Jedi Buggy

[hadfield4wd]

Most likely premature, but here it is. I’m building a buggy for my boys. 7 and 10 years old. Got the idea from the Honda Powered Kid buggy (No surprise there)

http://www.pirate4x4.com/forum/showthread.php?t=633445&highlight=honda+powered+kid+buggy

We’re calling it the Jedi Buggy because the boys are Star Wars crazy.

I am doing it differently and trying to do it less expensively. I wanted it to be simpler as well. No cooling, computers etc.

So the basic specs.

Sammy axles welded
Leaf sprung 2 long leaves from the sammy pack
2 seater
Polaris tranny and cvt
20 hp Kohler motor on propane, electric start
Full hydro steering using SE ram and MR2 12v power steering pump
31” MT tires
Manual brakes with floor mounted adjustable pedals
Adjustable 5 points and window nets

I have had a lot of help in this as far as tech help and free parts. Coily, Drake, Randy and Jim. There are others as well.

The main frame is out of 2x2.

Here I am with the 7 yr old laying out and building the frame.


http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame002.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame007.jpg

[hadfield4wd]

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame001.jpg

Got a little smokey in the garage

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame008.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame011.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/frame009.jpg

[hadfield4wd]

Next we disassembled the axles and welded the side gears like the sammy guys call a “Fozzy Locker”

So we took the axles apart to weld the diff. I hate to say this but these little axles are “cute”. Here is a picture of the Kingpin next to the thumb of a 7 year old.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/kingpin.jpg

We pulled the diffs apart. These are different than any dana diff. You have to pull the whole thing apart to get to the side gears. As you can see in this picture the side and spider gears are housed in the bolted together carrier.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/gears002.jpg

Had some help.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/gears004.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/gears006.jpg

[hadfield4wd]

I hope I can get all this back together.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/gears007.jpg

What the sammy people say is you weld up the side gears like this. I’ve got 20 hp so I’m not worried.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/gears009.jpg

Both axles are done. Will get the tabs welded onto the frame this weekend and rolling this weekend. Possibly the drivetrain as well.

[FitchVA]

i can't wait to see this thing done! :driving:

[DAZYDG]

I cant wait to see it either! :2thumbsup:

[hadfield4wd]

Well not all goes as planned. I’ve been travelling a ton for work and with the kids activities and the honey-do list not a lot has been accomplished.

Anyway, I have the rear tacked in. The front is sitting where it needs to for ride height. It seems very high and short. We’ll see how it goes. The wheelbase is 60”. I want to keep the leaves for cost savings and I want to keep it shorter than 102” so it will go sideways on the trailer. If I need more wheelbase I’ll have to go links.

Here are some pictures.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/rearinfrontmockup006.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/rearinfrontmockup003.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/rearinfrontmockup001.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/rearinfrontmockup002.jpg

[hadfield4wd]

Well haven’t done much visually, however progress continues. I changed up the rear shackle mounts. And the front is all tacked in.

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/fixedrear.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/fronthanger1.jpg

http://i85.photobucket.com/albums/k51/hadfield4wd/Jedi%20Buggy/fronthanger2.jpg

The motor is rebuilt and good to go.

All the drivetrain parts are at the machine shop so they all fit where they are supposed to. I’ll provide details with pictures when I have them back.

All the steering parts should be here in the next couple of weeks. Just need the orbital now. I’ll provide details to this setup when it’s here.

Once the drivetrain is in I can mock up the seats then get to work on the cage.

[Big Red 95]

That thing is going to be awesome. your kids will definitely be the envy of all others. You can't find a better project than that to bond with you kids and mold the next generation of 4 wheelers.