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Discussion Starter #1 (Edited)
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.



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.

 

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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.
 

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Discussion Starter #8 (Edited)
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.

20160724_145829_zps8drsnnpk by boardbysled, on Flickr

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

20160724_153118_zps2bnhcyha by boardbysled, on Flickr

20160724_165807_zpshdljxqfu by boardbysled, on Flickr

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

20160724_204425_zpsstomxxun by boardbysled, on Flickr

New style follower die from JD2.

20160821_150204_zpshv6nzdzp by boardbysled, on Flickr

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

20160724_212754_zpsvnfynmqi by boardbysled, on Flickr

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

20160724_212745_zpsviuiyvgg by boardbysled, on Flickr
 

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Discussion Starter #9 (Edited)
Matching rear 'framerail'

20160828_144304_zpssl3pjs1z by boardbysled, on Flickr

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

20160828_151809_zpsmyanobfk by boardbysled, on Flickr

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

20160828_182940_zpsg75qlnim by boardbysled, on Flickr

Slider bar and b-pillar mocked up.

20160903_172715_zpsxtcj2c7g by boardbysled, on Flickr

Rear belt-line bar mocked up

20160903_211845_zpssilvmehq by boardbysled, on Flickr

Rear seatbar mocked in

20160905_201933_zps9ivyk29s by boardbysled, on Flickr

Bend in the front seatbar to clear the transmission shifter cable

20160917_152358_zps4xhpkrkb by boardbysled, on Flickr
 

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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.
 

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Discussion Starter #12
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.
 

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Discussion Starter #14 (Edited)

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Discussion Starter #17 (Edited)
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.

20161015_200512_zps0ijxoa2v by boardbysled, on Flickr

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.

20161016_151110_zps9gcadc1u by boardbysled, on Flickr

20161016_151126_zpsq4lokzbl by boardbysled, on Flickr

20161016_151140_zpsfvfcbgrg by boardbysled, on Flickr

20161016_151147_zpsue0as8av by boardbysled, on Flickr

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.

20161016_183436_zpstca6h0gc by boardbysled, on Flickr

20161016_183448_zps6gvulciy by boardbysled, on Flickr

20161016_183614_zpsq4surdd1 by boardbysled, on Flickr
 

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Discussion Starter #18 (Edited)
Wanted to see where I was going next, so I did some layout with painter's tape.

20161017_165831_zpsfdffg20v by boardbysled, on Flickr

20161017_165847_zpsezksrx8u by boardbysled, on Flickr

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.

20161023_163341_zpseasy9a9w by boardbysled, on Flickr

20161023_163354_zpswzipuapg by boardbysled, on Flickr

20161023_165340_zpsudshvnsd by boardbysled, on Flickr

20161023_165353_zpsyue6djgn by boardbysled, on Flickr

20161023_181939_zpscyjefvuz by boardbysled, on Flickr

20161023_182023_zpskzhlcchi by boardbysled, on Flickr

20161023_182033_zpsj3jghjk4 by boardbysled, on Flickr

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.
 

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Discussion Starter #19 (Edited)
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