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

[rayfalcon]

whats the total vehicle weight non loaded dry weight? also How would it do if you took and got a little subaru wrx engine, a 4 cylinder engine or just added a turbo to the engine that you have on there now? and maybe wire a tuner chip or peformance chip into the mix with any of the engines. another thought that you might be able to do is synch 2 engines same size and everything one to drive the front axle and one for the rear axle, this way you get more speed possibly, less strain on one engine and if necessary you could always just run one engine and kick the other in only when needed

[marklundquist]

Vehicle weight: guessing about 700lbs. The Subaru engine looks to large to place it in. Also the transaxle is rated at 20hp. I have been looking at this engine:
http://glenssurplus.com/proddetail.php?prod=4a032-4&cat=471
It's a military 18hp 4 cylinder.

The engine that I used really has a lot of pep for what it is. I removed the governor and that helped. I am making a plow for it now we will see how it does.
Thanks for your suggestions.

[nate1211]

can you take some more pictures and go more into detail on how you have the jackshaft all rigged up.

[marklundquist]

I added jack-shaft info and pics please let me know if you have more questions.

[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