Ians Buggy Build

[Drivermod]

After some thoughtfull consideration I decided to part out the CJ and use as much of it as I can to put together a full tube buggy. Todd at Shotgun Fab will be helping immensly on this build and is the one who finally convinced me to go for it. I sold the frame, tub, and steering to a local guy. Here is a picture of what is left, minus the engine, wheels and tires.
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2388.jpg (the chassis you see in this pic is another one Todd put together with a friend of his on Monday and Tuesday. He's been busy.

I took some time to sketch out my ideas in AutoCAD before getting started just to keep the scale of it in check. I picked up a stack of tubing from Carwash last week and started bending on Wednsday. Got the main tubing of the chassis together yesterday. We got to try out his new Baleigh tubing notcher on my chassis and it worked really well. Much quicker and more precise than his old setup.
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2487.jpg
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2486.jpg
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2483.jpg

In the pics the chassis is sitting at ride height but the axles are not in the correct locations. We put in two 15 hr days but got alot done. So far I'm really liking it. Roughly 114" wheelbase, with a 21" belly, 51" wide at the belt line and 68" to the top of the cage. I'm using the SBC 400/700R4/Atlas drivetrain out of the Jeep along with the axles (Dana 60/70) tires (39.5 TSLs) and wheels. Using 17" Bilstein 9100 series coil overs to suspend it. Next big purchases will be heims, steering components and seats. Have a double ended ram but need to locate an orbital. Not sure what to go with yet. Seats will be Kirky Pro Drag 16" wide (I'm a scrawny guy). I'll continue to update as things progress. Realistically, I hope to be riding by Memorial Day weekend. With 6 kids at home finding time to work on it will be the biggest hurdle. Big thanks to Todd for motivating me and helping out as well as the garage space and use of tools. He has a great setup for fabrication and is working on a new chassis for himself to move out of the single seater. It's gonna be pretty radical.

[jwend]

thats sweet man, i like it alot simple but cool.. I dig it for sure..I drive by his shop once a week and always think about stoping i may have to next time

[yellowjacket]

very nice start sir!. i been waiting to see your vision...make sure you leave room for suspension seats down the road... is it all 1.75 ?

[Drivermod]

I wrestled with the suspension seat vs Kirky thing for awhile and just decided with a flat belly it would be too tall with suspension seats. As it is now I should have around 5-6"s of head clearance. A suspension seat would easily fit the drivers side but wouldn't work well on the passenger side because of the transfercase. The Bilsteins should absorb most of the hits unless I land hard on the belly skid. Thanks for the replys. I can't wait to see as a roller. Shouldn't be too long.

All 1.75" except the windshield braces. I will be adding some more 1.75 and 1.25" gussets here and there. The belly is framed in 1/4 wall and the rest is .120 wall.

[timido]

Way cool that thing is coming along nice!

[Yotajunk]

I really like the lines on that chassis! Glad it's coming along man!

[Drivermod]

Time for some updates. I took a few days over the last couple of weeks to make all the little parts that would allow us to finish off the suspension. This weekend I took Friday off so we could spend two days on it in hopes of knocking it out and finishing all the work we would need to do up on the fabrication table. It went smoothly and we not only got the suspension knocked out but mounted the drivers seat, steering ram and my new to me Creepy Crawlers. Check out the pics. Todd and I have about 7 days total in this build so far. Alot of the big hurdles are past but I know the real work begins now.

http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2695.jpg

http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2700.jpg

http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2709.jpg

58"s under the front tire:eek:
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2710.jpg

60"s under the rear tire:evilgrin:
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2715.jpg

Ian and Todd's buggies
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2707.jpg

We started on his in early December and mine just after Christmas. I hope the rest of the project goes as smoothly.

Ian

[Drivermod]

As it sits I ended up at 114" wheelbase, 21" belly height and 66.5" roof height. The shocks are 17" Bilsteins set at roughly 8"s of uptravel.

