Big Earl - 17-7-2009 at 10:49 AM
Here is a list of the materials I used to make the current version of my buggy. I will put up how I did things and the bend and cut angles I used over
the next week or so. I hope this is helpful.
Materials list:
8'- 1" i.d. schedule 40 pipe - side rails
5'- 1 1/2" o.d. .120 wall pipe - axle
3'- 1 1/2" x 2 1/2" .120 wall box - swan neck
7'- 1" o.d. .120 wall pipe - forks, foot pegs, backrest
6"- 1 1/2" o.d. (1 3/8 i.d.) pipe - headset
1'- 1 1/4" solid round - axle bosses (what the rear wheels screw into
2 pcs. 5/8 i.d. x 1 1/2" spacers - front axle guide
3'- 1/4 x 1 1/2 strap - side rail axle mounts
1'- 3/16 x 4" strap - swan neck/ side rail mount
4'- 1/4 x 1" strap - foot peg mounts, forks, fork supports
2 pcs 5/8 i.d. x 1 3/8 o.d. radial bearings (precision bearings are probably better but the radial ones are cheap and easy)
3 pcs. wheel barrow wheels/ tires with 5/8 bearings
4 pcs. 1/4 x 2 1/2" hardened bolts - swan neck/ side rail mount
4 pcs. 1/4 x 1 1/4" hardened bolts - axle/ side rail mount
8 pcs. 1/4" nylock nuts - all 1/4" bolts
16 pcs. 1/4" washers - 2 ea. all 1/4" bolts
1 pcs. 5/8 x 8" bolt - front axle
1 pcs. 5/8 x 6" - headset
2 pcs. 5/8 x 5" - rear wheel bolts
2 pcs. 1/4 x 1" steel bolts - foot peg mount
2 pcs. 5/8" nylock nuts - headset, front axle
2 5/8" washers - headset
Thread lock
Tool list:
Tape measure
Hydraulic pipe bender (I have a 12 ton)
Welder suitable for 1/4" material
angle grinder with a grinding wheel and a 4 or 4 1/2" cut off wheel
Drill with 9/32, 5/8, and 29/32 bits ( a large universal bit will work for the 5/8 and 29/32 bits )
Miter saw with a metal cutting disc
Pliers
Wrenches 15/16 and 1/2
Vice not essencial but very helpful
2 - 3" clamps
2 - 2" clamps
Any body building a buggy and would like some ideas, good or bad I would love to be in on your project!
Here is a pic of the swan neck before welding. It shows the angles to cut it at and the length of the tube(the length is for the side the arrow points
to). After getting all the pieces cut I ground a 45 degree bevel on the edges to be welded together(this helps the weld get better penetration). Then
I put one piece in the vice and the connecting piece on top and lined everything up with the aid of a magnetic square. Next I put 4 spot welds on the
corners to secure it, next I welded each side. After that I did the same thing with the third piece.
dylanj423 - 17-7-2009 at 11:09 AM
any pics of the finished product?
Big Earl - 17-7-2009 at 01:05 PM
Here it is.........
The first set of how to pics doesn't have the suspension, that will follow. I think I may remake it to work the same but look a bit cleaner.
dylanj423 - 17-7-2009 at 01:14 PM
csa_deadon - 17-7-2009 at 04:38 PM
Nice job.
Big Earl - 17-7-2009 at 05:13 PM
The next installment, click to enlarge the picture it will make reading easier.
Big Earl - 17-7-2009 at 05:34 PM
The headset. It's not as complicated as you may think.
Big Earl - 17-7-2009 at 06:05 PM
The forks. This one is getting a bit crouded, please bear with me.
Big Earl - 17-7-2009 at 07:15 PM
More info on the forks......
Big Earl - 17-7-2009 at 07:26 PM
Foot pegs........
Big Earl - 17-7-2009 at 07:38 PM
Finishing forks....
Big Earl - 17-7-2009 at 08:46 PM
Plate work begins......
Big Earl - 18-7-2009 at 05:56 PM
More plates.......
Big Earl - 18-7-2009 at 07:44 PM
Side rails......
Big Earl - 22-7-2009 at 05:47 PM
Suspension!......
Big Earl - 22-7-2009 at 05:48 PM
more suspension......
Big Earl - 22-7-2009 at 05:49 PM
still more.......
Big Earl - 22-7-2009 at 05:50 PM
Don't forget to click on the image to make it readable
