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Discussion Starter #1
Figured I would finally start a build thread here for my new buggy.

Last year after beating on my old buggy for a while, I decided that I wanted a bit more motor (had a 4.3 in the old one) and some more wheelbase (had 107 in the old one). I did a bunch of measuring and spent some time laying under the old one and trying to wrap my brain around doing what I wanted….

Here is what I had before and where 90% of the parts are coming from:



I eventually came to the conclusion that it would make much more sense to build a new chassis rather than try to adapt this one to the changes. The old one was just so small and tightly packed in, it would have taken a TON of cutting to get to a point of starting to make things fit.

A friend and I had been talking for a while about building chassis and so we both decided that we would pull the trigger and make it happen. We would build 2 “twin” chassis (I say twins…but there are slight differences in the two to make them fit exactly what we each wanted; but the base chassis is the same on both). We picked up Bend-Tech and some tools and got to work. We took a lot of measuring from my old buggy, his old buggy, and a lot of ideas and styles from some other chassis out there and put them all together. It is no secret which ones are predominately used… :flipoff2:

The basic plans are for the following:

5.3 with a few small/standard goodies
4L60E trans
Atlas
Solid MFG HP60 front and rear from my old buggy
16" ORI STX in rear, 14" ORI STX in front
40” Trepadors on Trailreadys
Shooting for ~110” wheelbase
Front radiator
All the rest of the standard buggy parts

Here is the chassis that we designed in Bend-Tech. There will be some changes made in the final design, but this is basically it.



There is a lot of .188 wall tube in this chassis as I had some dented tubes in the old one and wanted to avoid that as much as possible. Any tubing you see throughout the build that is the dark color is the .188 and the light color tube is .120

There is a mix of 1.75, 1.5, and 1.25 in the chassis.

You will notice another chassis sitting off to the side…that is the rolling chassis that is the twin to this one…it was built before mine. Here it is as a roller and what mine will “basically” look like:







On to the pictures of mine…I am open to feedback and ideas if people see things that they have questions about.







 

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Discussion Starter #2
Here is where we originally had the shoulder bar…I thought it ended up too low, so we eventually moved it up, which you will notice in a bit:







Both seats “mocked in”. It looks smaller than it really is because the seats are so big. It is 48” at the cowl and 50” at the b-pillar. From here on, the shoulder bar is at the correct height.



Much better:



The X-brace is in, things are starting to take shape



It looks tight in this picture too…but my legs are stretched nearly all the way flat out at the front of the rocker, should be just right

 

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Discussion Starter #3
Dash bar mocked in. It may be moved down a bit, but we will do that as things take shape if need be



Seats out to see some more shape



Pulled it outside to get a profile look at it. The rear is obviously next on the list. This will get the TC/Jims Garage “tailgate” that really makes buggies look good in my opinion





That brings us up to currently….this will of course be an ongoing build thread. I hope to have this thing riding by next spring/summer.

Thanks for watching. Go fuck yourself if you think its ugly :flipoff2:
 

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Kind of looks like a Twisted Customs/Jim's Garage/M&M Fab Chassis. Why the fuck are you copying people? That is NOT ok. :flipoff2:

Looking good, simple.
 

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Discussion Starter #14 (Edited)
Or a garage floor/ 2x4 jig. Looks good, though.
Those are billet, custom fabricated, 100% accurate jigs.

Shit cost dollaz! :flipoff2:

but in reality...this is all a stupid money pit. On top of that...I dont have Ultra4 money! :laughing:
 

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I know you are not done with the chassis, but what keeps the whole main hoop from collapsing at the b-pillar? I know you have x-bracing but there is nothing tying not the shoulder bar and it could spread at that point.

I guess I'm over thinking it though. The X-Brace should do the trick - Im just thinking you need a seatbelt bar or something that would keep the chassis from spreading near your shoulder bar.
 

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Discussion Starter #17 (Edited)
I know you are not done with the chassis, but what keeps the whole main hoop from collapsing at the b-pillar? I know you have x-bracing but there is nothing tying not the shoulder bar and it could spread at that point.

I guess I'm over thinking it though. The X-Brace should do the trick - Im just thinking you need a seatbelt bar or something that would keep the chassis from spreading near your shoulder bar.
there will be a shoulder bar in there as well. Its just not in yet. wont be until we get the seats in and know where we need to put it.

You can see where it goes in the roller chassis, its all tied togehter with the shock hoops and such right there.


EDIT - i guess you cant really see it in the roller chassis pictures...but its there.
 

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Discussion Starter #19
A little bit more was done this weekend.

Got the X in the doors tacked in. Nothing really ground breaking here....there will be a window "wing" bar (you can see the mock up in tape on the other side) that will also continue down to the bottom of the A-pillar at the rocker to terminate.



Already rolled it too....

Got the subframe in. Its about 1" lower than the other chassis so that we could fit everything in there and have a flat and sealed floor. One of the main things I wanted with this buggy was for it to be sealed in below the shoulder bar. I want to be able to put something in there and it not fall out. My old one had a hole in the middle and the back was completely open...I lost an ipod and a camera out of that buggy.

 
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