Brad’s – Manxter 2+2 Offroad Build, A-Arm, Subaru and Toys

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Brad
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Brad’s – Manxter 2+2 Offroad Build, A-Arm, Subaru and Toys

Postby Brad » Mon Apr 01, 2013 5:49 pm

Ok so where to start … I guess the beginning was so long ago so I will skip to now. I moved to the USA in Aug 2012 from Australia and Winnie had Manxter 2+2 kit ready to pickup the week before I got here. Since then I have been trying hard to come to terms with the USA Buggy Building Market as opposed to the Australian Market.

It is funny I have built a couple of buggies before but when you sit down and think about it I realized that a lot of the things I did I did because that is all the Australia Dept of Transport would allow me to do. Now being in America a lot of the boundaries I had known my entire life in relation to Building Buggies now came into question.

I initially started off trying to just build what I was use to in terms of suspension, brakes engine etc but found funnily enough that a lot of the parts I was used to having ready access to where simply not available and if they were they were not cheap. So I began looking into new options such as A-Arm front ends, 3x3 rears, after market disc brake kits etc etc.

Anyway fast forward 6 mths and I am now ready to start the actual build. Like a lot of people if I don’t have a time line of sorts I will slip backwards and probably never get it finished. With that in mind the Manx Club Big Bear Event ( July 13) has been selected as my to be finished by event.

Luckily I have a Manxter 2+2 kit already here although Winnie was nice enough to let me vary a few things from standard but more on that later.

There is only one colour for a Manxter 2+2 to be if it is going to be mine ... blue of course :D

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Sitting in the garage ready to start the build

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With the kit sorted and collecting dust it was onto the rest of the bits.

Engine would be an EJ 22 Subaru from an early 1990's Liberty / Legacy. I found a nice rusty one cheap with just over 300 000 miles on her so she was cheap and being a subaru still running like a top.

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I will be using the stock EJ 22 ECU, engine loom, steering column, wiper motor etc so buying a complete car made economic sense.

For a transmission I got a SubaruGears.com Transmission off Todd. It is running one of the proto type 4.86 Ring and Pinions on a subaru gear set. Should be interesting to see how it pulls the 33's. Todd shipped it direct from Australia for me in a nice wheelie bin, although the wheelie bin got hammered the box arrived in perfect condition.

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So that gets me to about where I am. I picked up a floor pan local with current tags which is a 1971 Model and will allow me to go IRS / BJ although I don't need the BJ part as I got an A-Arm front end of Pete at A-Arm.com.

Parts wise Dan at Dans Performance Parts ( dansparts.com) has hooked me up with most of the other stuff I need but I will cover that as I get to unpacking the boxes and polishing the bling.

mmm buggy bling..
Brad
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Lovebuggy » Mon Apr 01, 2013 8:59 pm

Love the wheely bin packaging.

Lucky he didn't mix it up with his domestic one at home :shock:
Are you a financial member of the club??

Go to "http://www.manxclub.org/phpbb3/viewtopic.php?f=50&t=1667" and sign up today.
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Tue Apr 02, 2013 12:53 pm

Lovebuggy wrote:Love the wheely bin packaging.

Lucky he didn't mix it up with his domestic one at home :shock:


Nah to heavy for a council worker to pickup :D
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Wed Apr 03, 2013 2:05 pm

Prior to starting the actual build I have done some research, checked out some options and surprisingly enough changed my mind more than a few times.

As you may gather from my time line I haven't really allowed to much fat and my design plan is now locked it and parts are rocking up in box's this week.

So as a brief overview here are the basic specs I am going into the build with ( be interesting to see what pops out :) )

Body - Manxter 2+2 Standard Kit ( with special order options)

Roll Cage - Manxter Dual Sports 1020 grade DOM cage, unwelded ( I will have to modify it to fit the 2+2 body).

Lift Kit - UpYerBug 3" Lift kit (with one of the new steel front yokes so I can weld it on to help with A-Arm design.

Floor Pan - IRS / BJ rust free and 100% factory including mint original floot halves

Seat - PRP Competition in front, custom bench in rear

Engine - Subaru EJ 22 with factory ECU, SteelrArt Stainless Exhaust System, Meyers Manx Australian Offroad sump kit ( 85mm shorter), custom intake.

Cooling - Custom Radiator in Meyers Manx Rear wing, design TBA.

Transmission - Subaru Gears 5 Speed with 4.86 R&P.

Suspension - A-Arm front, , 3x3 Rears with microstubs, fox 2.0 coil overs, dual rate springs, hydraulic bumps.

Brakes - Jamar wide 5, 4 pot front, 2 pot rear with 2 pot e-brake, braided lines, Jamar Under Slung pedals.

Wheels and Tyres - Custom Rims with correct offset, 33" rear, 235 x 75 or so fronts.

Wiring - Custom loom from Meyers Manx Australia. Using Subaru Wiper motor and controls.

Dash - Custom Meyers Manx Australia integrated dash complete with ADR Compliant module, hazard switch, switches etc.

Steering - Rack and pinion using A-Arm.com parts and Subaru liberty parts.

I think that is about it, I will go into more details as I get to each part of the build and start taking pictures while it is all still nice and clean.

Special Thanks up front must go to the following guys who are making this build a reality:

My Wife - anyone who is married etc will understand why although she doesn't spin a spanner without her support the rest would be irrelevant.

Paul - SteelArt Creations ( www.steelart.com.au) great guy, awesome fabricator.