[kentuckytwostep]

looking sweet!

[underpowered]

i am really liking the look of those buggies.

[Drivermod]

i am really liking the look of those buggies.

Thanks. Stop by and check em out.

[underpowered]

i may be out to check out Todds shop one day, see what kinda stuff he can get for the blazer i am picking up this week.

[boomhauer]

i have to agree with whomever it was about the suspension seats. trust me, as someone with a bad back it will be the best upgrade you could ever do. i just got around to doing it myself a few months ago but i wish i had done it years ago. no matter how smooth it rides or you think it might ride it will be much better with a good set of susp. seats and your whole body (not just your back) will appreciate it immensely. surely there is something you can do to make the pass. side work out.

[carwash]

Not everyone has a pansy back like yours boomhauer. Timmie Cameron runs kirkeys, they must be cool. I'll have them in my new rig, and all I've ever owned is PRP suspension seats. If you want a tight rig, you can't fit a suspension seat in it.

[Nuts]

I'd rather have soft seats and the roof line a couple inches taller than have a smashed vertebrae. Whats the rule for distance from the top of your head to the cage? 2",3",5"?

[Drivermod]

3"s is reasonable. I'll have 4-5" easily once the pads are in the seat. I plan to wear a light helmet at all times anyway.
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/IMG_2706.jpg




Jury is still out on the seats for me. Suspension seats are nice for puttin' around but when it's time to get serious and you are pulling your belts down tight, how much give are your seats gonna have anyway. That and as the seats gives and your belts loosen, what problem does that create. This is one aspect of suspension seats that I never liked. I always felt like I was having to tighten my belts and then when you go to get in next time they are too tight to fasten. There is also a HUGE difference in ride quality, and therefore comfort, between air shocks and properly set up coilovers.

[carwash]

With my new rig, it won't be an issue of head room as much as it is width. The narrowness of the kirkeys allow you to build a nice tight chassis all around. Like I said, I have always ran suspension seats, something new for a change will be nice. Maybe I'll hate them. But I won't knock them till i try them. One thing i do LOVE is the containment they offer you. I have used high side PRP comp seats forever, and while they have a nice high side on them, they are nothing compared to how a kirkey holds your ass in place.

[kirbyiv]

With my new rig, it won't be an issue of head room as much as it is width. The narrowness of the kirkeys allow you to build a nice tight chassis all around. Like I said, I have always ran suspension seats, something new for a change will be nice. Maybe I'll hate them. But I won't knock them till i try them. One thing i do LOVE is the containment they offer you. I have used high side PRP comp seats forever, and while they have a nice high side on them, they are nothing compared to how a kirkey holds your ass in place.

Whats the point of a tight chassis if you're running full width axles under it?

[carwash]

Whats the point of a tight chassis if you're running full width axles under it?
dammit...

[Nuts]

Whats the point of a tight chassis if you're running full width axles under it?

Tires will push pull and drag their way past most obstacles,and a body or fat cage is like dropping anchor. Full width axles will earn their place by keeping you stable,while a wide cage doesn't do anything that a skinny cage can't.

[Drivermod]

Tires will push pull and drag their way past most obstacles,and a body or fat cage is like dropping anchor. Full width axles will earn their place by keeping you stable,while a wide cage doesn't do anything that a skinny cage can't.

I agree. After driving Todds single seater, I have seen first hand that having a narrow body can be an advantage sneaking through the woods or around rocks. I have yet to see anything glide through the Lions Den like it would. Thats not to say I wouldnt' mind slightly narrower axles but I'm gonna stick with what I have for now. Budget is an issue with this build so I'm willing to sacrafice on width for now to get on the trail sooner. On the plus side at 89"s wide in the front and only 66"s tall I'm gonna be about as stable as one can be in off camber situations. If you're following me be secure in knowing that if I fit through most anything will.:rolleyes:
Width was not the deciding factor for me. I could sneak suspension seats in width wise. The bigger issue is putting one over the transfercase. It wouldn't safely fit without raising the roof or stretching the passenger compartment. Neither of which I was willing to do.

