I've been interested in buying a zooter to retrofit for my flexifoil buggy, but after studying the pictures on their site, I realized it looks like it's a basically a bunch of windsurfing gear fitted to a the goose neck of a buggy.

So I decided instead of paying $900 for the kit (which only has one size sail), I'd try the DIY route.

I've already picked up 2 sails and a mast extension. I still need a mast, I'm hoping to have the mast/sails/extension covered for less than $300 total.

What I do need is the mast base, where the sail meets the buggy, and unfortunately I'm not a metal fabricator. But I am an engineer and I'm in the process of designing the base for fabrication.

If anyone on here want's a small fabrication project, I'll be happy to make it worth your while, and I can provide drawing with all the specs I'm looking for. I know there's some extremely skilled metal smiths on this forum, so if you want to help I will forever be in your debt!

I'll post pics as I go, but for now it's just a couple of sails. I welcome any advice or ideas people have along the way.

I might be up for that Ben,I will need sketches and measurements and I'm also on the east coast.

Cool man, I should have something sketched up this week. Once you know what I'm after you can let me know if it's doable.

I was going to suggest WG. He will do a good job for you.

I've got a similar project I've been working on. I recently acquired a "Windskate", which is an aluminum framed delta shaped wing, meant for use with rollerblades, but which I've been trying to adapt for use with the buggy. I've devised a method to attach the apex of the wing to the headstock of the buggy with a welded steel ring around the neck tube, then using chain and connectors to attach to the wing.(I'll post pics tomorrow) This leaves the wing free to be brought overhead/to the other side of the buggy when changing directions. This setup works, I've gotten moving on a few occaisions and have turned and come back to starting point, but the problem with it is I'm taking all the force on my arms, and can't hold on for very long. I'm thinking a line from the rear axle that ends in a pulley, which is strung over a line from wing-tip to wing-tip might provide the added leverage needed to hold on longer. More on this when I can give that a try.

Sounds cool Bob, I'm looking forward to pictures.

WG - This is a rough design of the mast base I'm looking to have fabricated. If you right click and "open in new window" there's a high res copy




I used a bunch of colors to make explanation easier, but it's basically all one piece.

As you can probably tell, the grey piece on the bottom is the gooseneck, so that doesn't need to be made but I included it for clarity.

The blue part would be an angled bracket to attach the yellow mast base which I estimate will be about 32" tall.

The green piece would be welded to the yellow mast base, and would support tie backs that would attach to the rear axle and provide support for the mast base. As you can probably tell the attachment points on the green piece are angled outwards.

The orange piece would be an attachment point for the boom. The attachment points are perpendicular to the yellow mast base. This piece would need to rotate freely around the mast base. so left and right rotation as well as variable angle for the mast which would attach to those points.

Aside from that there are 2 attachment points for the main sheet blocks. One just below the green piece, and one on the mast blue attachment bracket.

So that's my plan, hopefully it's something that's easy enough to fabricate. I'm waiting for one more part to come in, which tracking says wednesday, and I'll have the exact measurements I need. I thought in the meantime I'd post my idea and see if it's doable.

So, WG, let me know what you think.

Awesome plan! I can't wait to see what this will look like once it's all done. Are you planning on bringing the finished project up to Wildwood in October?

It will definitely be making the trek down to WW this october, assuming I can get it all together by then, aside from this piece I've got basically everything else I need.

I'm thinking about getting a wide axel for the flexi as well, add some stability for the Booter (ben's zooter?? still working on a good name) and just conventional kite buggying, since this rig should be easily removable.

Cool. That drawing looks like it was done in CadKey.

I sketched it up in Microstation....it's not the best but I usually do transportation related work so this was a bit of a departure for me....

Are you planning on drilling holes in the Flexi downtube to mount that angled bracket, or are you having a new downtube made?

I would definately add a longer axel for this bad boy! I was fortunate enough to ride a blokart and a zooter both at JIBE and though the zooter imho was easier to pilot, the blokart was MUCH more stable. I think the wider axle would help with that

To Jovver - I was planning on drilling the downtube I've got, probably use the same size holes as it has where the rest of the frame connects.

To mougl - stability is my friend, I'm really more interested in cruising than getting a wheel up in the air, not to say I won't try, but it's not the ultimate goal. I'm thinking I'm going to make a rigid frame adjustable seat back, recline it for sailing, sit it up for kiting. That's another project though, I just want to get this thing rolling. At least the long axle will give me a little room to build a new seat.

Oh, you will still be able to get a wheel up with a wider axle :P

I was able to get some 2 wheeling going with the blokart, though it was much easier with the zooter. I think what you are aiming for is the perfect mix! The ease of sailing from the zooter with the stability of the blokart....match made in heaven!

Disclaimer: Not saying blokarts are difficult to sail at all, in fact they are quite easy. I just wasnt a fan of the handlebar

I talked to a lot of people at Wildwood this spring and a lot of people said the same thing, "blokarts are really fun and easy, just wish I could steer with my feet" it will be nice having a free hand most of the time, better to gather footage :D

Ben, Do you think the new holes will compromise the structural rigidity of the downtube while in buggy mode? The ones for downtube length adjustment are ok because the frame side tubes clamp around them and then are bolted through. In blokart/ zooter mode the angled bracket will add support so that should be ok.

scab plates for buggy mode

I'm not to worried about the holes through the side of the neck, the downtube will be subject to a bending moment so the top will be in compression and the bottom in tension. The vertical aspects of the square section will have some shear forces but the majority of the force will be in the top & bottom, thus the side holes instead of top/bottom holes. (end nerd rant)

The whole section will be torqued once the sail is on it but I'm not to worried about that, should be plenty strong, the flexi's are pretty robust.

And if I break it, well that's the price of DIY, I can design a stronger one if that happens :D

I think it would be ok too. Just wanted to make sure in case you hadn't already thought of that.

Ben, I will need the angle of the gooseneck w/ buggy sitting flat and level. I will need the mast OD.
Material-wise, I was thinking AL, so weight and COG aren't an issue. Seems doable to me.

Sounds great, I'll measure everything up and send it your way as soon as I can. It's gonna be a couple of day's as I'm actually out of town at the moment....

whenever dude , I am here awaiting instructions.

Got the last part I needed to polish off the design, and now I'm really started to get excited for this project:




The mast also finally came into today, it's 100% carbon fiber, eerily lightweight, really a crazy piece of kit, those windsurfers have some nice technology. I'll stretch the sails onto it this weekend and take some pictures.

Did some mock-ups to get the proportions right

looking good :bigok:

That looks real good! Also that is a pretty legit drawing... showoff... :frog:

Not to scale :D

Looks good!

I tried ordering the long axel but it looks like they ate hard to come by on this side of the pond, anybody know where I might find one?

Rigged the sails on the new mast today, come together really nice. It's really cool how rigid the sails are once tensioned, windsurfing stuff is really cool. special thanks to my wife for 'Vanna Whiting the sails". I might add here that she actually encourages these hairbrained projects, what a gal!

Here's the 5.5 m sail:



And the 4.0 m sail:



After seeing both of them rigged, I may look for a 4.7m sail since the size difference is quite noticeable.