEpKmH7fqjollzRNM5AGiDfmU2APrlsqRJAe kLPOGcyiiSyfvL3q3zHrvipV9dd_X1g=w1680-h944-rw

[Weldangrind]

I'm getting the dreaded little X.

[Wild_Alaskan]

I'm getting the dreaded little X.

yeah photo bucket is not letting me log in to my account out of nowhere, but just found i can get in through my mobile app!

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170330_204224548_zpsihkkk7o4.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170330_204202273_HDR_zpsuzayj2fr.jpg

[Weldangrind]

Is that an old FWD Chev sedan, like a Lumina?

[Wild_Alaskan]

Is that an old FWD Chev sedan, like a Lumina?

They are chevrolet parts but they are off of a 90s era 2500 pickup truck.

[Wild_Alaskan]

suspension mounts and a-arms are finished, drive train axels are cut and installed. waiting on the machine shop for the flanges to integrate with CV axels. I added a jackshaft since I may have needed to offset the chain for the flange couplers, it now has an additional reduction there as well as a larger rear sprocket, all chains are now 530 /#50.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170404_111342238_zpstjnaem5l.jpg

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170404_111356437_HDR_zpskz5dfev7.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170404_111356437_HDR_zpskz5dfev7.jpg.html)

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170404_161637063_zpsenpnsryk.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170404_161637063_zpsenpnsryk.jpg.html)

[Wild_Alaskan]

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170404_161655194_zpsgwaynnbe.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170404_161655194_zpsgwaynnbe.jpg.html)



If you like math and are interested in the gearing calculations here is the calculator I created

https://docs.google.com/spreadsheets/d/1I8_YKi-ttV9fBmvOMBMaDvIrZiH5Lywt0SeNGtc6uog/edit?usp=sharing

[Weldangrind]

You're an Excel star! Do you think you'll hit the theoretical 73mph in 6th?

[Wild_Alaskan]

You're an Excel star! Do you think you'll hit the theoretical 73mph in 6th?

hard to say, I am hoping to at least be able to reach 55 in 6th without needing to be on the redline. Anything beyond that is just a bonus!

[2LZ]

Welcome back, WA! Cool project!
I figured you're be designing Mars landers for NASA by now....... ;-)

[Wild_Alaskan]

Drive flanges are installed!

just have to extend the cvs, finish weld everything, and repaint

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170405_164830349_zpsu1v2sova.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170405_164830349_zpsu1v2sova.jpg.html)

[Wild_Alaskan]

Welcome back, WA! Cool project!
I figured you're be designing Mars landers for NASA by now....... ;-)

Not quite but I have created a design for a prototype reversible gear box that should comfortably hold 200 hp and easily be retrofitted in to motorcycle engine powered buggies and shifter carts. There is only one other out there and is priced at a ridiculous $1500 and forces the output shaft to be offset from the original driveline.

[pete]

looks like a fun toy..



..

[Wild_Alaskan]

Jackshaft arrangement

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170508_140619031_zpsohlbfkte.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170508_140619031_zpsohlbfkte.jpg.html)


Switched to modified porsche 930 cv joint on the upper part of the shaft since the chevrolet ones could not handle the 29 degrees of max angle I wanted.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170508_140649588_HDR_zpsdfafbc0g.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170508_140649588_HDR_zpsdfafbc0g.jpg.html)

[Wild_Alaskan]

It is once again back on the road, Just have to machine up the rear brake disc, make the caliper mount, and get these crappy carbs to work properly and I will try and get some action videos out.

[Weldangrind]

I'm looking forward to seeing that crazy articulation in action!

[Wild_Alaskan]

Final shaft chain tensioners
http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170511_185018702_zpsc6ssqwpj.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170511_185018702_zpsc6ssqwpj.jpg.html)

back on the ground with the old rear wheels on the front!

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170511_185050807_HDR_zpsgzjkrfo9.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170511_185050807_HDR_zpsgzjkrfo9.jpg.html)

[Weldangrind]

That poor Honda motor on the bench needs some love.

[Wild_Alaskan]

That poor Honda motor on the bench needs some love.

It got a new clutch and is back to the customer now. It is for some sort of three wheeler project.

Since these pictures the shop is unrecognizable, has been getting cleaned and upgraded for the last week!

[Weldangrind]

Shop pics are always welcome!

[Wild_Alaskan]

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170518_172259345_HDR_zps41rowwln.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170518_172259345_HDR_zps41rowwln.jpg.html)

[Wild_Alaskan]

well I warped out the keyways on the shafting a couple weeks ago, and have since put together and machined a new shaft design.

I guess I should believe the computer next time
http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/shaft%20failure_zpsc17ae0tu.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/shaft%20failure_zpsc17ae0tu.jpg.html)

The new design has permanently welded on brake and sprocket mount and splined cv hub connections allowing the bearings to be removed if necessary. The shaft is now 1 3/8 inches thick and was made out of two of these to save machine time: http://www.ebay.com/itm/291121564506?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT. They are coupled by a precision bored collar in the center so both ends are splined. The CV adapters were bored to accept splined couplers matching the shaft and welded to them. the sprocket and brake hubs were bored to near perfect angular runout before being welded to the shaft.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170604_135124720_zpsztqpsfgt.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170604_135124720_zpsztqpsfgt.jpg.html)

Doesn't seem to have any issue chirping the sticky automotive snow tires when cornering on pavement. or ripping full throttle 2nd gear doughnuts on gravel. Soon I will take it to the dunes for a real test, just need to do some serious upgrades to the trailer :)

[Weldangrind]

That is a work of art. I never thought of buying splined shafts like that; good to know they're available.


Will it be a big deal to remove the rotor when it requires replacement?


BTW, loving your YouTube channel! :D

[Wild_Alaskan]

That is a work of art. I never thought of buying splined shafts like that; good to know they're available.


Will it be a big deal to remove the rotor when it requires replacement?


BTW, loving your YouTube channel! :D

Thanks! I hope to have some good buggy content posted in the next couple weeks.

No it shouldn't be a very big deal, the flange for the cv will slide off the splines once the set screw is removed and the bearing will also slide off the shaft so wouldn't be too big of a deal. The sprocket is the same process for replacement

[Wild_Alaskan]

I spent the day adding rails to my shitty trailer to allow the buggy to park on it, so it can now go fun places.

http://i1154.photobucket.com/albums/p531/Sheridan_Joyce/Dune%20Buggy/IMG_20170606_192638082_zpsrci2vl0d.jpg (http://s1154.photobucket.com/user/Sheridan_Joyce/media/Dune%20Buggy/IMG_20170606_192638082_zpsrci2vl0d.jpg.html)

[Wild_Alaskan]

Finally a real ride video...

https://youtu.be/mjoXgcs5fhs

[Weldangrind]

Awesome! The suspension looks like it's working really well. Where were you riding?

[Wild_Alaskan]

copper river delta Alaska

[Gh426]

Nice work! Inboard brakes tons of travel done on the cheap! Diy at its best. beautiful & amazing.

Gh