I'm opening up a thread to ask questions about my buggy. I know I'm going to have a ton. Hopefully by the time I finish, this will turn into a useful thread of awesome DIY buggy info.

I'm going to work hard on this buggy to get something really quality, that I feel proud of. Granted I am trying to spend as little as possible.


First question on my mind is, what kind of material is everyone using for home made buggies? I was looking at EMT Conduit, which was cheap, light, and my favorite feature, they sold bending tools to bend it with out pneumatics and such. Just not sure how strong it is, but based on how thin it was, it was much stronger then I expected.

conduit has a seam in it that will split when stressed.Because of Dynamic loading and stresses, you really need to use tubing or pipe.Conduit was not made for structural apps.You wouldn't want your buggy to crap out on ya' at 35 mph , could be painful. Or collapse the first time you spin out.

Hey ther ..I used pipe fitting and some steel tubing and rods....bicycle headset custom fit and other parts

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Originally posted by WELDNGOD conduit has a seam in it that will split when stressed.Because of Dynamic loading and stresses, you really need to use tubing or pipe.Conduit was not made for structural apps.You wouldn't want your buggy to crap out on ya' at 35 mph , could be painful. Or collapse the first time you spin out.

What specific kind of piping? I know they have the black iron piping but that stuff weighs a ton. Whats the best way to go about bending the piping?

check out art-lessings buggy. His is the real deal. I don't think he bent anything he used fittings and put a tack weld to hold it if memory serves me correct. From what I remember his buggy was no heavier than my libre. It sure is comfortable to sit in I would trust it as fast as I could take it.

some helpful ideas here Barns

http://pic7.piczo.com/Popeyethewelder/?g=33349545

http://pic7.piczo.com/Popeyethewelder/?g=33348430

and a whole host of home brews here to wet your appetite

http://pic7.piczo.com/Popeyethewelder/?g=41859403&cr=7

http://popeyethewelder.piczo.com/?g=33355493&cr=7

Popeye, I've read every page on y our site twice at this point. Love everything about, think I'm ready to go other then finding piping to use.

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Originally posted by barnes Popeye, I've read every page on y our site twice at this point. Love everything about, think I'm ready to go other then finding piping to use.

sorry for the links, my only advice then is to use tube with at least 3mm wall thickness, easier to bend without kinking and takes a hard side impact

you could use threaded pipe, but be warned of shear strength reduction at the threads. I have seen many threaded fitting shear the pipe off! Threads cut into pipe by 50%= disaster at wrong time. It might not break until you push the envelope! That is what you have to consider when building your own. CYOA cause your butt is gonna be the one doin'30+ mph in it. You don't really wanna end up riding half a buggy at speed.I would cut the threads off and bevel and weld it all( if you got a welder). Just my opinion,just be safe in what you do.

hey Popeye, here is an updated photo of # 127 I made a few changes. And I have started a new aluminum buggy for bigfoot tires,here's a peek.

Here's the new one

Weldngod, whats your suggestion for cheap material, where can I get it?

It seams the biggest job when building anything is sourcing the materials to build with, I think you'll need to find a steel store that will sell you cut lengths,(we have the metal supermarket) when it comes to price the bottomline is you pay usually by weight so to get the best value for your dollar use thinner tubes with a larger diameter.

I used .o65 wall cold rolled 2" diameter for the rear axle if over 48" wide, you should be able to go smaller dia if narrower,

side rails 1.25- 1.5" diameter,

flanges 1/8- 3/16"flat bar 2' wide.

down tube 2 " square

buy a 1/2" steel pipe nipple the inside diameter fits well with a 5/8" bolt you may have to ream it out with a 5/8" drill bit, weld that steel nipple cut to the right length into your downtube with a 1/2" shoulder top and bottom, this will make a cheap and strong steering head but will need regular lubrication.

front fork can be made with 2" flat bar and a vice, it is not easy but can be done with very little welding , its basically 2 hoops with enough clearance for the tire and enough clearance for the steering swivel between. The tines of the 2 hoops are welded together as they extend down to the wheel axle, it makes it strong. Drill a 5/8 hole in top and lower hoop to acomodate the steering bolt keeping everything square and aligned. use a nyloc nut and don't over tighten the bolt. lastly drill holes in the tines to accomodate the wheel axle.

you can segmentally weld the side rails instead of bending but can be tricky to keep it all aligned you will need a jig

If i had my hard drive out of my dead computer i could send a couple of pics. i could always take some new ones if your interested I could go on and on.

cheers
Jim

Hey barnes see if you can find a scrap yard. We sometimes look for material there, you might have to clean it up. But prices are usually good.

