Dune Buggy Build

[holeski]

You all can let me know if you are interested in this or not since it’s not a “4x4” but is for offroad.. If so I’ll keep the post up to date.

Since my YJ is my daily driver I haven’t really felt like tearing into it for all I have to do to it. Heather has the WRX as her DD right now until we move and I can start her XJ swap.

Wayne (fix-it) and I spent a few days earlier this month trying to get the buggy running. All this time I thought the motor need a rebuild. We got it going and after a day of messing with the timing it was ripping. We took it out to South Cushman and ran the crap out of it. Not one problem all day. So that’s when Wayne and I decided to take it up Fairbanks Creek. She died at the top just before the rocks and had to be towed home. Turns out the carburetor was dumping too much gas in. That’s how it all started. I started ripping everything off. I had to wait for a carb rebuild kit so I would state something else, so on and so on. I had to drill and tap a broken exhaust stud., clean up the muffler, pipes and get new gaskets .The distributor keep moving around so I ordered a new distributor bolt down key along with some water proof boots for the coil and cap. New plug wires and the hottest plugs I could get. The stock replacement coil wasn’t putting out the power I was looking for so I took it back and picked up an Accel #8140c that was only $5 more. Should have gotten that in the first place. Wayne donated a Red Top Optima since him and I broke the plates in the old one down at South Cushman. Too many jumps. Thank Wayne. I adjusted the valves to .006, witch they where way off. Moved the fiberglass top back 4” so a grown man could see out the windshield while driving. Pulled the dash out (that would skin your leg every time you tired to get in) and am building a new slimmer one. Moved the steering wheel up and back a few inches and now looking for a bearing to fit the shaft to take out the slop.
Adjusted the rear brakes, the only ones there are. Pulled the IRS apart and adjusted the ride height and rear wheel travel. I gained about 5” under the rear skid plate, with 3” down and 6” up travel. It now sets with 14 ¾” under the back and 10 ½ under the front as its lowest points. Swapped the 25” tires for some 30” ones I found in our back junk yard. There SCAT TRAC! Still looking for some new fronts, the ones that are on there are 165SR15 (what ever that is). I’m looking for some new front shocks. There small 14” open and 10” closed. I would like to get a bit more wheel travel out of the front and use a longer shock, but they need to be soft since one person can lift the front of this thing up. I have been trying to find ATV coil over shocks, but no one says they have anything that long. So that’s where I am with this project. I still need to rebuild the carb.

Here is how it sits right now.
http://www.arcticoffroad.com/albums/Members-only/DSC03071.sized.jpg
http://www.arcticoffroad.com/albums/Members-only/DSC03072.sized.jpg
http://www.arcticoffroad.com/albums/Members-only/DSC03073.sized.jpg
This is the only photo I have that is from before. Wayne might have some of us jumpping it.
http://www.arcticoffroad.com/albums/album84/Carcross_Desert.jpg

[mousee]

165SR15 (what ever that is).

bug tyres. check the bug shocks too.

[FixIt]

that thing is a blast to drive i had it up to 75 mph down the road behind his house power sliding it around the corners . even a couple of 6ft plus jumps and lived to talk about it . hopefullt we will work out the bugs .

[STOMPR]

Go Speed Buggy... Those things are cool I always wanted one.

[sevenslats]

Sweet.

[holeski]

I have the carb all pulled apart and waiting for me to clean and reassemble it. Just need to try and save some of my brain cells before I go back out there.
Here it set in peaces.
http://www.arcticoffroad.com/albums/Members-only/DSC03080.sized.jpg
OK. So who was it that said “carburetors are simpler the fuel injection”??













Kevin!

[ChevyKev]

:ROL:

Not to rebuild! easier to adjust a screw than to replace computer/bad sensors!

And I was gonna post : Man that looks like fun! :lol:

but that was before the rebuild picture!

