On road, off road racing buggy

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shaihulud
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On road, off road racing buggy

Postby shaihulud » Mon Jan 30, 2017 12:17 am

This is what I've been working on lately.

I'm re-bodying a Type 3 chassis and stock mechanicals with a old off road racing buggy frame.

I have a VW Type 3 chassis in good condition which has a registration history as a convertible. I have the papers.

I started with a Type 1 Beetle but a better Type 3 came my way and I changed to that.

I bought a superseded, old technology off road racing buggy frame with a CAMS certification and comprehensive engineer's report, which I have.

My engineer inspected them and O.Kd. the project and he sent me a covering letter on his business stationery to that effect.

I then sent an application with a copy of all my documents, a covering letter, lots of pictures, drawings, specifications before and after pictures and pictures of what it will look like when it is finished to engineering section of WA DoT. They gave me permission, in principle, to build it.

Google Chenowth of fast attack vehicle to see what it will look like. Of course it won't be bristling with machine guns and rocket launchers.

I'll show you the beginning pictures first and then keep you posted
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PUD
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Re: On road, off road racing buggy

Postby PUD » Mon Jan 30, 2017 5:15 pm

Wow, cool! ....recon would feel pretty safe strapped in there, lots of bracing! :)
shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Mon Jan 30, 2017 11:00 pm

The end result won't be as well braced as that, but it will still be strong.

I had to remove the side intrusion bars as rego won't let you climb into a car through the windows like the Dukes of Hazard. They will be re-fitted lower at hip level. I also removed the front and rear suspensions, the floor and most of the other steel bracing that is no longer required as the old off road frame is no longer a stress bearing chassis but its now a body.

It's reduced in weight by about 100 kilograms. It now looks more like a sand rail than the original.

More pics soon.
Vduboy
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Re: On road, off road racing buggy

Postby Vduboy » Tue Jan 31, 2017 10:18 am

Sweet!! Looks like a fun build.
It will all be ok in the end.. if is not ok its not the end!
shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Tue Jan 31, 2017 7:01 pm

The floor, front and rear suspensions were completely removed.
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shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Mon Mar 06, 2017 4:55 pm

I bought a Type 3 convertible with papers which was in poor condition.and I have permission to continue with that. The Type 3 has an adjustable front suspension, ball joints and disc brakes, The rear is rubber suspended and IRS with bigger brakes. It is much to be preferred over the older drum braked, king pin, swing axle Type 1 that I started with.

The off road frame has now been welded up and is ready for inspection by my engineer. I had that done by a local certified welder. My welding is not good enough.

As you can see, the fit of two interrelated but independently made parts is remarkably good. I am lucky that the off road frame is not a few inches shorter or longer, wider or narrower. It would have made this build much more difficult. Goldilocks comes to mind.

I have fitted a 2 inch lift kit, which is essential to make it all fit together and to give it enough head room to comply with the ADRs.
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BBTJ
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Re: On road, off road racing buggy

Postby BBTJ » Wed Mar 08, 2017 6:39 am

Really interested in this build 8) 8) 8)
shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Wed Mar 08, 2017 3:32 pm

To give you an idea of how much steel I removed from the original off road frame, one picture shows it all in a pile and the others spread out. Add to that the picture of the rear suspension (which I gave away).

I must have removed about 100 kilograms of steel. This will not be a light weight car, but I suspect that it will weigh about the same as a stock Beetle
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shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Fri Mar 10, 2017 5:28 pm

As is always the case with this kind of build, decisions that could be made early on are left until much later.

Two examples are the parts that hang down at the front and the one at the rear of the frame.

There are two good places at the front for bumper bars which are where the original transverse suspension tubes were and there is also a good place to fit a winch, but will that hang down too far and interfere with entry to steep river crossings or the bottom of the slip face of a dune to horizontal sand?

I am going to fit a 4 cylinder water cooled Toyota 2T GEU engine from a Celica which has a huge 4 into 1 exhaust extractor beside it. I bought it for the price of an adapter and a flywheel, so air an aircooled VW engine is not going to be fitted..

The other at the rear is a good place to fit a big aluminium radiator from a V8 car and also to mount longitudinal bars for the engine mounts and a tow bar. The question is, is it a good place to fit a radiator behind an engine and especially the exhaust? Will it require air ducts, or a deflection heat shield around the exhaust which I don't want to do?

They both require more thought and research.

Ah! The joys of special building.
BBTJ
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Re: On road, off road racing buggy

Postby BBTJ » Sat Mar 11, 2017 7:37 pm

Crikey :shock: That is going to be some buggy. What body goes on this ???
shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Sat Mar 11, 2017 11:19 pm

This is a picture of the off road frame with its bodywork on it. Most of that will be replaced. It was held on with Dzus fasteners.

I promised to fit bodywork to it when I asked for permission to build it, but I'm hoping that my engineer will let me register it without bodywork and make it optional to fit if I want to.

I'd like to have it so that I can drive it without bodywork in the dry and with it when it's wet.

I'm even considering seeing if I can get it registered without a windscreen and to make that optional.

My reading of the Australian Design Rules is that there is no regulation that a car must have doors, but if you have them then they must comply etc. That's why beach buggies don't have to have doors. I think that it doesn't say that a windscreen or body work are compulsory either, but if they are there then they must comply etc.. More reading/research is needed there.
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shaihulud
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Re: On road, off road racing buggy

Postby shaihulud » Sun May 14, 2017 9:52 pm

Finally the buggy is at the "bolt the body to the pan" stage.

My engineer said that I could continue and he answered lots of questions about seat belts, lights, padding, etc., etc.

The seat belt crush tubes are in the right place and O.K.

The seats are from a Toyota Tercel. I know. They are ugly, but seat covers will fix that.

The steering is stock Superbug, so it needs no extra engineering.

The frame welding has been certified.

The pedal box fits well and needs a bit more work.

The front, where I was considering whether or not to keep it has been removed as the engineer said that it was "sharp and nasty" and a danger to pedestrians. A round pipe there, isn't "round and nasty"????

The engineer said ,"No." to the Toyota engine as with the radiator it would make the buggy tail heavy, it would make it an ICV but it is too old for an ICV. I have arranged to swap it for a complete, tatty, Superbug so the buggy will now have a stock 1600 TP engine.

Buggy building is a bit like the building of a new office in the City. For months there is a hole in the ground and little progress seems to be being made to the casual onlooker, then suddenly a building shoots up.

After months of work, but no seeming progress I can now get into the wiring, fuel tank fitting, brakes, brake and fuel lines. I am so tired of putting the body on the frame, deciding something, taking it off, fiddling about, changing my mind, putting it back, ad infinitum, ad nauseum. Soon it will be over at last.
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BBTJ
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Re: On road, off road racing buggy

Postby BBTJ » Tue May 16, 2017 9:15 am

:D Bugger about the engine, I was really looking forward to the Toyota install - just for something different :D

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