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  View original topic: Six seater buggy build ( long term project) Page: 1, 2, 3, 4, 5, 6  Next
matthewl Wed Apr 17, 2019 10:48 pm

So been going with my friends in there bajas and buggy's, and now it's time to have one again. Only thing is my family has grown quite substantial since my last two seater buggy, even a Baja is not big enough. So I bit the bullet and had a custom chassis made to fit all six of us. It uses two bench seats to keep the cost sum what under control lol.
This is a long term project and will take quite awhile to finish. But I thought I would document it here in case someone else wants some ideas lol.
The chassis is custom made by Fisher Buggies in Tampa FL.
They said it is the largest one they have built to date.







Also I will try to post video ever now and again on my YouTube channel https://www.youtube.com/channel/UCl9IVR1svnDmH1i6yQ4_o1Q

Cody Loren Thu Apr 18, 2019 7:50 am

That frame sure looks monster big! What are your plans for power? Where are you going to use it?

PhillipM Thu Apr 18, 2019 9:17 am

Please tell me there's some triangulation left to go in the roof and hoops?
It'll fold like a domino run in an accident atm.

matthewl Thu Apr 18, 2019 10:05 am

Yes it is huge 14' long so far. The plan is to just do some trail riding as that's all we really have in Florida. For now it will be stock suspension ( IRS and link pin) and air-cooled VW power. As for the frame I'm going to add more bracing to the roof and put an x in the top of the cage. Much cheaper for me to do than the shop to do it.

matthewl Wed Apr 24, 2019 8:19 am

So Craigslist came in handy. Got some aluminum for the floors, roof and hopefully enough for some side panels.

A video explaining how I got it
https://youtu.be/_cAJyiLpAXI


matthewl Sat Apr 27, 2019 2:41 pm

Well got some time to work on the buggy for a little bit. Was pricing things out and decided to make the floor tabs myself as they are kind of expensive for the amount I will need. Made them out of some flat stock, they did not come out to bad.




Here's a small video of them
https://youtu.be/m0k37W0f8y0

Going to mount the floor and roof first as I have those pieces. Plus with out the torsion housing it is light enough to flip over with two people lol.

matthewl Wed May 01, 2019 5:07 pm

Got a fuel cell from my brother. It's approximately 12 gallons and has a sending unit.

Video of the other stuff he had to donate.
https://youtu.be/vUD-sgJhv78


matthewl Sat May 04, 2019 5:35 pm

Well got the floor tabs welded on to the chassis. Had to borrow my brother's mig welder, it's about the max for his welder but they will not fall off lol.





Some video of the progress
https://youtu.be/KKopCencJBQ

matthewl Mon May 06, 2019 9:09 am

Got the floor cut to size this weekend. Used a jig saw with fair results, if I had a plasma cutter I would have used that lol. The jig saw did good as I had to make a few curve cuts.



Video of the work
https://youtu.be/umlPr6phNZo

matthewl Wed May 08, 2019 11:28 am

Got the bolt holes drilled in the floor, and once I get the nuts will have the floor bolted in.

So now I'm going to make some side panels out of my leftovers. But I have a question for you guys. I bought a gusset kit that had some body tabs and small gussets with holes in them from speedway motors. I would like to use the gusset in some places to save on using so many body tabs.
So my question is where on the tube should I place the gusset for the most strength? On the center line of the tube or flush with the outer side? Would seem to me the center line would be best but I'm not sure.

center line of tube



Offset to the out side



The kit I bought, yes the gussets are small

Video of progress https://youtu.be/SfN_vVHWDg8

matthewl Fri May 10, 2019 9:15 pm

Welded on the tabs for the side panels. Should be enough to hold them on, if not I can always weld on some more. I did not line them up square with each other as the bracing is kinda In the way. But now I wish I did as it would look more pleasing to the eye once the panels or on. O well live and learn and move on.