[holeski]

I pushed the Buggy into the garage since it was raining when I got up this morning. I tacked welded the exhaust and painted it with some high heat paint to keep the rust at bay. Wayne came over to help out and told me that I put the carbs jets on the wrong sides, so I have to fix that still. He also brought over some universal Accel 8mm plug wires and made me a sweet set of wires for the motor. Thanks buddy. We started to work on the steering and decided to go get a $30.00 bearing to stabilize the steering shaft. He paid for that too, I forgot my wallet. We fabed up a mounting location for the new bearing and welded it in place. The old welds on the steering shaft where not straight so when I put the bearing in it would lock up after one turn of the wheel. So now I need to get some 1” tube to make a whole new shaft. The more I try to get this thing back together the more it seems to come apart. I finished up the night buy doing some wiring and general cleaning.

[holeski]

I haven’t gotten too much done the last few days. Busted the $30.00 bearing and have to take it back Monday morning. Most of the motor is back together, but still need to swap the jets around in the carb and bolt it on. I put new fuel line, filter, water proof boots for the coil and the distributor and have been doing a bunch of rewiring, rerouting of wires. I ordered a breather box for the oil and am tiring to find a good set of shocks for the front. Hard to find in the size and spring rate I need. I have found a few new spots to run it so I’m itching to get her ready and rolling again.

[crazy4ink]

That thing looks like it's a blast!

[holeski]

It’s been a long couple of days working on the buggy. I have most of the wiring done. Having a problem with the turn signals. I think what I might do is go to Radio Shack and get a few high intensity LED, drill some holes in the back of my tail lights, stuff the LED’s in them and hook them up to my turn signals. I put oil in it and it started right up. I have never seen it start up so easily before. Had a fuel leak so I fixed that and she ran ruff but wanted to run. The carb needs to be tuned. Any carb guys out there what to help?? After setting for a bit I tried to start it again and it wouldn’t fire. I pulled the pugs and they where soaked with gas. So I’m leavening them out over night and I’ll try tomorrow. I also put a new brake master cylinder in It is a large 22mm bore so I should have batter breaks as soon as I bleed the system. I built a new dash cluster out of some aluminum and got the steering all welded up with the new bearing. It has way better response and feels solid. I have some new shocks. Longer then the old ones and they are adjustable progressive coil overs of an ATV. Finding shock was a pain in the butt for this thing. It is so light up fount that most shocks felt like a sold steel bar. With the light wait of ATVs I thought I would take a chance on them. What I didn’t think of was that with the coils the shock would bleed wide in diameter and that the mounting eyes are smaller the normal shocks. So now I’m back to having to make new shock towers with is what I was tiring to avoid and I need to find shock bushings that will work. I think I’ll call Carl at Jantz 4x4 and have him make me a set out of the same stuff I have him make my synthetic fairleads out of. So all I have left is to mount and hook up the new oil breather box, quick steering adapter (witch hasn’t come yet), the LEDs, bleed breaks, Manual choke (not here yet) setup shocks and towers...
I found a bunch of new trails today that would be a blast to get her out on. So I’m real anxious to get it all back together.

[ChevyKev]

Sounds like you've been doing quite a bit of work! I need to see/drive that thing one of these days!

[holeski]

It runs again. Some how I was shorting out the coil. :? ??? :? It is still a bit ruff but run with out me have to mess with the gas. Kevin it will be close enough to you very soon, :thewack: It will be my transport between our houses. :drive:

Update:
It's run nice now. Even with 4" bigger rear tires it rips. It has more power then I have ever seen it. I don't have the front shocks on so no jumping right now. The quick steering adepter was the wrong part for what I needed. So it’s all back together and ready to be moved to the new house.

Update:
I blew a spark pulg out of the head so now I need to drill and tap it.

