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Full suspension buggy build

Old 09-25-2009, 03:38 AM
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sam123
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Default Full suspension buggy build

Hey everyone here is my latest project. I plan to make it with fully independent suspension, and it will be powered by either a chainsaw engine or a g260rc. It dosen't look like much at the moment, but hopefully when its finished it will resemble a 1/7th scale offroad buggy .

As you can see, I have decided to start with the rear section of the car first:









The suspension arms are made from square-section steel and the hinge pins are 5mm thick. The rear hubs took a while to make, but they are nice and beefy
I don't really mind how heavy the car's components end up being, as long as they are strong.

More updates should be posted soon.
Old 09-25-2009, 07:01 AM
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Default RE: Full suspension buggy build

Wow I can see where this is heading.
Looking good.


You put lots of work in to what's in those pictures already.
Wish I had the patience to file and sand everything like that......


Old 09-25-2009, 07:53 AM
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Default RE: Full suspension buggy build

Thanks DV.
Yes its very time consuming, trying to get everything to look respectable...creates alot of mess too. My workbench is currently covered in a blanket of aluminium filings about 10cm deep
Old 09-25-2009, 04:33 PM
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da mad maori
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Default RE: Full suspension buggy build

wow your attention to detail is outstanding.....
nice simple design too
Old 09-25-2009, 04:57 PM
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Default RE: Full suspension buggy build

wow!!

i like what i see here.

well done sam
Old 09-25-2009, 05:00 PM
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SAVAGEJIM
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Default RE: Full suspension buggy build

I am so totally impressed. Out of that alum bar/block, you cut that trunnion without any use of a CAD machine!

Would you mind sharing how you fabricated those parts by hand so cleanly and precisely?
Old 09-25-2009, 06:12 PM
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Default RE: Full suspension buggy build


ORIGINAL: SAVAGEJIM

cut that trunnion without any use of a CAD machine!

CAD schmad.
People made precision work long before computers existed.
These days it seems a novelty when someone makes something using their hands and time.
Old 09-26-2009, 05:20 AM
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Default RE: Full suspension buggy build

Thanks guys

The bearing blocks were made using the following process:

First, I drilled all the holes using a drill press (as you can see in the first picture). Next I removed the semi-circle shaped chunk of aluminium using a hacksaw and a pair of pliers. Then, using a tungston carbide cutter (the one installed in the dremel) I removed the spikey chunks of aluminium left behind from the previous step. Then, I rounded off the edges using the file with the curved surface and the stone cutter. Finally, I used the sanding/polishing bit with some wd-40 sprayed on it to achieve a nice smooth surface for the bearing to sit on.





The other, flat file is the one I used to get a nice flat edge on all the parts.

Also, the drill bit I have been using is a double sided pop-rivet bit, and is by far the most durable drill bit I have ever used...the sharp angle at which the tip of the bit has been cut makes it very accurate too
Old 09-26-2009, 05:54 AM
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Default RE: Full suspension buggy build

Very juicy looking
Old 09-26-2009, 07:38 AM
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Default RE: Full suspension buggy build

That's awesome dedication there, and the end result is great.


I probably would have cut a hole in a piece of aluminium with one of these

and then cut it in half to make those pieces up....



Can't wait to see what else you're gonna fabricate for this build.
So is this the rebuild/new version of [link=http://www.rcuniverse.com/forum/m_8508330/tm.htm]THIS[/link] car?



Old 09-26-2009, 08:22 AM
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Default RE: Full suspension buggy build

i agree with you dvp

man this is awesome work.......well done...
Old 09-26-2009, 10:50 AM
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Default RE: Full suspension buggy build

Thanks once again guys.

DV - hmm that might have saved some time. Are those holesaws ok with cutting thick aluminium?

