Handmade Offroad Buggy (UTV)

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

I am a junior student at Turkey, i was planning to building a buggy since i was high school student. 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...

Mostly inspired from Chris Kraft's awesome creations, a.k.a 'Rather B welding' on youtube. Specially GS500 is my favorite.Thank you him from here for giving me ideas.

Chris's GS500 buggy : https://www.youtube.com/watch?v=4aDVCqYMWgY&t=602s

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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    17 Discussions

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    Makerneer

    18 days ago

    That looks fun to drive!

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    HuseynS1

    20 days ago

    Çok güzel sevdim! Bol Şans)))

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    ssiron

    23 days 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.

    3 replies
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    mertnalbssiron

    Reply 23 days 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.

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    ssironmertnalb

    Reply 23 days 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

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    Don Barthel

    23 days ago

    At first I thought that the combined engine and rear wheels platform, separately sprung, was a brilliant idea. Until I remembered the concept of unsprung weight:

    https://en.wikipedia.org/wiki/Unsprung_mass

    For good road handling, one wants as much of the weight of the vehicle sprung as possible.

    1 reply
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    mertnalbDon Barthel

    Reply 23 days ago

    Thank you for this brilliant comment Don! We started this project by focusing mostly on the off road issues like can it climb the hill? Or how much torque we should arrange? Actually the speed of buggy was at background just a little, so we never had problem of weight unsprung parts of the buggy. The max speed of the vehicle is not fast enough to be concerned. But i will definitely consider your advice in my future projects !!

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    kcmccready

    Question 24 days ago on Step 5

    Great project! I am interested in your DCT and 1:1 reverse. Can you share brands and/or from where you sourced the parts? I am using a similar 13hp Honda clone, not interested in using a 40-series torque converter. A DCT and reverse would fit quite nicely in my project.

    1 answer
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    mertnalbkcmccready

    Answer 23 days ago

    Thanks for your interest and good comments. I don't know what are you expecting from your project. Speed or torque? But if you want both i strongly recommend you to use a torque conventer or a multi-forward gear, because the speed will not satisfy you with the engine you have. My goal was high torque and i didn't use any gear system also we did increase the torque by decreasing the speed, with gears connections. Also you can write/ask me for anything. nalbantoglumertcan@gmail.com

    I bought the parts at a local shop which in Turkey. You can see in the links.
    http://www.baskentfreze.com/?newUrun=1&Id=893868&C...

    http://www.baskentfreze.com/?newUrun=1&Id=894006&C...

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    billbillt

    24 days ago

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