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boardbysled 09-18-2016 12:00 AM

Boardbysled's Buggy Build
 
I recently started a new project and figured it was getting far enough along to share.

This build will be a budget build reusing many parts from my old rig ( The Pathy). (which is currently still together and I am still wheeling it for the time being.

New rig will be lots of tube with just mostly the firewall and windshield frame left from the stock rig. Frame will be cutoff in front of the motor mounts and behind the seats.

http://i1325.photobucket.com/albums/...i.jpg~original

Couple reasons for starting fresh versus just building my current rig:

-Pathy's motor is on deaths doorstep
-Pathy has a 5 speed versus an auto in the new rig
-Fresh frame (Pathy's frame has a few patch jobs on it

Parts I plan to use off the Pathy include:

-Waggy D44 Front axle (4.56's, yukon chromos & super joints, lock-right)
-NWF TX-10/D300 doubler kit & JB Fab twinsticks
-Rear H233b 4.63 third member w/lock-right

and thats about all haha.

Here is the 'new' project. Stock 1992 Pathfinder VG30E and a auto trans.

http://i1325.photobucket.com/albums/...z.jpg~original

boardbysled 09-18-2016 12:12 AM

Well, pictures don't appear to be working. I will screw with it tomorrow and add some more photos.

onlyonedr 09-18-2016 07:55 PM

So are you going to build a buggy off of the Pathfinder chassis or kind of cut up the Pathy body into a buggy-ish thing? Not completely following here.

crazybluerider 09-18-2016 08:00 PM

https://scontent.fsnc1-1.fna.fbcdn.n...9a&oe=58698D38

boardbysled 09-18-2016 09:30 PM

^ Spy photo from today haha.

Finally figured out the photo stuff.

Started tearing down the the new Pathfinder.

http://i1325.photobucket.com/albums/...n.jpg~original

http://i1325.photobucket.com/albums/...t.jpg~original

http://i1325.photobucket.com/albums/...k.jpg~original

http://i1325.photobucket.com/albums/...j.jpg~original

http://i1325.photobucket.com/albums/...l.jpg~original

http://i1325.photobucket.com/albums/...v.jpg~original

http://i1325.photobucket.com/albums/...c.jpg~original

boardbysled 09-18-2016 09:44 PM

Some new parts,

EMPI Wide vinyl suspension seats from Jeep Swag

2.5"x16" FOA Coilover shocks with reservoirs

Speedway steering wheel and quick disconnect

http://i1325.photobucket.com/albums/...g.jpg~original

Pulled the housing and stripped the brackets off it and shaved the drain plug

http://i1325.photobucket.com/albums/...9.jpg~original

Started building an axle truss

http://i1325.photobucket.com/albums/...m.jpg~original

http://i1325.photobucket.com/albums/...j.jpg~original

http://i1325.photobucket.com/albums/...3.jpg~original

http://i1325.photobucket.com/albums/...1.jpg~original

http://i1325.photobucket.com/albums/...y.jpg~original

boardbysled 09-18-2016 09:52 PM

Fabb'd up the rear 4 link, double triangulated with decent numbers according to the 4link calculator. Barnes 4wd brackets and heim joints. PVC links for now.:D

http://i1325.photobucket.com/albums/...4.jpg~original

http://i1325.photobucket.com/albums/...l.jpg~original

http://i1325.photobucket.com/albums/...j.jpg~original

boardbysled 09-18-2016 10:03 PM

Started on the tube work! Most of the tube is 1.75"x.120" DOM with some 1.75"x.120" HREW where it won't make contact with rock, along with some 1.5"x.120" HREW mixed in.

Hole-sawed a hole in the frame.

http://i1325.photobucket.com/albums/...k.jpg~original

Cut it off in the center of the hole so the tube mates up well.

http://i1325.photobucket.com/albums/...a.jpg~original

http://i1325.photobucket.com/albums/...u.jpg~original

Broke the follower die getting the bends too close together.:mad3:

http://i1325.photobucket.com/albums/...n.jpg~original

New style follower die from JD2.

http://i1325.photobucket.com/albums/...p.jpg~original

HF notcher setup. (Drill died today after about 18 notches)

http://i1325.photobucket.com/albums/...i.jpg~original

Notch fresh from the HF setup, just needs a little flap wheel work.

http://i1325.photobucket.com/albums/...g.jpg~original

boardbysled 09-18-2016 10:11 PM

Matching rear 'framerail'

http://i1325.photobucket.com/albums/...z.jpg~original

Crossbar in the rear (hopefully setup for a rear swaybar in the future)

http://i1325.photobucket.com/albums/...k.jpg~original

Cut the rocker panel off to make room for the slider bar.

