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Discussion Starter #1 (Edited)
I started building this early June 2020 when I was sitting at home with nothing to do. I’m starting this thread for advice and motivation to actual finish this thing. I have never built a buggy before so feel free to roast me and tell me what I’m doing wrong…

The goal is to finish this in time to take it to king of the Hammers 2022....

Specs:

2 Seater
1.75 and 1.5 DOM tubing
WB: 106”
Axles: Volvo C303 portals
Suspension: 4 link front and rear with 14" 2.0 air shocks for now
Transfer case: Suzuki Samurai…... ( it’s what I had lying around)
Transmission: TH350
Engine: I got a crazy deal on a L33 Vortec originally I was planing on a 4 cyl Totoya....
Tires: I want to run 40' Treps but im not sure the sami transfer case can handle that...

Here's a incomplete render of what it should look like
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I really don’t have the space or proper tools to be doing this, I have a 12’x18’ “Garage” a TIG welder, a grinder and a Model 3 tube bender…. I learnt how to use Solidworks so I could design my own frame. A lot of the ideas I used are not my own and taken from Instagram pictures of other buggies I liked.
 

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Discussion Starter #2
The only table I had at the time was a 2’x4’ steel table so I tried to design the frame to be built in sections. This is the start of the lower sub frame. All the pieces of tubing was hand notched with a grinder using templates I made from Solidworks.



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Discussion Starter #5
This is where it gets interesting, I ran out of room on my table and needed to be able to move the chassis around my garage. I ended up building a cart so I could finish building the chassis on it.



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Thats awesome, I want to see more.
 

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1979 F150 351w np435 on 37s. 1995 YJ 4Banger with 5speed on 31s. 2000 XJ 4.0 auto on 31s.
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Great looking so far. Have you already finished this build, or are is it still in progress?
 

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Discussion Starter #11
The only way I figured I could remotely get the back of the cab done square was to use the wall of my garage and “square” the cart to the wall. After marking the center line of the lower subframe I started with the first few pieces. It actually fell into place pretty fast.


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The front of the cab was a little more interesting. Yes that is a Manfrotto camera tripod….. It took a few attempts and a few beers but it actually turned out square and level.
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Discussion Starter #12
Manually bending tubing is a challenge… bend rotation and trying to get the notches to line up is an art form. I don’t know the proper way to do it but here is what I did.

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I “straightened” the bent tube in Solidworks and created a 1:1 scale drawing of the flattened tube. I drew a line all the way down the tube as a reference line. I wrapped the 1:1 paper drawing around the tube on either side. I notched the tube on both ends and stuck it in the bender and it actually worked the first time!


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You’re probably nowhere near me... but I’m in north eastern CT. If you’re anywhere near here and get stuck on something, give me a shout, I’ve got plenty of equipment to help you get back on track.


Sent from my iPhone using Tapatalk
 

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Discussion Starter #15
You’re probably nowhere near me... but I’m in north eastern CT. If you’re anywhere near here and get stuck on something, give me a shout, I’ve got plenty of equipment to help you get back on track.


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I appreciate the offer but that would defiantly be a far drive!
 

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Discussion Starter #16
Next up is the rear upper control arm brackets, I borrowed my friends plasma cutter. I used 3/16” plate and chrome molly weld washers.


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