Buggy with his own hands

Buggy with his own hands.

History of creation of completely homemade transport.


Ever since I was a kid, I loved doing things with my own hands, fixing bikes, mopeds. I had a dream of getting a quad bike or a buggy. As I got older, smarter and wiser, I thought, “Shouldn’t I do something of my own?” I started reading articles and watching videos of homemade construction. The first buggy was making from what I had in stock.

I was very excited about my first homemade transport. Everyone wanted to take a picture and take a ride on such a “miracle” technique that I was very excited! But in the process of operation, I found many flaws and design errors that interfered with the ride. By that time I had learned computer modeling and decided to build a new buggy in Compass 3D, taking into account previous errors. Inspired by the new idea and great experience behind my shoulders, I decided to design a new buggy.

It took a lot of time, effort and money to build the new buggy. The buggy was designed for about one year, on weekends. On weekdays after university, he sat at his computer, watched a 3D model and planned what he would do next. Just a little bit, in small steps, that’s how my new buggy was going to be.

The first stage. Frame

The frame was boiled from a 35mm diameter pipe. The whole project took about 45 meters. With the help of a 3D model, it was easy to know the right size. This buggy is suitable for a person not taller than 180cm.

The second stage. Suspension levers

The buggy suspension at the front and back consists of levers. Since the levers are the same everywhere, I decided to weld the “conductor”, with it the process of assembling the lever will be faster and more accurate.

In the assembly of the lever used: a pipe diameter of 35 mm (18 pieces)

Step three. Steering control

The steering rack was used from the Daewoo Nexia.

The rail was subjected to turning works, because the size of the rail did not match the size of the buggy. More precisely, the body of the rail itself was shortened and a symmetrical arrangement of holes for the steering ends was made.

The most important thing is the length of the shaft. Its ends should be equal to the beginning of the suspension lever to avoid the buggy being thrown on uneven roads. Another nuance in steering is the corner of Ackerman. This corner is adjusted for proper wheel spin when turning.

Step four. Shock absorbers

For rear suspension used shock absorbers and springs. I used them, because the shock absorber has a high stroke of the rod, and the springs provide the necessary stiffness, suitable for the buggy.

I used such design.

The shock absorbers and springs from Oka were used for front suspension. Such a configuration is very good for the easy front of the buggy.

And it turns out to be assembled with such design.

The fifth stage. The braking system

The braking system is only installed at the rear, as installation in the front is complicated by some factors (but may be done in the future). At the rear, swivel cams from the 2109 vase and brake calipers from the same vase are used. The main brake cylinder is from the 2106 vase.

The front circuit has been blanked because it is not needed. The brake tube is led from the rear circuit to the rear calipers via a tee.

Step six. Powertrain

This buggy was equipped with a motor and a gearbox from the Ant scooter. The drive from the gearbox to the hub was converted. Everything works very well. The motor is weak for such wheels, of course, but you can ride. There was one drawback that didn’t leave me alone – a chain gear from motor to gearbox.

The buggy was designed for a ride where you have to put a lot of stress on the gearing of the wheels, but the chain couldn’t cope with it, it broke off. And the engine from the OCA car came to mind, because it is small in size and has the right power. But there was a problem: when trying on the engine and the Oka gearbox, they wouldn’t fit into the buggy’s engine compartment. I didn’t want to remake the entire frame: there were no means or desire. Fortunately, I had a gearbox from Moskvich 2141. It had a very interesting drive arrangement, which was perfect for this buggy. Thought I’d try to put it together.

Started making an adapter plate. First I cut the template on the cardboard, marking the holes, then moved it to a 7mm thick metal plate.

Replaced a native Oka clutch basket. First, the primary shaft of the Moskvich gearbox on splines fits this clutch. Secondly, it is bigger, which means that it can withstand more load. When connecting the gearbox and the engine everything fits perfectly, but there is one “But”. The primary shaft entered the clutch disc by about 3 mm, which is 10 times less than the one you should. The only way out was to disassemble the gearbox and lengthen the primary shaft by the correct size.

After the lengthening, everything worked out. There were also small changes in the squeezing fork of the bearing and the bushing on which the squeezing bearing slides. Since the bushing also had to be extended by 3cm, it was necessary to make the whole part new from metal (plastic goes factory).

After all the work had been done, everything worked out!

Next, we had to figure out how to start the engine, because the standard starter mounts did not fully fit due to this arrangement. I found a suitable place in the bell and made an opening there. The starter was used as a gearbox from the front drive vase, as it is small in size.

After a couple of hours of adjustment, it was all twisted up.

Step seven. Drive

Since the drives have different designs, we had to connect two in one.

The eighth stage. Shift lever

After installing the motor on the frame, he started thinking about the switching mechanism. The mechanism was assembled from the stabilizer racks.

Ninth stage. Complete assembly

After assembly of the switching mechanism, it remains to connect the ignition system and engine cooling system. There are no major problems.

Step ten. Testing. Painting .
After installing the new units, we got a completely different buggy! There was speed, traction from the bottom and a lot of other advantages. After 3 months of riding the buggy, no problems were detected. The road holds up well, dirt and fields are not afraid of him. Very pleased with the work done!

In the future the necessary sensors (temperature, speed, oil pressure and battery charge) will be installed.