http://i1325.photobucket.com/albums/...m.jpg~original

Slider bar and b-pillar mocked up.

http://i1325.photobucket.com/albums/...g.jpg~original

Rear belt-line bar mocked up

http://i1325.photobucket.com/albums/...o.jpg~original

Rear seatbar mocked in

http://i1325.photobucket.com/albums/...s.jpg~original

Bend in the front seatbar to clear the transmission shifter cable

http://i1325.photobucket.com/albums/...b.jpg~original

boardbysled 09-18-2016 10:17 PM

And now we are caught up to today:

Started on the roof-line bar.

http://i1325.photobucket.com/albums/...m.jpg~original

Roof-line bar & B-pillar connected. Next step will be to bend the roof-line bar down to meet the belt-line bar at where the rear shocks will mount in the future to make a node.

http://i1325.photobucket.com/albums/...l.jpg~original

pennsylvaniaboy 09-20-2016 06:05 AM

Just thinking here, but I would raise your rocker bar to level with your seat bar. Then run a boatside to the frame. It would give your clearance, look cleaner, and get rid of the stepper bar from the rail to the seat bar.

boardbysled 09-20-2016 06:10 PM

Quote:

Originally Posted by pennsylvaniaboy (Post 38291001)
Just thinking here, but I would raise your rocker bar to level with your seat bar. Then run a boatside to the frame. It would give your clearance, look cleaner, and get rid of the stepper bar from the rail to the seat bar.

Everytime I look at the rocker bar, I think the same thing, just haven't done anything about it yet.

Whatever I end up doing there, I am going to put some 1.5" in the 1.75" to beef it up.

boardbysled 09-25-2016 09:37 PM

Worked on it a bit more today. Decided that before I got much further, that I should redo the rocker bars. Moved them up about 6". Made sure to add frame plates.

http://i1325.photobucket.com/albums/...2.jpg~original

http://i1325.photobucket.com/albums/...q.jpg~original

boardbysled 10-02-2016 09:16 PM

Was able to work on it a bit this weekend,

Shortened the rear framerails

http://i1325.photobucket.com/albums/...6.jpg~original

B-pillars and rear belt-line bar in:

http://i1325.photobucket.com/albums/...b.jpg~original

Notching the A-pillar

http://i1325.photobucket.com/albums/...m.jpg~original

Roofline bar in, just need to cut and turn it and notch the C-Pillar.

http://i1325.photobucket.com/albums/...9.jpg~original

onlyonedr 10-02-2016 10:03 PM

Keep going!

boardbysled 10-09-2016 08:19 PM

Didn't get a chance to work on it a whole lot this weekend, but got a little bit done.

Got the A-pillar/roofline/C-pillar bar in. All one piece, 3 bends, with 2 offsets.

http://i1325.photobucket.com/albums/...z.jpg~original

No pictures, but worked on the seat mounts some. Being 6'4" and mostly torso is making it a little challenging.

boardbysled 10-16-2016 08:27 PM

After about 4 different variations, I was able to get the seat mounts in. I'm 6'4" 300lbs so it was hard to get them low enough without having to raise the roofline a bunch. They are sat as low as they can go in the chassis, but should work good.

http://i1325.photobucket.com/albums/...v.jpg~original

Got the passenger side roofline bar bent up. Had to cut and sleeve this one as one of my offsets was a few degrees off.

http://i1325.photobucket.com/albums/...u.jpg~original

http://i1325.photobucket.com/albums/...g.jpg~original

http://i1325.photobucket.com/albums/...g.jpg~original

http://i1325.photobucket.com/albums/...v.jpg~original

Did a timelapse of bending up the roofline bar:
https://youtu.be/K8xVM1xtaIE

Got one of the roof bars in along with the harness bar. Also got some of the triangulation bars for the B-pillar in. I plan on ditching the normal headrests and making some that attach to the diagonal bars.

http://i1325.photobucket.com/albums/...c.jpg~original

http://i1325.photobucket.com/albums/...y.jpg~original

http://i1325.photobucket.com/albums/...1.jpg~original

boardbysled 10-23-2016 08:13 PM

Wanted to see where I was going next, so I did some layout with painter's tape.

http://i1325.photobucket.com/albums/...v.jpg~original

http://i1325.photobucket.com/albums/...u.jpg~original

Got started on the rear shock mounts. Shocks are 16"x2.5" FOA's. Using a behind the axle shock mount bracket from Barnes 4wd.

Had a bunch of grand ideas for shock mounts, but once I mock'd it up, a plan for a nice easy mount came together, almost like I had planned it...

