Instructables
Picture of Home made Utility Vehicle A.K.A UTV
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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.
 
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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.
marklundquist (author) 7 months ago
I used a torque converter which is a kind of automatic transmission. The transaxle has forward and reverse. Thanks.
jcramer47 months ago

did you do any kind of gearbox I've been working on a project very similar it would really help if you had any ideas. overall its a great instructable.

marklundquist (author) 7 months ago

I added 2 photos of the rear end (on page 3), I hope they help you.

pwensel7 months ago

My wife and I are moving to africa next year. I would like to build a few to take with me. Could you provide a lot more pics of the rear end?

ProfessorJWN10 months ago
That is a nice build. Good step by step instructions as well. Might go with a shade bigger rear tires and increase the speed a bit. never tried it myself, but for tractor pulling they used to alter the rim width to change tire height. might be able to do that with same tires, or just get some bigger kendas or somthign off CL:
marklundquist (author) 10 months ago
@amd_33 - speed = 32.19kph. Replacing the trunk/bed with seats, you would have to account for the engine location but sure anything is possible.
amd_3310 months ago
Hi I have 2 questions
-how fast does it go in km/h if you don't mind me asking?

-could I replace the trunk with 2 Back seats?
rayfalcon1 year ago
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 (author)  rayfalcon1 year ago
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.
nate12112 years ago
can you take some more pictures and go more into detail on how you have the jackshaft all rigged up.
marklundquist (author)  nate12112 years ago
I added jack-shaft info and pics please let me know if you have more questions.
pj632 years ago
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....
l8nite2 years ago
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