[Drivermod]

I don't have any picture updates cause we lost our camera. I think my 17 month old threw it in the trash. The seats, battery, steering, winch mount and dash are in. Should be getting the radiator this week and then I can finish out the back of the buggy. It's coming along slowly. We took Todd's new buggy out today and did some testing at a friends farm in Glenco. It worked great. Might have to make a few changes with the spring rates but otherwise it's pretty much good to go. The seating position is very comfotable and the visibility really wasn't an issue. It's a climber for sure.

[carwash]

The Silencer isn't so silent from what I heard...

[Drivermod]

The Silencer isn't so silent from what I heard...

Uhh yeah, it doesn't live up to it's name.:evilgrin:

[Nuts]

This thing done yet? Any updates?:beers:

[Drivermod]

Man I wish. I'm on vacation in Michigan but should be freshening up the engine in the next week or two. Tore it down cause the cam was wiped out. Once it's back in I'm down to mainly wiring and plumbing then it'll be ready to fire.

[Nuts]

I'm looking forward to seeing it. Been stealing ideas for the last 8 months and I'm finally ready to start bending this weekend. Hopefully.....:rolleyes:

[Drivermod]

Engine is all together and back in the buggy. Still have to fabricate a fuel cell (bending that up today at work) and engine skid then it's time for wiring and plumbing.

[timido]

Good deal! Ger er done.

[Drivermod]

Fuel cell is in, wiring complete and fuel system is plumbed. Nearly ready to fire it up.:sweatin:

[timido]

You want to shake it down on sunday? We were taking about going to Horseshoe bend and check it out. I have done exhaust insulation for you as well

[Drivermod]

I need to get that from you. I will be at Superlift Offroad Park in Hot Springs AR for the SRRS finals this weekend. Todd and Jason Spegal are competing. Wish I was taking something more capable than my Ford Ranger.:o

[timido]

I will my sure kenny gets the insulation you can pick it up next week

[Drivermod]

http://i369.photobucket.com/albums/oo140/drivermod/Buggy10202012_zpsef945476.jpg

Tried to start it up last weekend. Had some issues. A friend of mine that is very familiar with Holley fuel injection offered to stop by and do some tuning. Still have to plumb the brakes before I can drive it. Hope to get that done Friday. So close:thumbup::sweatin:

[yellowjacket]

That looks really nice.

[Drivermod]

I will my sure kenny gets the insulation you can pick it up next week Did you get a chance to get this to Kenny? Feet are going to get toasty while tuning.

[Drivermod]

Couple more shots
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/iso10202012_zpsbe7fc329.jpg
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/siderear10202012_zps9372ebbc.jpg
http://i369.photobucket.com/albums/oo140/drivermod/Buggy%20Project/isorear10202012_zps94559257.jpg

[Jonesy]

Very nice. Really like how the rear tube work is done. What colors are the chassis and panels going to be?

[timido]

The duct tape is a nice touch. Kenny has the insulation.

[Redriverranger]

Good looking rig for sure.

[Drivermod]

The duct tape is a nice touch. Kenny has the insulation.

No build would be complete without a little Kentucky chrome. I stopped by Kenny's yesterday. Thanks.:beers:

[Drivermod]

Good looking rig for sure.

Thanks. Can't wait to get some color on it.

[Coppertop]

Man ,that's a good looking rig..:thumbup:

Nick

[WrenchMonkey]

Thanks. Can't wait to get some color on it.

Don't you dare! It lookes AWESOME exactly as is! Clear it if you have to, to keep it from rusting, but I personally love the bare metal look!

Robert

[Drivermod]

It's already surface rusting. I'm going to paint it Rustoleum hammered charcoal grey. Probably just brush the aluminum panels and stainless gas tank. I want to keep it a darker color because of the shock towers being in my line of sight.

