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Plowboy Rock Bouncer to Ultra4 Rebuild - KOH 2015 or bust

31K views 89 replies 57 participants last post by  patooyee  
#1 ·
PlowBoy KOH Rebuild Version 3.0 :: Wide Open Design

Richie Keith came to us with his Plowboy buggy and plans to race it in the 2015 King of the Hammers. His buggy was originally built as a "rock bouncer". After some modifications it was taken to KOH 2014 and since then has been abused and sustained some serious damage. We evaluated the chassis and suspension and it was apparent that a lot of repairs and modifications were needed to get this buggy drivable and race ready again. We developed a plan, laying out what we could complete before it was time to head west to Johnson Valley. Here is the list of what we determined must be done in hopes to get this buggy to finish KOH.

1) Redoing 4 link front and rear to achieve proper geometry.
2) Redoing front and rear shock/bypass mounts to get full travel without components hitting and tires contacting shocks.
3) Retube rear axle and properly truss.
4) Build entire new front axle using Ouverson Knuckles, and Rockwell RCVs
5) Regear to 4.88 or 5.13 for ability to pull high range w/o too much load on the transmission (last years KOH failure)
6) Install new radiator in the rear for better protection.
7) Replace broken tubes in chassis and redesign as needed, correctly add bracing
8 ) Add few elements to pass Ultra 4 tech
9) Lower Ride Height while still maintaining proper up-travel
10) Address issues with the drive train mounts
11) Build a new skid plate


We have a lot more that we would like to do with this buggy, but we will have to see how time ends up at the end of this part of the transformation.

PlowBoy KOH Rebuild Version 3.0 :: Wide Open Design

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Chassis break from rollover damage
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Seat damage resulting from the chassis shifting around in the roll..
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Starting the cutting...
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See more:
PlowBoy KOH Rebuild Version 3.0 :: Wide Open Design


More coming as we cut it up!
 
#5 ·
Yes he is going to run Swampers this year. I was let down last year when he didn't run them. We are going to pack them full of tire balls and leave the spare in the pits. We plan on putting him together a solid buggy this year and try to get him across the finish line.

We thought about a new buggy but Richie just wasn't down for it. Honestly after going over it I think we can pull off what he is wanting. He said if he is going to do a new buggy then he would want enough time to make it right. We don't have enough time to make it right between now and then.
 
#11 ·
Yes he is going to run Swampers this year. I was let down last year when he didn't run them. We are going to pack them full of tire balls and leave the spare in the pits. We plan on putting him together a solid buggy this year and try to get him across the finish line.
nice! :grinpimp: i was also disappointed he didnt run them last year
 
#6 ·
I look forward to seeing this again. I saw it at Superlift but no other Ultra4 races this year on the East coast. I know it is in good hands and Woodlee knows what it takes to finish KOH!
 
#13 ·
We dug into this thing hard this week and got a lot of the stuff out of the way that we wanted to change. We decided that we wanted to move all of the suspension points on the chassis except for the rear lower link mounts. We jumped in and removed everything that we wanted to and cleaned up the frame where the mounts were. We measured and figured we can get 6.5" of up travel in the front of the buggy with a 22" belly height. The rear will easily get 8' of up travel. The front axle is re-tubed now; and it will be going in next week along with setting up the front suspension. Hopefully, by the time the front axle is in place and the front suspension is done the rear axle will be re-tubed. Then we can carry on with the rear suspension.

We are leaving some of the tube work in the rear until the new radiator gets here and we see how it fits. Richie really wants to mount it down low, so we are going to see if we can make that happen for him. As soon as we get that crossed off the list we will go into mounting the shocks. We are leaving some of the current tube work until that happens. The plan is to do a pretty cool rear shock mount that is kind of desert inspired. That will give us a good place to end the old tube work and start off with the new tubes.



We also cut out the front shock mounts on the front of the chassis. We only cut out a portion of these right now. We needed to leave enough to visualize the theme of the buggy throughout the rebuild. It’s just a little easier to see where you’re going with a few tubes out there for reference. All of the front tube work from the frame rails up will be replaced before the build is done. It’s been a nasty week for these guys getting this thing cut back to where we can work with it. Next week will get back to fabricating. Hopefully, next week we can make the turn and get this thing headed back in the direction of running and driving again.


From all of us here at Wide Open Design have a happy Thanksgiving; and if you’re headed to RBD afterwards, look us up. There will be a few of us from the shop out there trail riding and having fun.


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See more pictures here: Plowboy Rebuild
 
#21 ·
Current update:

While not everything is cut off yet, we are already looking at going together with things like the suspension mounts. *


Few pics:
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New rear axle with thick custom tubes
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Rear mounted radiator to replace the front mounted radiator it had
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Wheelbase will be stretched about 4" total
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Link brackets are braced significantly
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#28 ·
The front lower links are about 36" and the upper are about 33". That's from memory but it's pretty close.

The buggy has been beat all of it's life pretty hard. The last crash it took on cable hill did the most damage you asked about. There is a video of the roll on you tube some where.
 
#31 ·
Has Richie been to the Hammers other than KOH last year? I mean this in the most constructive way possible, but he NEEDS more experience on those trails. The terrain out here is much different than out east. He needs to spend a month in JV before the race and learn the trails if he wants to be halfway competitive in the main event.
Best of luck