Home made Utility Vehicle A.K.A UTV

I started this project after I traded my quad for a motorcycle, my wife told me that I was not going to buy another. I told her that I would build one!

This guide is not intended to be a step by step, rather to show that it is possible without a great deal of skill.
I had no master plan, I just designed as I went. I also wasted quite a bit of time on parts that I ended up not using. The first mistake was trying to adapt a vertical lawn mower engine to horizontal (don’t waste your time).


A few major components and links:
Engine:

http://www.harborfreight.com/predator-420-cc-ohv-horizontal-shaft-gas-engine-certified-for-california-68306.html

Transaxle:
https://www.surpluscenter.com/item.asp?item=13-1468&catname=powerTrans

Gas tank:
https://www.surpluscenter.com/item.asp?item=28-1648-A&catname=powerTrans



Warning: Welding can be dangerous. I recommend taking a class if you do not know how.

Step 1 The Start

The first thing I bought to get started was a $50 ATV from craigslist that was missing an engine. I stripped everything from the frame and with an angle grinder cut it in half.

My brother has a Polaris Ranger that I got most of the dimensions from. I first determined the wheel base and extended my frame to match ( more or less).

The next part of this project I bought 1 1/4” square tubing to create a frame for the seat and floorboards.

Next I had to extend the width of the original ATV so I cut  off the shock mounts about 4” from the shock. I fabricated an extension plate to match the u-shape of the shock mount then welded both top and bottom of the seam to really reinforce this high stress area. With 1” square tubing I built out the frame and welded on bolt tabs for the swing arms.

Comments

[pj63]

What a GREAT Instructable.... It gives me awesome Ideas for a future Instuctable..... I Will post it once i've built it.... Right off to the 'Drawing Board' .... Thank You For a Well Written Project......Well Done....

[l8nite]

a work horse doesn't have to be pretty, just do what it needs to do. Nice bit of recycling/scavenging ! thank you for sharing