[Drivermod]

It's alive! A friend of mine that is very familiar with Holley fuel injection came over and helped me get it running. Once we erased the old tune and loaded one of the Holley base tunes it fired right up. We were able to break the cam in and fix some fliud leaks for now. Once I get the brakes plumbed we'll be able to drive it around and fine tune the drivability. Excited!:D If I can figure out how to get the video of my dang phone I'll post it up.

[Coppertop]

Any chance of seeing it at Big Rock next weekend ??

Nick

[Drivermod]

Nah, still lots of little things to do and not much time. I wish it was ready but don't want to rush it. I'll probably take it out locally first to shake down any issues and get some more driveability tuning done on it. Here is a video link.

http://www.youtube.com/watch?v=0Ea8_6RVRXk&feature=BFa&list=ULKhcKnIuB5GE

[67fastback]

looks like the top bar to the rear axle might bend if it does not get some more bracing... :eek:

[timido]

is there a rear link hiding? nevermind I see the 4th link now

[Drivermod]

looks like the top bar to the rear axle might bend if it does not get some more bracing... :eek:

Not likely, it's 0.250 wall 1.75 tubing but I am going to add a piece of tube directly under the link mount.

[Drivermod]

Drove it around the parking lot today. Man, what a good feeling. Still need to bleed the steering and brakes a little better but it was pretty cool. Today was day number 37 (according to my wife, apparently she's counting:)) of actual work on the build. So close I can taste it.

[xplorer55]

id like to see it in action. thats one hell of a rig

[Drivermod]

Drove it around offroad a bit. First big hill I pulled up to I thought the transmission was slipping...forgot it still has manual hubs and they weren';t locked in:rolleyes:. Having some steering issues but we'll get em ironed out soon enough. Here is a walk around video taken while we were figuring out the drive shaft carrier bearing placement.
https://www.youtube.com/watch?v=d7l09GC_qnY

[drmeece]

Ian that is too cool...Good job

[JeffK5]

Good lookin ...that rear spoiler thingy is cool..

[Drivermod]

Thanks. That was an after thought. I didn't like how the rear ended up so I added the "spoiler". I kinda dig it.

[Drivermod]

http://i369.photobucket.com/albums/oo140/drivermod/buggyasof12222012_zpsa7f28f58.jpg

Ready to ride. Come on nice weather...

Winch will be in place this weekend. Air bumps and limit straps and seat covers to come in the next couple weeks. Chains are temporarily in place in case I get a chance to get it out.

[timido]

60 degrees this weekend

[biggin69]

Looks good! :thumbup:

[Drivermod]

60 degrees this weekend

And rain. Not in the mood to deal with the mess this time of year. Winter wheeling is when I miss the Jeep. It would be different if it was summer time.

[Drivermod]

Laid some paint on it this weekend and got it mostly back together. Was shooting for a charcoal gray but it turned out closer to silver. I still like it with the black panels and red accents.

http://i369.photobucket.com/albums/oo140/drivermod/IMG_20130223_204430_zpsd3111fc1.jpg
http://i369.photobucket.com/albums/oo140/drivermod/IMG_20130223_204403_zps7111a464.jpg
http://i369.photobucket.com/albums/oo140/drivermod/IMG_20130223_204219_zps30c86b9d.jpg

[Coppertop]

Looks great Man ...I'm diggin' the full size cherokee in the background.

Nick

[Drivermod]

Looks great Man ...I'm diggin' the full size cherokee in the background.

Nick

The Cherokee is a really clean piece. Getting the tranny rebuilt and scrapping the quadratrac transfercase for an NP205.

[coachholland]

Jeebus Ian, that's gorgeous. When and where is the maiden voyage?

[Drivermod]

Jeebus Ian, that's gorgeous. When and where is the maiden voyage?