This car is sort of based on that car, but it is really the next stage of this build: http://www.rcuniverse.com/forum/m_77...tm.htm#7710838

I was going to re-make the chainsaw powered car you posted the link to, with a trailing arm suspension setup on the rear, but it ended up being too complicated. I also decided that with summer not long away It would be nice to build something that can be used off road.



Here are some more pictures of the rear end. Bolting on the shocks was too easy . The LST shocks will hopefully be strong enough for this application. I also need to get some nice drill-rod to make the outer hinge pins from.
Next I will be making the suspension tower and the upper suspension arms.





My biggest concern for this project is the driveshafts...the 1/8th scale ones that are on there at the moment will not last long im sure. I might end up having to use baja driveshafts []
Old 09-26-2009, 04:04 PM
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Default RE: Full suspension buggy build


ORIGINAL: sam123


Are those holesaws ok with cutting thick aluminium?


Yeah but you need to get the top of the line ones with hardened teeth.
Slowly slowly with lots of WD-40.


Old 09-27-2009, 10:55 AM
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Default RE: Full suspension buggy build

Here is the suspension tower finished. I know it looks ugly but it is very strong.

Old 09-27-2009, 04:11 PM
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Default RE: Full suspension buggy build

Really?
I think it looks cool [8D]


Old 09-27-2009, 06:07 PM
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Default RE: Full suspension buggy build

Form over function! So long as it works, that is what counts!
Old 09-27-2009, 08:34 PM
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Default RE: Full suspension buggy build


ORIGINAL: SAVAGEJIM

Form over function!
Don't you mean the other way around? [&:]
Assuming you're saying it's ugly - which of course you're not - but practical, then it should be function over form, should it not?






Old 09-27-2009, 08:47 PM
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Default RE: Full suspension buggy build

Yeah, my bad! [&:]
Old 09-30-2009, 08:24 PM
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Default RE: Full suspension buggy build

Looking good mate. Those X ray machines must be disappearing by now!
Nothing wrong with old school hand made stuff
Old 10-01-2009, 03:06 AM
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Default RE: Full suspension buggy build

do you ever stop building? give you some scrap metal and a radio and you'll drive it!!
Old 11-05-2009, 12:47 AM
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Default RE: Full suspension buggy build

Hi guys sorry about the lack of updates on this project. I will be working on it again soon.

I decided to buy a pipe for the engine. The thought of using the stock 'can' seemed like such a waste.





The pipe is made by cpi and is designed for the baja, but I should be able to make it fit onto my build. It sure sounds and looks awsome: http://www.youtube.com/watch?v=VPsj4ausKsU

I have also decided to use baja 5b axles and drive cups, since there is no way the 1/8th scale axles would be able to handle this much power.

Anyway, I will be working on this build again shortly. I promise
Old 11-05-2009, 03:43 AM
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Default RE: Full suspension buggy build

Hmmmm....

Is that one of your old weedwacker clutch housings bolted on to that motor?



Nice pipe too.
Will listen to it later when I'm at my own computer with decent speakers.



Old 11-05-2009, 03:57 AM
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Default RE: Full suspension buggy build


ORIGINAL: Dirty_Vinylpusher
Is that one of your old weedwacker clutch housings bolted on to that motor?
Yep. The entire clutch housing, bell, and shoes all came from an old weedie I might have to get a stiffer spring for it because the clutch is almost engaging at this engine's idle speed [&:].
Old 11-06-2009, 01:50 AM
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Default RE: Full suspension buggy build

Sounds like this is gonna be a pretty powerful beast!

I've been away from home for almost 2 weeks.
Get back on Sunday and can't wait to take the Traktor for a spin again.
Then I'm gonna look in to putting the 47cc chainsaw motor on it and big wheels on the front as well....



Old 11-06-2009, 02:16 AM
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Default RE: Full suspension buggy build


ORIGINAL: Dirty_Vinylpusher
Then I'm gonna look in to putting the 47cc chainsaw motor on it and big wheels on the front as well....
Sweeet! This should be interesting .

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