Burro Buggy 2.0 build

[heywebonya]

Samba Enthusiasts,

I recently picked up an old school sled and realized that I do not live near the dunes or any recreational area and would need to tow it everywhere. I have decided that making it road legal is the best approach (plus really fun)

Looking around at all the UTVs and RZRs that are around made me realize that they are just short sandrails. I found links to the Burro by Tiny. I took some images and got a few key measurements:

I found a RZR custom top cage that was removed and test fit on the frame.

Now to find some time to keep going.

I just rebuilt a 1600 DP and it runs great.

I am going to replace the pans with 1" x 3" perimeter and widen it to 42".

Any suggestions?
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If I knew what I was doing; I wouldn't be building a buggy!

[Q-Dog]

I always thought the Burro was cool. Would be fun to build one.

What does the wheelbase on yours come out to?
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Brian

'69 Dune Buggy
'69 Beetle Convertible
'70 Beetle

[pullstart]

Those back tires and the cage makes it look like a rat/buggy... Need some "Fink" inspiration on it, for sure!
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[heywebonya]

Yes it does! The biggest challenge was deciding whether to build a full cage, that drove the rest of the design.
_________________
If I knew what I was doing; I wouldn't be building a buggy!

[pullstart]

If you ever manage to head to Yankee Springs with it, I'll be sure to meet ya for some trail riding fun...
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4 seater Appletree buggy, road legal with 002 IRS, 3x3 Appletree kit, 6" over Dan's beam with 10" towers and Fox 2.0 shocks, '00 Subaru EJ25 with KEP stage 3 clutch and KEP adapter plate.

my build page: https://www.thesamba.com/vw/forum/viewtopic.php?t=662104&start=0

[dustymojave]

[heywebonya]

I started to clean up the frame for a new floor and started a smoldering fire in the tunnel because of all the nuts, leaves and other debris. So, I stripped it all down. I always kind of delay the full teardown, but it always happens. I am surprised at what I find.

Lots of stuff

Solid 1" steel steering support ~ 25 lbs

Favorite surprise: frame horns held in by love! Not threaded in, just relying on the add on frame mounts

Had the idea to zip tie the shift rod in place.

The results of stripping a buggy down:

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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

New Frame Build

0.095" 1" x 2" perimeter floor and made the floor 41" wide the whole width.

Started connections to the torsion tubes. Any reason to not connect the pan directly to the tube?

45 degree angle - simple math and plenty of tire clearance

_________________
If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Had an opportunity to get some welding done today (although I am out of gas, it was flux core).

Finished the floor and tacked the cage together. I should get back to normal welding early next week.

The biggest challenge was positioning the cage roof on top and then inserting the filler pieces. The cage was a CL find that was well built .095 with an aluminum top.

I ended up building a 2"x 12" tower inside to support the roof and then measured several dozen times.

Put a 5 degree downward tilt and the height is 44" inside.

53" wide at the widest part. I forgot how messy flux core welding can be.

Need to start adding more bracing and then the fun bits.
_________________
If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Added a front end and mounted seats.

I like how the front end radius matches the roof line; but last night I was thinking how cool sloped front end with a tire mounted would look - kind of like a sportster shape. Too many choices.

Seat mounts were just angle iron drilled and welded in place. There is not much room for adjustment, so I built it for me.

Question: What is the best way to mount the steering wheel shaft? Do I need a special bearing or pillow block?
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If I knew what I was doing; I wouldn't be building a buggy!

[It's a play thing]

Some use the pillow block.
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It's not the size of your shop, it's what comes out of it that counts.

I've been playing with my thing ever since I got it...

[tobiism]

looking good so far!
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"There has never been a genius without a hint of madness."
-Albert Einstein

[heywebonya]

Cut off the front end and changed the shape to be more Burro-like

Mounted the steering

_________________
If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Update: Rear cage and hand brake additions

Started to build the rear cage to mount the fuel tank and battery.

I like the flow of the tubing through the pillar. Keeps it nicely aligned. There will be diagonal bracing in the future.

the hardest part was keeping the parts aligned and even

The frame is almost ready for some paint. (need the cut in the hand brake first. Will likely require cutting the tunnel.)

I have been thinking about a hand brake for safety and street legal issues. I was planning on using the surplus Army trailer handbrake, but the challenges of trying to route the cables made me buy a stock VW handbrake.

Any ideas for fuel tank mounting?
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If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

A little paint goes a long way to restoring motivation! I needed to paints some areas in the rear so I can mount the transmission and brake lines.

Paint always makes it look like the plan is coming together!

_________________
If I knew what I was doing; I wouldn't be building a buggy!

[tobiism]

coming along nicely!
_________________
"There has never been a genius without a hint of madness."
-Albert Einstein

[SamT]

I’d have just restored that buggy to its original glory. Pretty dang cool.
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Rides:
300HP 900lb turbo VW rail 18/15 travel
Never ending jeep/rzr hybrid build!
http://www.thesamba.com/vw/forum/viewtopic.php?t=546712

[SamT]

I’d have just restored that buggy to its original glory. Pretty dang cool.
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Rides:
300HP 900lb turbo VW rail 18/15 travel
Never ending jeep/rzr hybrid build!
http://www.thesamba.com/vw/forum/viewtopic.php?t=546712

[heywebonya]

Update for the buggy - hand brakes and brake lines

Note: I did not restore the buggy to the old school style as there is no where nearby that I can run the buggy. By adding a cage, I can get this street legal.

Before the frame got too heavy I wanted to prime and paint the bottom. I used rattle can undercoating. Worked well on my other buggy, no issues.

Added frame supports for a 12 gallon fuel cell and the battery box.

Painted the cage

I have also replaced the rear bearing covers and seals. Updated the bearing covers from the earlier slinger design to the weep hole design.

Replaced the rear brakes, shortened the hand brake cables and hooked them up.

Mounted the pedals (temporarily since I don't have the clutch cable)

Any suggestions are appreciated! Have a great day
_________________
If I knew what I was doing; I wouldn't be building a buggy!

[heywebonya]

Hand brake mounting went well. The hardest part was deciding where to shorten the cable.

_________________
If I knew what I was doing; I wouldn't be building a buggy!