For what it's worth. I have a bunch of aircraft quality Aluminum tubing sitting around here from my hang gliding days. Should be enough to build an ultralight. (I entertained the idea the idea of building an ultralight. Obviously it never left the entertaining idea.) Ranging in size from 1 1/2 inch down to 1/2 inch. Some of it is sleeved already. Probably not the best material for a buggy but...... I'll inventory if anyone is interested. I could arrange a pick up somewhere in the Northwest if anyone is so inclined. Not real interested in shipping since some lengths are in the 20 ft range. But may be persuaded. I haven't checked for years what the price of this stuff goes for but I would listen to offers.

(I thought about sticking this in the for sale section but since this thread was on buggy building I put it here.)

What's the wall thickness?

And what grade is the alum ... T-6061:?:

Grade - 6061 T6

wall thickness - 058

The 1/2 pieces might be a thinner wall thickness.

The 1 1/2 inch pieces look like they have all been sleeved for extra reinforcement at the ends.

ultralight for sure!

8' is UPS's limit, so if you cut it down to 8' segments for shipping you should be alright.

It seems everybody is providing detailed info on how to build a buggy but surely the first question is;
What kind of buggy do you want?
The buggy application & your size will influence the kind of buggy that you need.
Will it be on hard or soft terrain?
Will it be used just for cruising up & down a flat beach?
Do you want it fro racing?
Would you like it for freestyling or as in my case designed to run up & down sand dunes.
I build my own buggies as I cannot find a production buggy that can withstand the rigours of my kind of buggying.

Here are my current 3 home made buggies:
Link:
<a href="http://s15.photobucket.com/albums/a394/Sand-Yeti/?action=view¤t=3Bugs03.jpg" target="_blank"><img src="http://i15.photobucket.com/albums/a394/Sand-Yeti/3Bugs03.jpg" border="0" alt="3 Bugs Xmas 2007"></a>

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Originally posted by Sand-Yeti It seems everybody is providing detailed info on how to build a buggy but surely the first question is; What kind of buggy do you want? The buggy application & your size will influence the kind of buggy that you need. Will it be on hard or soft terrain? Will it be used just for cruising up & down a flat beach? Do you want it fro racing? Would you like it for freestyling or as in my case designed to run up & down sand dunes. I build my own buggies as I cannot find a production buggy that can withstand the rigours of my kind of buggying. Here are my current 3 home made buggies: Link: <a href="http://s15.photobucket.com/albums/a394/Sand-Yeti/?action=view¤t=3Bugs03.jpg" target="_blank"><img src="http://i15.photobucket.com/albums/a394/Sand-Yeti/3Bugs03.jpg" border="0" alt="3 Bugs Xmas 2007"></a>

I'd like the cheapest possible buggy, preferably in the more 'freestyle' category. Currently, considering my skill, I'll be just cursing. I think I understand how to build the buggy based on Popeyes site, but I just need to get a better grip on materials.

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Originally posted by Barnes I'd like the cheapest possible buggy, preferably in the more 'freestyle' category. Currently, considering my skill, I'll be just cursing.

Lets hope you don't curse too long. I bet you're having fun on it in no time once you figure out what to do with the kite in the turns.

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Originally posted by BeamerBob Quote: Originally posted by Barnes I'd like the cheapest possible buggy, preferably in the more 'freestyle' category. Currently, considering my skill, I'll be just cursing. Lets hope you don't curse too long. I bet you're having fun on it in no time once you figure out what to do with the kite in the turns.

A convenient typo, I mean CRUISING. :P

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Originally posted by WELDNGOD hey Popeye, here is an updated photo of # 127 I made a few changes. And I have started a new aluminum buggy for bigfoot tires,here's a peek.

Nice one I have updated the photo of the buggy

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Originally posted by WELDNGOD Here's the new one

Looking good, I have some ideas for something completely different.....I'll have to do a few more sketches yet before I commit to making it