[holeski]

Well the move slowed this down, but I've got it back on track. The spark plug hole is fixed. I broke a shock mount off running it around the new house, so I ordered some new ones. These are 4'' longer, made out of 1/4'' steel and come with lower drop mounts also. I just need to weld them up, cut whats left of the old ones off and weld them on. I also swaped the old gen. for a new alt, witch ment I needed to find a new intake. That was ok so I found a way better one with better flow, and the carb is tight in place now. I plumed a remote oil filter so now not only do I have more oil rolling around in there but it's cleaner. All the valve covers and oil filler are now plumed up to a berather box to help stop any blow by. tomarrow will be a test run with out front shocks, I only need them if I'm jumping.

[AlaskaToy]

Good to see you the other day. maybe I could by somtime a check out thebuggy. Maybe I could test drive it for you :mrgreen:

Oh yeah. Tell H. thanks for the Toy. Marcus was playing with it today. :Sun:

[holeski]

Stop by and take it for a spin. I poped a wheely the other day going to Kevin's.

[AlaskaToy]

:mrgreen:

[holeski]

All thats left is to weld up the shock mounts. Heather got me a 2110cc motor for it. It's only 1600cc right now. So next summer when it gets here that thing should rip.

[crazy4ink]

Nice! That thing should scream with the bigger motor Heather got you!

BTW, were those coil buckets what you wanted? Do you want the rear upper coil perches when I cut those off?

[mousee]

2110 cc's now time for the 31" boggers... :roll:

[holeski]

I would have to go to coilovers in the rear to fit a bigger tire on there then what I have now. The torsion bar is in the way.

[mousee]

were there is a will... :roll:

[holeski]

There are poor people!! I need less projects.

[mousee]

trust me i TOTALLY understand! I haven't worked on my own junk in so long...

[crazy4ink]

trust me i TOTALLY understand! I haven't worked on my own junk in so long...

Yeah, sorry about that... :oops:

[ChevyKev]

trust me i TOTALLY understand! I haven't worked on my own junk in so long...

:cry: I feel no pity for the man who is paid to modify and fabricate!

Not being hard on ya, just showing my jealousy! :lol: And it is very cool that this is working for ya! But the mechanic's car is always that last one worked on. I've seen that over and over and over again.

[ziggy]

oh so true Kev! :ROL:

[holeski]

Well with the J-10 looking like it will be running soon and my rear tire carrier on the YJ almost done I am looking to get some work done on the buggy. I have or will be picking up a set of snow machine skis. Oh yes! I still have new long travel shock mounts to weld on, but I will be fitting a set of skis to the front of the sandrail. Or should I call it the snowrail? I’m really not sure how well this is going to work, but should be fun none the less. This warm weather would have been perfect if I would have had this done.

[sevenslats]

:shock: :-o :!: :yes1:

[LowNSlowNeon]

Looks cool... I should rebuild my carb but I am afraid.. I think it's either the carb or a vacuum line jacking up my idle. (zuk runs fine at all speeds but idle :( :lol: )

After seeing that pic.. it makes me not wanna rebuild it.. LOL

[holeski]

I had the buggy inside the last week. Have the old rusted shock towers off and the new long travel ones on. Looks bad. Sorry for the lack of photos hope to have some more soon as soon as the site is back to somewhat normal.

[4x4_MMMH_4x4]

if you do skis becareful, when i was 16 and didnt think, i uh made a setup to hook them the spindles of my 4 wheeler... notice bearings spin!!! pretty colorful accident but what doesnt kill you makes you wiser and stronger

[mousee]

you must be one smart and strong guy... :LOL:

[4x4_MMMH_4x4]

you know damien that really makes me laugh, maybe i should have thought about that before i posted it... maybe before i was born my parents were like well we better make him right this sob is going to need to learn a lot and get hurt alot lol... anyways BOT post some pics eric!!! i wanna see this thing with skis on it:P what kind of skis are you going to use, airplane skis, homemade skis, snowmachine skis??? did i miss any???