Video
https://youtu.be/tz76oRlZMks

matthewl Sun May 12, 2019 7:50 pm

Cut the side panels out today. Used the left overs from the floor/roof material, it's kind of thick for the sides at 1/8" but I already had it so minuses well use it. The panels are 9' x 16" and will need more trimming as the sides go from 12" to 16" in the back. Sorry no photos this time ☹️ forgot to take them. But I did video some of it , if you care to watch.
https://youtu.be/6-24hAgNQjg

Now I got to find a way to bend it so it will follow the chassis in the front. I have an idea or two but will see what works. Really don't want to cut it if I don't have too, I really like the look of a one piece side panel.

matthewl Mon May 13, 2019 7:13 pm

Well bending the side panels is done. My first thought was to heat the aluminum panel up where it needed to bend, failed lol. The aluminum just dissipated the heat too quickly. So went on to plan B, bent it in my 20ton press. Used an old black iron pipe and used lifter to be the arbor. Came out pretty good and was easier to do than I thought it would be. Now just got to trim the panels down to the correct size, and wait for the boat to get here with the hardwares LOL.








Here is a video of bending it and the tool I use to do it.
https://youtu.be/FDiuecVC5Sk

matthewl Thu May 16, 2019 8:53 pm

On to cutting the side panels down to follow the top rails. The height of the the side rails taper from 12" to 16" in the rear approximately. So this time instead of using the old jig saw I bought some cut off wheels for my angle grinder. Was hoping to make faster and straighter cuts. Unfortunately that failed on both accounts lol. The most surprising thing was how fast it went through the wheels. Was hoping that one wheel would do both panels, but it took one wheel per panel.( And took longer than the jig saw). O well when we do the roof panels, it back to the jig saw lol.




Video of progress
https://youtu.be/9ePcbRRmfXs

Cody Loren Thu May 16, 2019 8:59 pm

Donít be scared get out the skill saw! Set up a guide and clamp it all to a good set of saw horses it will be fast and super straight. Clean it up with a file and some scotch brute after

Wulfthang Thu May 16, 2019 9:30 pm

You can get an 8" cut off wheel at most any hardware store to mount on your circular saw. Then just cut it like a piece or plywood! It's a little slower than cutting wood but it works and will give you straight cuts. I cut a heavy steel 2 foot diameter culvert in half and only used one blade. I strongly suggest that you use ear protection though. It's loud!!

matthewl Thu May 16, 2019 9:34 pm

Cody Loren will do that for the roof for sure, it's all straight cuts. Was just blown away how quickly the abrasive cut off wheels wore out. Would have expected that from cheap wheels or on steel but not aluminum. Straight edge next time will be used,thanks for the tip.

matthewl Thu May 16, 2019 9:40 pm

Wulfthang will do the circular saw next time for sure as I want the roof panels to look good. Been wearing ear protection, got to preserve what I have left lol.

Mike E. Thu May 16, 2019 10:05 pm

Wulfthang wrote: You can get an 8" cut off wheel at most any hardware store to mount on your circular saw. Then just cut it like a piece or plywood! It's a little slower than cutting wood but it works and will give you straight cuts. I cut a heavy steel 2 foot diameter culvert in half and only used one blade. I strongly suggest that you use ear protection though. It's loud!!

If you're cutting aluminum sheet with your Skill saw just put on a new carbide tooth blade and go to town using a straight edge as a guide. I would not recommend a cut-off wheel for any aluminum as I have never had good luck with that program. I use my wood 10" miter saw with a carbide blade for cutting aluminum stock quite often.

Good work and it looks nice. Should be able to make lots and lots of memories along the way, both in the building and the enjoying after its done.

Wulfthang Fri May 17, 2019 1:34 am

Mike E. wrote: Wulfthang wrote: You can get an 8" cut off wheel at most any hardware store to mount on your circular saw. Then just cut it like a piece or plywood! It's a little slower than cutting wood but it works and will give you straight cuts. I cut a heavy steel 2 foot diameter culvert in half and only used one blade. I strongly suggest that you use ear protection though. It's loud!!

If you're cutting aluminum sheet with your Skill saw just put on a new carbide tooth blade and go to town using a straight edge as a guide. I would not recommend a cut-off wheel for any aluminum as I have never had good luck with that program. I use my wood 10" miter saw with a carbide blade for cutting aluminum stock quite often.

Good work and it looks nice. Should be able to make lots and lots of memories along the way, both in the building and the enjoying after its done.

Yeah, I've heard that and heard that it works very well but I've never tried it. I saw a guy (on tv) cut a 2 inch thick block of Aluminum with a carbide blade. He said it "gummed up" the blade and he had to chip it off but otherwise, it worked fine.



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