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Author Topic: My Winter Buggy Project  (Read 5729 times)

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Odyknuck

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My Winter Buggy Project
« on: January 19, 2010, 10:50:53 AM »
I have taken a break from the Turbo Buggy to get back to work on another Long travel Pilot mini Buggy. I started this 2 years ago and it got shelved to build the Woodsbuggy. Then shelved another year to do the Subie Motor Swap. The other Long travel Pilot has a 75 HP 500 cc 2 stroke motor in it. My wife drove it and now somehow its hers. Funny how that happens. So not to be out run by the Wife unit I have to build this one with a 700 CC 126 HP Rotax. I have streached the frame to make more room for the new motor and to give me moro stability with the additional HP and speed.  The original roll cage would not fit after that and is to weak in my opion so I built a new one.
Here are some progress pics:

http://s293.photobucket.com/albums/mm72/Odyknuck/Pilot%20Build/
« Last Edit: January 19, 2010, 10:54:05 AM by Odyknuck »
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DaveM

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Re: My Winter Buggy Project
« Reply #1 on: January 22, 2010, 09:48:06 AM »
 Do you do anything to the carb return springs on the Rotax engines to make the throttle effort easier? I find the throttle on my 670 is gonna be too stiff for lengthy use.
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Odyknuck

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Re: My Winter Buggy Project
« Reply #2 on: January 22, 2010, 10:29:41 AM »
I have not got that far yet.  All the guys I know have the same complaint. I suggest removing the spring the thumb throttle for starters. There is plenty of spring pull on the Sled motor carbs to not have worry about that spring.   I am considering a foot throttle however I have not made the decision yet. I have toyed with the Ideal of a bell crank to Increase the leverage ratio however you would need to push the thumb throttle farther. I dont know yet if there is enough lattude to do that.  I have also thought about spring assist however that gets tricky to balance. The last thing you want is a stuck throttle on a 100 Plus HP motor.
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Offline Engineer

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Re: My Winter Buggy Project
« Reply #3 on: January 22, 2010, 03:55:56 PM »
Looking good!  Looks like the cage work is done.  Are you building new suspension?  Is this a new conversion to the Rotax motor?  Why did you build a whole new upper cage?  Strength, saftey structure?
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Odyknuck

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Re: My Winter Buggy Project
« Reply #4 on: January 23, 2010, 09:10:07 PM »
In the process of steaching the frame it also got wider as you went back so the Bolt on cage would have need to be modified a lot to make it fit. Also After watching one crush in front of me on a ride a few years back i decided to make one out of 1 3/8" .095 DOM in lieu of the OEM  .062 ERW. Yes I will be building new long travel for the rear w/ Fox 10" Coil overs and using one of Aftershock motorsports long travel kits with Works Coilovers on the front. My other Long travel Pilot is using the same front and rear setups and work well. Except the rear has Axis Shocks.
« Last Edit: January 23, 2010, 09:13:07 PM by Odyknuck »
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Odyknuck

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Re: My Winter Buggy Project
« Reply #5 on: January 26, 2010, 07:37:13 AM »
Got the radiator and Air Filter mounted over the Weekend. Also made new Acetel Trans mount Bushings.

http://s293.photobucket.com/albums/mm72/Odyknuck/Pilot%20Build/
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Offline fabr

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Re: My Winter Buggy Project
« Reply #6 on: January 26, 2010, 08:54:56 AM »
Tell me more about that air filter.
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"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

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 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"

Odyknuck

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Re: My Winter Buggy Project
« Reply #7 on: January 26, 2010, 09:19:32 AM »
The Air Filter is a 4 stage design with an Inlet turbine to throw out the majority of dirt and water before it hits the filter media.  One of my riding Buddies tryed one of these in his Woodsbuggy with great sucess. His is the earlyer version with the bolt on Turbine. Here is the link to the Manufacture. BTW you can buy direct.

http://www.enginaire.com/integrated.htm
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Offline fabr

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Re: My Winter Buggy Project
« Reply #8 on: January 26, 2010, 09:46:10 AM »
Cool,thanks for the link.
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"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

-----------------------------------------------------------
 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"

Offline fabr

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Re: My Winter Buggy Project
« Reply #9 on: January 26, 2010, 11:02:59 AM »
Approx what cost was yours?
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"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

-----------------------------------------------------------
 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"

Odyknuck

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Re: My Winter Buggy Project
« Reply #10 on: February 01, 2010, 10:49:02 AM »
Weekend updates:
Mocked up a cardboard gas tank so I could weld the mounts on, Modified the Exhaust expansion chamber to fit the application.  Ordered a new custom silenser from AAEN today. Did I say welding sheet metal is a pain? Made Tree bar mounts and welded them in.  Added "X" bracing on the front. The stock Pilot lower "A" arm section is a poor design in the front and can and will bend on a full weight corner hit. Been there done that.

http://s293.photobucket.com/albums/mm72/Odyknuck/Pilot%20Build/
« Last Edit: February 01, 2010, 01:13:32 PM by Odyknuck »
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Offline fabr

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Re: My Winter Buggy Project
« Reply #11 on: February 01, 2010, 10:55:25 AM »
Quote from: masterfabr on January 26, 2010, 11:02:59 AM
Approx what cost was yours?
^^^^^^^^^^^^^?????????
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"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

-----------------------------------------------------------
 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"

Odyknuck

  • Guest
Re: My Winter Buggy Project
« Reply #12 on: February 01, 2010, 01:12:33 PM »
If your asking the cost of the Air filter it was around $140.00
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Offline fabr

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Re: My Winter Buggy Project
« Reply #13 on: February 01, 2010, 02:59:06 PM »
Not bad for a good filter/prefilter that does a good job of keeping clean air available. I was looking at their sizing chart and it appears it needs to be HUGE for a turbo busa. Am I missing something? I guess I COULD call them huh? Well,there's another thing i need to get done. drowning
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"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

-----------------------------------------------------------
 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"

Offline fabr

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Re: My Winter Buggy Project
« Reply #14 on: February 01, 2010, 02:59:55 PM »
BTW ,I am quite interested it one if they're not huge for the busa.
Logged
"There can be no divided allegiance here.  Any man who says he is an American,
but something else also, isn't an American at all.  We have room for but one
flag, the American flag... We have room for but one language here, and that is
the English language... and we have room for but one sole loyalty and that is a
loyalty to the American people."
Theodore Roosevelt 1907

-----------------------------------------------------------
 " You have all the right in the world to believe any damn thing you'd like, but you don't have the right to demand that I agree with your fantasy"
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