buggy Home Build of a real Franken Buggy

[PiratePete]

ok here goes, i'm putting together a buggy from what once was a trailer when i had the dragster.

it is 1.8m wide and yet to find out the length.

i've just started cutting the downtube and will weld it this weekend. got 40 x 8 flat for the forks and headstock, will work it out as i go along.

 

 

 

 

[PiratePete]

just finished welding downtube and forks

[Clive]

In the interest of safety...... Geez how can I put this......

Do you have a friend who has a mig welder, thin walled is much easier with one, the stick welder can be a bit brutal if you don't do a lot of it.

 

Edited September 4, 2015 by Clive
:-)

[the_hatman]

the forks may need some lateral stiffening(that being kind, the may). So what size rubber are you putting on the front?

[PiratePete]

how much thicker than 3mm you want the walls? not light weight at all.

the forks may need some lateral stiffening(that being kind, the may). So what size rubber are you putting on the front?

the single wheel is the front, same as back

[the_hatman]

@PiratePete the 40x8 will be about 12" from axle to the yoke

[PiratePete]

you can see my old hot wire on the dragster in this video, i'll have to go hot wire again, this buggy is gonna be very heavy.

[andy666]

Good on ya for having a go at building your own buggy. There are only a few of us on here who have.

[gum-nuts]

you can see my old hot wire on the dragster in this video, i'll have to go hot wire again, this buggy is gonna be very heavy.

similar to my Hotwire, but mine's hooked to a depower chicken loop.

Good on ya for having a go at building your own buggy. There are only a few of us on here who have.

I wish I had the skill/knowledge to build my own.

[PiratePete]

downtube ground and undercoated, forks light undercoat,

to do list

** drill holes and assemble steering head,

**drill holes for axle and fit axle and wheel.

**adjust side rail connection to take new size downtube.

**cut downtube to length and weld into side rails.

**find location for footpegs, weld footpeg supports, and pegs. fit straps.

**fit mud/sand flap

similar to my Hotwire, but mine's hooked to a depower chicken loop.

I wish I had the skill/knowledge to build my own.

not that much skill required mate, but just add a little know how,  a little experience with big buggies, and with a little bit of welding with a small home welder, and a grinder to fix the mistakes and make it look nice. mild steel is easy to weld, so thats what i use. thick as i can get, mostly 50 x 50 x 3mm box and 40 x 8mm flat.

[IMK]

Nice!  Out of curiosity, what are you going to do for the seat?

Edited September 4, 2015 by IMK

[PiratePete]

Nice!  Out of curiosity, what are you going to do for the seat?

arrgh!!!!!!!!!!!!!!!

HAHARRRRRR!!!

good question. got a few options. first is to use a plastic chair, modified to fit and held in place with belts , not the average plastic chair btw. a type i have used before. this is easy, and quick and i might go this way while i tackle the seat built and saw up.

second option is to make one. i found an outboard motor cover, it has a remarkable resemblance (turned upside down, and with the use of a vivid imagination)  to a  comfy race buggy seat. add some straps to attach it, add some wooden back support, some padding, and a second skin. i think i have an old gold bag cover in a draw somewhere.

i need to get a seating position worked out so i can work out the foot peg attachments and supports. and also finalize the overall length.

to do list

** drill holes and assemble steering head,

**drill holes for axle and fit axle and wheel.

**adjust side rail connection to take new size downtube. WORKING ON TODAY

**cut downtube to length and weld into side rails. WORKING ON TODAY

**find location for footpegs, weld footpeg supports, and pegs. fit straps.

**fit mud/sand flap

**Seat

**GPS holder

**pump up and check tires. that are all 20 x 10 x 8 what pressure?

[PiratePete]

bit more done today, steering head almost 100%, attached downtube to side rails.

bit of a crap photo, but hay, was a quick one.

to do list

done    ** drill holes and assemble steering head,

**** steel for fork extention and footpeg bracket and footpegs, + axle.

**drill holes for axle and fit axle and wheel.

done    **adjust side rail connection to take new size downtube. WORKING ON TODAY

done    **cut downtube to length and weld into side rails. WORKING ON TODAY

**find location for footpegs, weld footpeg supports, and pegs. fit straps.

**fit mud/sand flap

**Seat

**GPS holder

**pump up and check tires. that are all 20 x 10 x 8 what pressure?

[PiratePete]

 

[ssayre]

Nice work. That didn't take long. 

[soliver]

I like how you made the flat bar on which the footrest is mounted the same as where you drilled for the front wheel... looking good! 

[PiratePete]

made two fabric seats, first was too small, second was comfy, but only lasted two laps of the beach.

did a rethink on trying to make anything look like i think i know what i'm doing and used an old billy cart seat, i had to remove it from the billy cart too!

anyway, ready for test run number two, had to work on freeing up the seized front wheel bearings, i've got a mud guard ready to attach, and am working on a hot wire.

during the first test run last weekend, i had forgotten how much these kites can pull, and i felt like i was being dragged out sideways, but i wasn't. i was trying to get the buggy slideways but alas the bloody seat gave-way, my ass was hanging out and dragging on the sand. good brakes......

[ssayre]

hotwire hotwire!!

Nice build.  Really itching to round up some steel and make one in the winter.

[soliver]

Truly Function over Form!... Great work and be sure to add more pictures as you finish it up with all the buts you just mentioned!

[the_hatman]

I used one of these in my first bug as the replacement seat

worked OK didn't have the handles.

 

Edited September 16, 2015 by the_hatman

[twojaythomo]

That looks great, I have never welded a thing in my life but I got a brand new mig in the shed, when I get to Newcaslte I will be making a heavier buggy to handle a bit more speed.

[PiratePete]

thanks for the comments.

as far as a seat goes, i'll try this wood one, if its ok it will stay, if not i'll get one custom made or just buy one off the shelf, hahaha, as if.

it's now ready to hit the beach full on, got the hotwire sorted, sand/mud guard fitted, foot & heal straps fitted,  got the front axle bolt and steering bolt double nutted, and most other issues like the seat sorted. bearings are passable but not new at all.

found my old gps holder and garmin handheld gps too! thats a win.

edit: making a couple of end plates for the foot pegs so i can loose the foot straps.

[SoutherlyBuster]

Pete, with the seat that low I think you might want to consider adding a scraper to smooth the beach out for your kiting buddies, like this one

[PiratePete]

second time out of the garage and i got a bumpy 55.1kph, gotta get the wheels balanced i think. really got to rethink the heal straps, need more security at speed.

 

[the_hatman]

no knead for the grader just follow Pete