I find it kinda funny that after I put so much "original" thought into this that I later browsed the forum archives to find others with many of the same solutions. Here is a simple tutorial for those who want to take this on, will most likely carry over to other types of buggies, but this project was with a Flexi.

For the Flexifoil, needed.
(all available from hardware store for @ $30)

4- 1.25" PVC couplers
2 - 1.25" T fittings
2- 1.25 to 1" reducers
3- 2" 1.25" sections of PVC
2 -1.25" elect. 90d elbows
2- 3/8x2.5" bolts w/ nylock nuts
1.25 pipe insulation
silicone sealant
tie wraps
PVC cement

1) Start by grinding the pipe stops inside 2 of the couplers to make a nice interference fit over the larger pipe coming off the axle. (the ones with the bushing in it)

2) slip a section into the coupler to find out how far it seats

3) measure the CL of the bolt hole from the end of the coupler and match drill it to the axle.

4) glue in the sections to the couplers

5) place the T fittings over the other end of the sections

6) fit the reducers in the other end of the T

(I did not use glue in the last two steps, you'll find the reducers already have a nice fitting over the side rails)

7) fit all this over the side rails and bolt into place

8) Fit the 90d elbows w/ 2 couplers and a section joining them together and fit into the T fittings,

(you might have to shave the section to get it just right)(again I did NOT glue the elbows to the T's)

9) after all is fitted together, glue the elbows to couplers and couplers to section.

10) Wrap assy with pipe insulation and tie wrap in place

11) seal ends of lower couplers and reducers with silicone sealant.

and your done!


http://i792.photobucket.com/albums/yy201/apextech1/P1011432....


http://i792.photobucket.com/albums/yy201/apextech1/P1011433....


http://i792.photobucket.com/albums/yy201/apextech1/P1011434....


http://i792.photobucket.com/albums/yy201/apextech1/P1011435....

Turned out pretty nice. It's amazing how quickly we become creative when are backs are killing us after hours of buggying in a buggy with no back rest!

Watch your elbows on those tires...!!!

One addition I've made was to fit a 1" diameter length of the grey PVC inside the top (so it fit inside the coupler and top part of the elbows). for strength. I originally flipped the bug and broke it there, now its very strong.

Are you going to make a cover for the back rest.

Susan (npw goddess)

hadn't planned on it, its covered with foam pipe insulation

COOL! good idea, and well executed.

I'm glad I have the VTT rails though,... I feel like I'm riding in a lazyboy.

Here is a copy for a back rest cannot remember who I ripped it from

I think its from Beamer Bob.

Very neat job there, well done

Quote:

Originally posted by nocando Here is a copy for a back rest cannot remember who I ripped it from

Yes, I did that drawing. Didn't look at the pic to see which one but I have a drawing for an XR+ and the previous model Flexi stainless which might also work on the Scout and forthcoming stainless model. Actual examples are currently on tridude's bigfoot, Pokitetrashes Flexi bigfoot and Drewculous has my old Flexi bigfoot with one. Sturdy and worked well too. No welding for those unable.