Thanks. Probably do a couple local runs on either private land or at one of the local parks, i.e. Big Rock, very soon. Hope to schedule a couple Harlan trips in the next few Months. Something in mid April and then maybe late May.

[Nuts]

I like this style better than all the new chassis you guys are putting out. These are a little diferent than everything out there, the new ones are starting to look alot like all the jimmy smith rip offs

[Drivermod]

I like this style better than all the new chassis you guys are putting out. These are a little diferent than everything out there, the new ones are starting to look alot like all the jimmy smith rip offs

Thanks, I like this style better too. I'm a fan of having panels to keep some of the mud and rocks off of ya and it is nice to look a little different. There is a long waiting list to get a Smith chassis so Todd is just tapping into that market while it's hot. Selling like hotcakes. Makes good business sense.

[Nuts]

I understand that, and I do like the new ones too, just like these a little more.

[Drivermod]

Got it on the dyno at Cincy Speed today. I highly recommend anyone bulding one of these get on the dyno and make sure the engine is running top notch. The guys at Cincy Speed specialize in GM tuning, especially late model LS based stuff, but they can tune other makes as well. Got it all dialed in and took it back to the Spegal farm for some offroad fun. Climbed the steepest hill I've ever been up right off the bat. Started having steering issues again after about a 1/2 hr of playing. Aparently I have some junk in the system and the valve in the pump is getting stuck. We'll get it taken care of. For now I'm just extatic that I was able to sling some mud around and for the most part every thing is working great. Just in time for riding season.:thumbup:

[twiztedzuki]

awesum! did they say % of power u lose through tranny and tcase? wifes pump on her buggy did same thing, just had little dirt in it sumhow

[Drivermod]

I think a commonly accepted loss through the drivetrain is about 40% on these big tired offroad vehicles. It put down 241 rwhp so thats about 400 hp at the crank. Not bad but I was expecting a bit more. It'll get the job done.

[nshefbuch]

40%???? I think that's way to high. I've spent a lot of time around engine and chassis dyno's and never seen a 40% loss of power. If your putting out 240 Hp at the wheels the motor is more than likely pushing 300-325 max. Should be more like 20% loss. The transfer case and large tires won't make up an extra 20% loss. Granted automatics lose more than manuals but its a difference of say 7% -10%.

[underpowered]

as a rule of thumb i was always told by dyno guys a manual has 10-15% loss, and an auto has about 20% power train loss.

40% does sound very high even with your big tires.

[Drivermod]

I drag raced for years and spent lots of time around chassis dyno's as well. As an example there is a thread on Pirate where one of the Ultra 4 guys posted up his flywheel numbers and at the tires. Both verified on a dyno. Difference for him was 37%. Top of the last page of this build thread.

http://www.pirate4x4.com/forum/general-4x4-discussion/1106802-2013-miller-motorsports-ultra4-car-23.html


The engine in my buggy is a 406 with Brodix heads, Holley Stealth Ram injection and a fairly large flat tappet cam. It better have more than 325 hp or something is seriously wrong. You'ed be surprised how much power all this heavy weight drivetrain sucks up. Wanna race?:D

[timido]

I am sure there is a lot more drive line HP loss through a transfer case and a Dana 60. What tires was it dynoed on?

[KillerKoatings]

Ian have you decided when you are taking it out again. We are coming home from the lake tomorrow so I should be around this weekend

Sent from my SCH-I605 using Tapatalk 2

[Drivermod]

If it dries up enough I'll be taking it to DTOR Saturday. If it's still a slop fest I may go to Big Rock on Sunday. Sorry, wish I could be more concrete. I'll let you know as soon as I'm sure.

[timido]

I might be next weekend at the earliest.

[Drivermod]

I might be next weekend at the earliest.

How about Harlan the last weekend of the month?

[timido]

Probably some local stuff and then Slade for the spring Fire run.

[Drivermod]

Little update...

