Just wondering what sort of mods folks have made to their PL bugs. One I'm considering, and maybe someone can advise for or against it, is converting the back axle to bolt on, like a flexi. Of course on the N. American version of the Comp XR+ the axle is held in place by the seat straps. I'd like to be able to get my seat lower but to loosen the straps means loosening the connection to the axle. I'm thinking of just drilling holes in the side rails and axle at their connection point and running bolts through them to hold the axle in place. My concern is the steel is just too thin to handle the bolts causing bending or cracking. Perhaps a local welder could weld on some sort of collar to strengthen the area. Thoughts?

You can pull the straps off and just sitting into the buggy will keep the rear axle on ... unless you are jumping with it, then you may have an issue. There is no structural stress on the rear axle bosses that the frame rails run into, so drilling a hole through them and putting in a bolt will cause no structural issues at all.

Also, if you lower your seat by loosening the straps, as soon as you sit into the seat you will tighten the straps again...either that or your backside will hit ground. Your body weight is what tightens the rear straps, if they are totally loose, you will hit the ground, if they are barely tight enough to keep your butt off the ground, they will be tight against the rear axle.

If you really want to mod your PL, look into Van's rail kits or get one of my bolt on backrest kits. Those both give the PL a huge upgrade in strength and comfort.

Thanks Kent. Part of my reasoning is that my bug tends to rattle quite a bit. I don't think it's anything to worry too much about, just annoying. Also, I guess I have a hard time leaving well enough alone. I like to tinker. I'm still not sure I want to drill holes in my baby just yet but it's a thought.

Since I have grabbed your attention, can we talk about your sweet back rest for the PL buggy. I'm not too concerned about the actual supporting of my back at this point but am intrigued at the prospect of adding a brace to stiffen things up. My worry it that I just don't see how it will fit. The pads on my side tubes go right over where your bar would mount. They're about as far forward as I can get them too, by the way. It looks like the bug you show on your web site have extended side rails, right? So, what's the solution? Would I have to cut down the pads? 3Shot says he was able to just squish them forward a bit.

Thanks,
Josh

Correct Josh! Here is a better side pic. I have the same "standard" lenght siderails as you. Those longer rails are a PL upgrade option.

I clamped mine right at the start of the turndown. The back of the bracket is about where my pads would normally be. As said, I did have to scrunch them up a bit as you can see. The backrest works just fine and locks the frame together more IMHO. Just scrunch em a little more

You have any trouble with your seat? My front buckle is already VERY deformed and I fear it won't be with us much longer. By the way, I really like you "mood". Especially in strong wind I now tend to sit in the bug, facing down wind and think to myself-hot launching in 5..4..3..2..Yee, haw!!!!

To fit the backrest on, you do have to trim the padding back, or scrunch it tightly.

The covers don't need to be cut at all, you can scrunch them but the best way is to just fold them inside ontop of themselves. You can fold them inward and then re velcro them back together. The folded covers fit nicely beneath the rear seat strap.

If you ever want to remove the backrest, the cover just unfolds to its original length. You would need to replace the padding if you trimmed it off.

I am going to try and get some pics or video when I get 5 minutes to do it.

Quote: Originally posted by ratfink13

My concern is the steel is just too thin to handle the bolts causing bending or cracking.

Well, they are known as "peter thin" . The only PL stuff I own are the seats on my "homebrew" Buggies . And a 8.6m Reactor II, that cheesycheese went through, like the tape at the finish line of a marathon.

@ 3shot, you have a "major"advantage to modding your buggy. You live in Hampton Roads,and so do I........:D:D

Quote: Originally posted by WELDNGOD

@ 3shot, you have a "major"advantage to modding your buggy. You live in Hampton Roads,and so do I........:D:D

I am a shadetree welder. Not a pro. I do have a small mig. I can put two pieces of metal together with a descent bead, but it stops there.
Might just have to hire you out for a mod/homebrew in the future :D. Of course, after I pass WELDNGOD's official buggy apprenticeship school this fall
I am 6'2" 210lbs. My PL is kinda cramped, but it does move from point A to B. LOL

I have sold pre-bent frame rails and pre-formed brackets for some others making their own buggies. All you would need to do is to trim and weld.

If this intrigues you, let me know.

Drill and bolt the rear axle to the side rails is fine. When I fitted the composite axle to my mk2 I had to drill the side rails (the axle comes per-drilled) and the PL ultra light comes drilled and bolted from the factory.
Yes if you do the bolts up really tight, you can crush the two pieces and lock them together. But if you are using stainless steel bolts then the bolt will probably strip before the tube crushes. 1st hand experience.

Another option, is to just do a couple of jumps, bend the steel axle slightly and this locks it onto the side rails. I have a pre bent axle here if you want it :D

I'm wondering why your bug is rattling so much. I have the same one and it barely rattles at all.

Check the bearing spacers, these have drove me crazy chasing down rattles! If they are 1 mm short they will rattle and have adverse effects trying to get your wheel to roll/ and stay on. Don't trust stock P.L. spacers to be correct. Make some custom ones at 47mm (20mm rims)
I also add 6" to all downtubes to have a stretched out feel.