Looks like I should end up with 6" uptravel and 10" down.

http://i1325.photobucket.com/albums/...w.jpg~original

http://i1325.photobucket.com/albums/...g.jpg~original

http://i1325.photobucket.com/albums/...d.jpg~original

http://i1325.photobucket.com/albums/...n.jpg~original

http://i1325.photobucket.com/albums/...z.jpg~original

http://i1325.photobucket.com/albums/...i.jpg~original

http://i1325.photobucket.com/albums/...4.jpg~original

I'll build a bracket in between the tubes for the upper shock mount.

The hope will be to squeeze a 2"x2" airbump in as well, should be plenty of room.

boardbysled 11-06-2016 08:02 PM

Little bit of progress.

Got the rear shocks mounted.

http://i1325.photobucket.com/albums/...m.jpg~original

Little bit of contact between upper links and seat bar mount at full bump that will have to get addressed.

http://i1325.photobucket.com/albums/...n.jpg~original

Started on the roof bars. Got the browbar in.

http://i1325.photobucket.com/albums/...b.jpg~original

http://i1325.photobucket.com/albums/...m.jpg~original

boardbysled 11-06-2016 09:35 PM

Also remembered I had this photo of the 4link calc with my rear link geometry.

http://i1325.photobucket.com/albums/...b.jpg~original

brokefinder 12-12-2016 04:43 PM

Are you going to brace the windshield frame? I'm not sure how strong it is as-is. Regardless it's a sick build.

boardbysled 12-12-2016 06:28 PM

Quote:

Originally Posted by brokefinder (Post 39178297)
Are you going to brace the windshield frame? I'm not sure how strong it is as-is. Regardless it's a sick build.

Yes, I plan on bracing it into the tube a-pillar. It is not very sturdy by itself.

When the glass windshield breaks, I will screw a piece of lexan in the windshield frame.

boardbysled 02-25-2017 12:17 PM

Haven't had much of a chance to work on this the last few months, busy with work and the holidays. But I have amassed a pile of parts:

For the Front:
2.5"x14" FOA reservoir coil overs
3 link kit w/7/8" heims from Barnes4wd
2.5"x8" Surplus Center Ram
22"Wx19"H crossflow aluminum radiator from Speedway
Set of Pacesetter headers (stock manifold is cracked to shit)

For the Rear:
22 gallon RCI fuel cell
2.5"x2" FOA air bumps

Still need to get a pile of steel to finish out the rear and start on the front.

http://i1325.photobucket.com/albums/...e.jpg~original

http://i1325.photobucket.com/albums/...f.jpg~original

http://i1325.photobucket.com/albums/...0.jpg~original

boardbysled 03-04-2017 08:01 PM

Finally killed the motor in my old rig a few weeks back so time to spend some more time on this.

Got a 2.5"x8" Surplus Center Ram.

http://i1325.photobucket.com/albums/...a.jpg~original

Was able to take a closer look at some of the stuff in the parts pile. Kinda disappointed with the quality of the FOA shocks and bumpstops. But they aren't leaking oil yet and the price was cheap enough to put up with some cosmetic issues. Not sure on the dual rate slider with 2 short sides though...

http://i1325.photobucket.com/albums/...o.jpg~original

http://i1325.photobucket.com/albums/...p.jpg~original

Hard plastic pads on the bumps should hopefully mean they are at least somewhat quieter then the all aluminum style.

http://i1325.photobucket.com/albums/...p.jpg~original

Looks like they should fit good on the rear axle. Little worried about fitting 2.5" on the front, guess we will have to see when I get it all mock'd up.

http://i1325.photobucket.com/albums/...7.jpg~original

Corners of the RCI cell are all beat up. Should be able to straighten them out though.

http://i1325.photobucket.com/albums/...3.jpg~original

Threw the fuel cell in to see how well it fit. Fits almost like I had planned for it all along! Should be plenty of room behind it for tool/spare storage. It will sit an in and a half lower when it is all said and done. Plenty of link clearance.

http://i1325.photobucket.com/albums/...z.jpg~original

http://i1325.photobucket.com/albums/...n.jpg~original

http://i1325.photobucket.com/albums/...9.jpg~original

boardbysled 03-04-2017 08:05 PM

Started mock'n up where I am going to add some more tubes in the rear.

http://i1325.photobucket.com/albums/...5.jpg~original

http://i1325.photobucket.com/albums/...7.jpg~original

http://i1325.photobucket.com/albums/...d.jpg~original

Worked on tearing the body forward of the firewall today. Plan is to chop the inner fenders/core support off at the firewall and tube it out forward of there and the motor mounts.

http://i1325.photobucket.com/albums/...i.jpg~original


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