Took the buggy to Harlan on Memorial Day weekend. Got to ride for about two hours before I had steering issues again. We did Your Turn, Crawfords Cry, Lower Damnation, The Waterfall, Rail Trail, Killin Time, Intimidator, and a few others I can't remember. Blew the front seal out of my new KRC pump below Grape Vine. Up until that point I was having a great time. We drug the buggy all the way back to camp. I ended up riding around for a few hours doing some engine tuning in Stumps turbo Huyabusa buggy. That thing is ridiculous. 300 hp and about 2500 lbs. Spent eh next two days bumming rides with a group of Jeepers that were camped next to us.

Once back home I completely disassembled the steering system. Gonna change a few things. While I had that apart I figured I'd fix some engine oil leaks and figure out why I kept getting moisture coming out of my crank case breather (never a good thing). Pulled the intake off and found out that epoxy in the lifter valley was covering up a 4" long crack that was now leaking water.:( I decided I didn't want to put any more money in this 406. Just so happens my neighbor was in the market to move from his 383 to a stroked 6.0 liter LS based engine in his Camaro drag car. The 383 is a nice little piece. 4340 crank and I-beam rods topped with Bischoff ported Canfield heads and Bischoff speced solid roller make for over 500 hp on pump gas (9.8:1 compression ratio):thumbup:.I picked up the engine today. I'm going to keep the Holley fuel injection and build a new exhaust system to get the heat out from under my feet. Can't wait to get it running again. Look forward to getting back on the dyno and seeing how this engine compares to the 406.

[Drivermod]

Everything is all back together and running. Heading to the dyno in the next week or two. Hopefully have all the bugs worked out now. New engine, all new steering, new LED lights, little more paint and fully custom exhaust. I'll paint the exhaust after the dyno session. So ready to ride after all this work and a long cold winter.

[Redriverranger]

Look's good!

[KillerKoatings]

Can't wait to get a ride this year

[93 Krawler]

Sweet!!

[Drivermod]

Thanks guys.

Kenny, any time but I will need to get a ride in your new toy in return.:smug:

[timido]

Looks great it smiles when the lights are on

[Drivermod]

Dynoed it yesterday at Cincy Speed. Around 100 more hp to the tires and it was still climbing when I hit the limiter at 6000 rpm. I may raise it a bit:winking: Happy with the turnout and the tune is very conservative so I can run on any old pump gas. Gonna do some local riding this Friday.

https://www.facebook.com/ian.mullane.9/posts/10202567408085029?notif_t=like#!/photo.php?v=10152272897289114&set=vb.147282994113&type=2&theater

We also dynoed Todds buggy and found some issues that would have been hard to nail down on the trail. Much better power curve now.

[Nuts]

Buggy looks awesome!

[hobbz]

Can't wait to see you buggy at Rush

[Drivermod]

Rode for about 5 hours today. No major issues. One little pin hole in a weld on the gas tank that needs to be fixed. Other than that and a bit more drivability tuning everything went great. The power is substantial over the last engine.:thumbsUp:

[Drivermod]

Rush Offroad at their anniversary bash...

[Drivermod]

Well, buggy's gone. Few weeks ago I traded it for a custom Jeep Rubicon pickup plus some cash. The buggy ended up in Mississippi and the guy already parted it out:eek: Just didn't see myself getting to use it much and was really missing my TJ. Probably going to sell the Jeep as well. I really want a nicely built LJ so I can take a couple of my boys with me when I go wheeling. The oldest boy is 12 but the next one in line is 4 now and ready to get out in the woods. For now this truck is pretty cool and nicely built. The frame was stretched with the wheelbase at 117" now. Custom long arm suspension with about 3"s of lift. Poison Spider armor from front to rear. 37" Trepador radials. I plan to be at the Rush event next weekend with it but I do have a few buyers lines up. Just waiting on the title to come back from the DMV.

[fordman00]

Looks sweet!