[nissan720]

It sounds like its going to be fun i want to see it with the skis on it

[akdsmer]

Looks cool... I should rebuild my carb but I am afraid.. I think it's either the carb or a vacuum line jacking up my idle. (zuk runs fine at all speeds but idle :( +:lol: +)

After seeing that pic.. it makes me not wanna rebuild it.. LOL


Take a look and see how much vacuum you have. I wonder if it's low.....maybe someone installed the timing belt wrong.... :o

Then take a look at the duty-cycle of the mixture control solenoid. The % will tell you if it's running lean or rich, you can then identify the problem, repair it and then properly adjust the carb (if needed).

[holeski]

if you do skis becareful, when i was 16 and didnt think, i uh made a setup to hook them the spindles of my 4 wheeler... notice bearings spin!!! pretty colorful accident but what doesnt kill you makes you wiser and stronger

I was thinking that then I remember I can,t keep this thing on the ground so I am still reworking it all out in my head. I am using snowmachine skis.

[4x4_MMMH_4x4]

can you get another set of spindles you can weld up??? how is the front suspension setup

[mousee]

Just keep the front of the skis under spring tension and a stop so they won't fold all the way up. that way when you jump it the skis come up and when you land they fall forward...

[4x4_MMMH_4x4]

as much as i would like to see it flip i wouldnt wish it upon anyone on this board or anyone who is a friend... is the front suspension set up IFS???

[holeski]

VW IFS. So there are torsion bars inside the tubes. Those let the two arms on each side move up and down. The torsion bars are progressive so the more they move the stiffer they get. That way I can adjust the stiffness on the front end by setting the lock nuts on the front axle tubes. Kind of hard to explain if you have never had one apart. I had never seen anything like it before.

[holeski]

So I never got to get the skis on this year. There is always next winter, right? I have had it out a few times. I lost the top to the air cleaner, but a kid found it after break up so that was cool. I have a new set of rear tires to go on. Some 30x9.50 Mud Rovers. They are just a tad be smaller but will offer a much needed increase in rear traction. I need a set of fronts now. They need to fit stock VW front rims. I readjusted the breaks so I can power slid with out having to pull the E-brake. Just a quick push on the pedal in a turn and it’ll go sideways. Hit the gas and drive it on out of the slid. Grate way to take sharp corners.

[Fix_It]

i miss that thing ! what a frickin hoot that thing is once u got the motor running awsome

[holeski]

Did you see the RTI photos?

http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10373 &g2_serialNumber=1 (http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10373&g2_serialNumber=1)

http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10375 &g2_serialNumber=1 (http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10375&g2_serialNumber=1)

http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10371 &g2_serialNumber=1 (http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.DownloadItem&g2_itemId=10371&g2_serialNumber=1)
__________________

[Fix_It]

that thing has some mad flex ! how did the new shock towers work out for you ?

i will be there on june 2nd for the club run i will have my baby brother with me .. see ya then . rain shine or high water im finally really gonna come home this time lol !

u need to take my bro for a spin around your block and scare the pee out of em lol !

[holeski]

Shock towers are good; I still haven’t put shocks on. I only need them for jumping since the front is so light and has a torsion bar. I took Dusty for a ride when there was still some snow on the back roads. Did a 180 on dry black top out in front of Kevin’s and I though Dusty was going to crap himself. White knuckled the Oh Shi! Bar the whole time. That was fun. Still only running on 3 cly though.

[4x4_MMMH_4x4]

ive got gas money...

[holeski]

I swapped out the old Scat Track JC Penny tires for some new 30x9.5 Mud rovers and it made a nice improvement. Just a tid bit smaller then the old ones but it gave me some pep. Handles a lot better too. I hit about 70MPH; I need to tighten up the front end some before I push it faster.

[4x4_MMMH_4x4]

dood i wanna go on a ride!!!

[holeski]

You need to come by one night. I need to tow it out to South Cushman and we can meet up.

[4x4_MMMH_4x4]

sounds good to me... gimme a call when your free 3474284