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I've gotten the letters and I've heard the harassment while on the trail. Yes, I am still building Project Fun Buggy. It's just taking a little while, but here is another installment of the buildup that began over a year ago (Aug. The idea for this tube buggy is an all-terrain vehicle that doesn't have a conventional body but rather is built for optimum fun off road.
Though my buildup uses premium parts, it can be duplicated with a junkyard drivetrain on a reasonable budget. To recap, we started by building front and rear steering axles with Dynatrac Pro-rock Dana 60 centersections, Reid Racing (formerly Dedenbear) end forgings and knuckles, 40-spline Superior shafts, CTM U-joints, and Detroit Lockers (Aug. In addition we used Yukon 5.38 gears with 35-spline pinions, and high-steer arms from OTT.
I then went to Scoggin-Dickey and assembled a fuel-injected GM Performance Parts ZZ383 small-block V-8 (Sept. This engine uses an ACCEL DFI fuel-injection system and was dyno'd at just over 400 hp and just shy of 500 lb-ft of torque.
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Following that, the mil-spec green Mastercraft suspension seats and 17-inch Walker Evans Racing bead-lock wheels were added (Oct. And then there was a lapse until our February 2006 issue where I discussed tubing and showed the difference between HREW, DOM, and chromoly tubing and the fact that I am using about 300 feet of DOM 1 3/4-inch x 0.120 wall tubing for the majority of my project. Then everything fell apart. To get everything moving I took my drivetrain parts to Poly and began the extended design, and that is what this month's story is all about.
Now I was assuming we would simply park the parts on the shop floor and begin bending tube around it, but boy was I wrong. The team at Poly Performance takes a different approach by measuring every drivetrain component and suspension part, then drawing them up on the computer.

This way they can get an initial layout before any tube is bent. It takes longer this way (way longer), and most of us can't duplicate these steps exactly, but similar procedures can be done with pencil and graph paper. Of course I was going crazy trying to get my buggy project moving, but the best advice for a project this big it to have a solid overall plan for the entire vehicle. Though some fabricators can whip a chassis out in their sleep, these drawings made it much easier once the dirty work finally began, and can keep the wasted tube to a minimum.
This process also allows many different configurations to be explored before a final design is set. The chassis was coming together nicely when I brought up another idea. Here is a pointer for anyone working on a custom buildup; if you keep making changes or 'bringing up ideas,' your project will take that much longer to get done, and at some point you will need to make a 'design freeze,' and just get the project moving ahead.
Luckily, since we were still at the drawing stage these changes could easily be tried out. My other idea was more a question; could a buggy be built completely out of sheetmetal? Basically build a unibody or monocoque vehicle, but design it to work off road, and be made of thin sheetmetal to keep the weight down.
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Where some designers would chase me out of the shop at this question, Burroughs rolled it over in his head and offered that we could do certain parts out of thin chromoly sheetmetal with dimpled holes for added rigidity. I liked the idea and soon we had a new substructure drawn where the link suspension will tie in.
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Description Fabrication Skills Rating: 3-4 Cost To Build Rating: 3-4 ST4 is a premium two seat motorcycle engine powered off road vehicle that you can build yourself at home using our highly detailed fabrication plans. ST4 features a long travel double a-arm suspension using Fox Air Shocks, both front and rear. We have done all of the engineering and geometry calculations to ensure your suspension, steering and driveline will function correctly and reliably for years.
We designed our ST4 off road vehicle to be simple for you to build at home using your own welder, tube bender and fabrication tools. ST4 fabrication plans are laid out in a logical step-by-step format. We explain all the necessary fabrication steps that you need to do to successfully construct this premium off road vehicle. Our fabrication plans include both metric and imperial measurements in millimeters and inches.
We show you how to cut and bend individual tubes, how to prepare the ends of tubes to accurately fit together, then how to weld individual tubes into an overall chassis frame. Our fabrication plans also include measured fabrication and machining drawings for constructing the entire front and rear suspension systems including detailed parts lists for all the parts you need to purchase. We also show you how to build the robust rack and pinion steering system.
You can purchase and install a variety of motorcycle engines. We do not show you how to install the engine, as every engine has different mounting points, however, we have designed the engine compartment of ST4 to accept just about any size of motorcycle engine. We have included files so you can have some parts precision laser cut. DXF files are two dimensional CAD (computer aided design) patterns that all laser cutting shops use worldwide to create precision laser cut steel plates. This saves you time and money. Your local laser cutting shop does not have to redraw any parts. You simply give them the DXF files supplied with your fabrication package and they can reproduce exact parts for you.
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All our flat steel plates are designed to be self-jigging. We have designed slots with mating tabs in our steel plates so they fit precisely together. There is no guessing how parts fit together, as we have done all the hard work for you. We also provide you with information on where you can purchase all of the bolt-on parts you will need. ST4 Fabrication Plans Package includes: 100 page Instruction Manual with measured drawings in PDF format, 40 DXF files (generic CAD) for all flat steel laser cut plates, 32 CAD renderings in JPEG format, 4 CAD models (uneditable) in DWF format (link to free CAD viewer) including 3D CAD model of entire vehicle, chassis weldment, front suspension, rear suspension & drive system, Parts Lists including Steel Order List, Nuts & Bolts List, Purchased Parts List in PDF & XLS formats c/w parts suppliers, part numbers, quantities, contact info.

ST4 Safety: Design includes mounts for 5 point racing harnesses (driver & passenger), racing certified polyethylene bucket seats, racing certified brake & clutch foot controls, dual front disc brakes, single rear disc brake, professionally designed roll cage & chassis system. ST4 Handling: Rack & pinion steering system, adjustable camber angles in front suspension/steering, 15 degrees of built-in castor angle in steering system (self-centering steering), Up to 14″ of wheel travel at all corners, double a-arm suspension all around, fully adjustable & tunable Fox 2.0 series air shocks (rebuildable & tunable dampening), lightweight tubular steel chassis design @ approx 200 lbs (ie: lightweight means improved power-to-weight ratio & improved handling/cornering). Overall vehicle will weigh approximately 1100 lbs with engine installed.
ST4 Ease of Fabrication: Our 100 page ST4 fabrication manual include step-by-step progressive fabrication drawings with sub-assemblies, weldments, bending details, flat plate details, etc Basically, you start at the beginning of the plans & work your way through step-by-step. Every drawing has a parts/materials list (where applicable). Chassis drawings show you how to start by making a square tube base frame then progressively build upon that starting point. All materials are readily available worldwide.