the new buggy project

[rober-VDP]

Hi everyone,

I'm Robert, and I'm new to the forum. I recently discovered how much valuable information is being shared here about kite buggies, and that’s exactly why this felt like the perfect place to share my own project and ideas.

I managed to get my hands on a buggy for just €100 — mainly to use as a base for reference — but to be honest, it’s such a rough self-built model that it almost brings tears to your eyes when you see it in person. So I’ve decided to design and build my own custom kite buggy from the ground up, using this one as a rough starting point and hopefully improving it with the help of your input and ideas.

My Plan:

• I want to build the frame primarily from 316 stainless steel, for strength, durability, and corrosion resistance.

• I have access to laser cutting for sheet metal and profile cutting for tubing, which allows me to work with precision and create a strong and clean design.

• I’ve got around 22 years of TIG welding experience, and I have a TIG welder and milling machine at home, plus access to a lathe at my brother’s workshop — so fabrication is definitely part of the fun for me.

The idea is to make this a proper design project — not just a one-off.

In fact, I plan to build not just one, but multiple buggies, for others who might be interested as well.
When I look at the prices of new bigfoot-style buggies here in the Netherlands (around €2200 / ~$2350), I strongly believe it’s possible to build something just as solid — if not better — for a much lower cost. Based on my calculations, I think the total material cost per buggy could stay around €800 / ~$855.

I'd love it if you’d like to follow along and help think things through — suggestions, improvements, and fresh ideas are all very welcome!

Looking forward to learning from you all and sharing the journey.

Cheers,
Robert
Noordhorn, Netherlands

[rober-VDP]

Anyone here own or have experience with a buggy that has rear suspension?
You don’t see it much — maybe because Bigfoot tires already soak up most of the bumps?
Still, I’d love to know how it rides if you’ve tried it.

I’ve come across a few examples like the VFlex and PTW Fandango — they definitely look awesome, and I imagine they ride super comfortably.
But is the added weight a major downside in practice?

And if you were building your own buggy from scratch — would you include rear suspension, or skip it altogether?
Curious to hear what you all think!

Robert.

[Elm Mousley]

Was a long time ago & didn’t end up going forward with it due to health, but info might help.

I never rode on a kite buggy, but rode in a few different diy sail buggies when I was planning to build my own & was looking for idea’s.

Some had suspension, other’s none, all had much more ridged wheel/tyre combinations (on salt lake SA)  & along with my stuffed back the suspension made a huge improvement in ride but I personally thought the more ridged lighter design’s, performance wise were quicker.

The ones I tried with suspension we’re mostly using modified snow skis as leaf spring’s in either duel & single leaf combination with both steel & aluminium frames.

The best of them was built from recycled aluminium roll/light bars, twin/split bar frame design with a pod nesting in between & using two split leaf’s either side. His first frame design was using a single bar & seat design similar to what you have (in steel), trying 3 & 4 leaf spring setups, but remember him saying cracking & bracing was always an issue both where the springs were mounted & axle met frame, (not pertains to you, but) also where the mast mounted. He experimented with steel twin bar frame with just a hammock seat laced in between, before he changed to much lighter aluminium which he said the two bar frame design gave him the strength to change too & added a pod for greater personal stability & wind resistance.

[RedSky]

Nice bug.

I had the Peter Lynn suspension buggy. It was my first bug so I had nothing to compare it with really.

If memory serves, the suspension helped resist lateral forces. Good on wet grass.

I currently ride the PTW Dominator 4, a very heavy bug with leading link front suspension. It helps dampen out ripples in the sand. It is nice to have but practically speaking, unless you're crossing the Gobi Desert then I'd skip it.

Instead I would design a buggy that made transportation easier.

I wouldn't be overly concerned about saving weight either unless you're entering your buggy into an organised race. Unevenly distributed weight will make you buggy twitchy and less effective at turning and stopping yet extra weight correctly balanced helps resist lateral forces and drives the kite further forward in the window for better performance.

I assume you are aware of the PTW website popeyethewelder.com and his many YouTube tutorial videos.

 

Good luck with your project. Keep us posted.

Tom

 

 

 

[rober-VDP]

Last week, I was able to ride my buggy for the first time on a large field near my house, and it went pretty well. I used a Nasawing 550, which is about 23.5 m². It was impossible to hold still when stationary, but once I was in the buggy, it felt great.

I also received the first drawings from a good friend who is helping me turn the paper design into a digital model, so I can have a solid basis for the design. There are still a few details that I might want to change, but I'm also curious about your thoughts.

[BobM]

Do you find this setup to be "twitchy"?

You might want to read up on "caster angle" https://en.wikipedia.org/wiki/Caster_angle