Handmade Offroad Buggy (UTV)

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Introduction: Handmade Offroad Buggy (UTV)

About: Manufacturing engineering student at Sabanci University (Senior), @Turkey. Interested at modeling and creating fun stuff.

I am a senior student at Turkey. After i learned Solidworks and 3d sketching methods, i started to planning it by myself. I got really helpful tips from the qualified work-mans when i get stuck and they handled the most of the building work like welding, cutting etc.. After really hard working effort, our first prototype was ready, of course with some deficient parts...

You can download Solidworks body sketch:
https://grabcad.com/library/handmade-offroad-buggy...

Solidworks Visualize animation:


For the test drive :

Step 1: Assembling the Ready Parts

First step was buying parts that we can't build with high efficiency. We bought the parts of Lx200 ATV vehicle (wheels, suspension, brake system, top and bottom swings, hubs, rods, etc.)

The second step was assembling the parts that we bought in order to design that we had planned as seen in the picture. After assembling, we realized that the shaft of the ATV wasn't rigid enough as we wanted, then we strengthen the shaft with shrink fit technique.

Step 2: Creating Front Chassis

After assembly, the measures of front chassis is determined. We sketched a 1:1 technical drawing and cut the parts according to dimensions.

Second step was creating the ears for suspensions.

After welding the cut parts, the front chassis is formed.

Step 3: Creating Middle Chassis

We watched to same steps as we did in the front chassis.

Step 4: Creating the Upper - Middle Chassis

After some measurement which is depending on seat, engine place etc.. We started to create upper part of the middle chassis which we are going to attach one edge of suspensions. Back support point.

Step 5: Mounting Engine

We used Loncin G420FD cc gasoline engine (15hp-2600rpm) and we used the dual clutch transmission and 1:1 reverse transmission for engine. I bought them online from a shop which manufacturing/selling hobby stuff for creators.

Step 6: Power Transmission and Steering Box

We connected to engine - 1:1 transmission - shaft by using the chain power transmission which has 1:2 ratio because it is an off road vehicle we need a higher torque.

After that, we bought a scrap steering box and other steering parts, which belong to a FIAT UNO, we cut it the dimensions as we demand.

Step 7: Gear Shift

We designed a basic gear shift system which has reverse and drive. Then we created it on a CNC machine.

Step 8: Creating Top Chasis

After finishing the design and painting of the top chassis, we assembled it with the main chassis.

Step 9: Final

At the end we have 2 different painted, top chassis.

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    29 Discussions

    0
    25stonta
    25stonta

    7 months ago

    now I want to make one for me and my brother's

    1
    TheOriginalNerd
    TheOriginalNerd

    1 year ago

    This turned out real nice! It sort of reminds me of the old Honda Odyssey from the 1970's and 80's. Those were lots of fun, so I'll bet yours is too!

    0
    somedude14
    somedude14

    Reply 1 year ago

    haha, cheers

    1
    Dumbphone
    Dumbphone

    1 year ago

    Amazing job on a beauty of a buggy.

    1
    yeetbruder
    yeetbruder

    1 year ago

    sweet
    gnarly, mate
    awesome project

    0
    Luke1906
    Luke1906

    Question 1 year ago

    could you share what parts you used and the estimated budget.

    0
    mertnalb
    mertnalb

    Answer 1 year ago

    Mostly used LX200 ATV vehicle perts (wheels, suspension, brake system, top and bottom swings, hubs, rods, etc.).

    0
    Luke1906
    Luke1906

    Reply 1 year ago

    Thanks a million!
    -Luke

    0
    Luke1906
    Luke1906

    Tip 1 year ago

    can you attach the solid works file

    1
    fred1896
    fred1896

    Question 1 year ago

    can i have a go? :D

    0
    billbillt
    billbillt

    1 year ago

    GREAT JOB!.. SOLID WORKS IS AN AMAZING 3D CAD PROGRAM.. GLAD YOU HAD ACCESS TO IT...

    0
    fred1896
    fred1896

    Reply 1 year ago

    yeh what he said i agree. i always used to use sketchup and programs like that but u can't beat solidworks :D

    It was a massive change when i upgraded ;)

    0
    Makerneer
    Makerneer

    1 year ago

    That looks fun to drive!

    0
    HuseynS1
    HuseynS1

    1 year ago

    Çok güzel sevdim! Bol Şans)))

    0
    ssiron
    ssiron

    1 year ago

    I built one similar except I used a Comet torque converter/variable speed clutch and a f/w reverse transmission. The bad news the transmission is no longer available. You designed an interesting project.

    0
    mertnalb
    mertnalb

    Reply 1 year ago

    Thank you for the good comment! We also had a similar experience, my gearbox was cracked last month. But fortunately it was in the warranty cover. Was the reason of your gearbox cracking is, ball bearing? Because mine was it is.

    0
    ssiron
    ssiron

    Reply 1 year ago

    What kind of transmission. Mine is still working, but since it's older having a source for a replacement is a good resource. They're getting scarce in the US