Ben - Meyers Manx Australia, buying my old Manxter 2+2 and helping out with wiring loom and other parts.

Bruce and Winnie - Meyers Manx Inc (meyersmanx.com) - Bruce, the man who started it all, without him there would be no Fibreglass Dune Buggy and Winnie, the great woman behind the man, without her no one would ever get an order filled.

Todd - SubaruGears.com, good to work with, great product well thought out and awesome customer support.

Dan - Dan's Performance Parts - (DansParts.com) - can't build much without parts and buggy bling.

Sonny - Downsouthmotorsports.com - awesome advice and shock supply, my Manxter would ride like crap without him.

I am sure there will be others along the way but I can only remember so much at once.

Buggy On !!!
Brad

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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby bajabone » Thu Apr 04, 2013 9:39 am

Brad I'm looking forward to hearing your feedback as regards the Subaru Gears 5 Speed with 4.86 R&P and the 33' tyres. (is first gear low enough and rpm at 100kms) I think you have convinced me again. This time its the gearbox!
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby bugman » Thu Apr 04, 2013 11:00 am

if i had the money i think a 5 speed box, with a crawler 1st gear and then set the box up to run 'normal' for the other 4 gears would be really nice!
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Thu Apr 04, 2013 11:07 am

So far my feedback is great ... box came all nice and clean.

My Ratios are as follows:

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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Smiley » Thu Apr 04, 2013 12:38 pm

bajabone wrote:Brad I'm looking forward to hearing your feedback as regards the Subaru Gears 5 Speed with 4.86 R&P and the 33' tyres. (is first gear low enough and rpm at 100kms) I think you have convinced me again. This time its the gearbox!


By my calculations it should be around 2522 rpm in 5th at 100km/h and 2775 at 110km/h.

And in 1st gear at 5km/h is 531 rpm.

For comparison a 3-rib box is 660 rpm at 5km/h
and a 5-rib is 584 rpm at 5km/h

So the first gear will be a tiny bit higher than a 5-rib is.

This will obviously depend exactly how tall your 33" tyres are, but this is a good rough indication.

Brad, do you know if Todd has any plans for a lower ratio diff than the 4.86??



Smiley :)
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Thu Apr 04, 2013 2:47 pm

Smiley wrote:Brad, do you know if Todd has any plans for a lower ratio diff than the 4.86??

Smiley :)


I hear things BUT why ? Just get an EJ22 and they have nice torque :)

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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Fri Apr 05, 2013 2:55 pm

Ok, so I found a few hours early today to get a start on this build. Got the pan onto the trolley and started the awesome job of getting all that tar stuff off the floor pan and tunnel. Man was that a PITA.

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I also started to unpack the box's Dan sent over with the brakes and stuff in from Jamar. I am going to try using a second circuit hydraulic system for my ebrake with a second calliper on the disc. This should mean I can do away with the brake cable.

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Hopefully I will get a chance over the weekend to finish up the pan and send it to powder next week.
Brad

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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby josh702 » Fri Apr 05, 2013 6:00 pm

The hydraullic parking brake is a good idea, those cables are a pain. Will this work the same as rally cars and drift cars hydraulic turning brakes that lock into the on position for parking but with seperate calipers? Is this a kit or something custom?
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Sat Apr 06, 2013 2:19 am

this will be custom and yes it will operate as a turning brake as well.
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby ttriebler » Sat Apr 06, 2013 3:27 pm

No plans for anything lower than 4.86. It's already pushing the limits as the pinion gear is getting small.
A complete redesign would be needed in order to get something like a 5.86 and try and keep the pinion large enough.
Real expensive and the market gets smaller and smaller.
To be honest, with the torque of the Subaru motors and a 4.4 or 4.86, you should be able to crawl fairly easily.

I've put another test 4.86 and LSD into Toddy101's gearbox today, powered by EJ20 turbo WRX motor. This previously had a 4.4 and LSD and runs on 31" tyres. With a bit of luck he'll be getting it going tomorrow and we'll see how different it is. Fingers crossed.
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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby manxiberty » Sat Apr 06, 2013 5:07 pm

Smiley wrote:
Brad, do you know if Todd has any plans for a lower ratio diff than the 4.86??

Smiley :)


Just drive faster smiley :lol:
if in doubt hit it with speed.... just don't hit the cactus!

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Re: Brad’s Before Big Bear Buggy Build – Manxter 2+2

Postby Brad » Sun Apr 07, 2013 5:33 pm

So I found some time today to unwrap my transmission from Subaru Gears, it is great having rebuilt stuff as it is nice and clean ..

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With the transmission out it was time to fit it into the floor pan. Now you don't need to cut as much out as I do but haveing been stuck working on more than one car where getting to the shift linkage is a PITA I like to make sure I have plenty of room.

With the transmission sitting in place you can see there is not much difference to a VW size and fit wise.

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The nose cone and shift tube hit though. Usually I fit one of these smaller style gusstes and trim to suit.

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In this case though I am running a hydraulic clutch and custom accelerator so I don't need either of the factor tubes so there is no need to retain them.

Because of that I used a much larger opening.

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With it clamped in place I did a test fit and decided I could make it even bigger and give myself some more room.

So with a larger one made I welded it in.

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The inside welds main purpose is to get ground back and well smoothed ensuring there is a nice feeling edge which is well rolled and friendly to access without catching.

With welding complete and everything nice and smooth I could again test fit the transmission, if you look closely at the left hand side you will see where I had to grind a bit out to clear it.

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Brad

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