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flashover
August 17th, 2005, 09:39 PM
I have not seen a whole lot of build up threads here. So for those of you that don't venture over to Pirate very often, I will share the build up here as well.

Specs:

Engine: Ford 5.0 HO from 88 Mustang
Transmission: Ford C6
Transfer Cases: NP205 with NP203 Doubler
Axles: Rockwell 2 1/2 ton
Tires: 16R20 Michelin XL (53")
Suspension: Sway-a-way Coilovers 12" travel front, 16" travel rear
Links: Triangulated 3 link arms with 1" heims and Evo joints
Wheelbase: About 126"

I started by building a wooden mockup of the chassis to get an idea of where everything will sit. It also provides a reference that I can take rough measurements from during the fabrication of the actual steel chassis.

http://flashover4x4.com/Wooden_Frame_03.JPG

http://flashover4x4.com/Wooden_Frame_06.JPG

I built a table to hold the chassis level while it is being built. It is built from large scrap steel that I had. All four feet are adjustable so that the table can be leveled.

http://flashover4x4.com/buggy/frame_table_1.JPG

http://flashover4x4.com/buggy/frame_table_2.JPG

And as of tonight I have gotten the first couple of tubes bent and tack welded together. These will form the main lower frame of the buggy.

http://flashover4x4.com/buggy/buggy01.JPG

http://flashover4x4.com/buggy/buggy02.JPG

With any luck, I will be able to have this thing driving this coming spring.

Ryan

1BGDOG
August 17th, 2005, 09:54 PM
Great idea and time into the mockup. Good luck and I look forward to the build.

XTJ a.k.a. Mark
August 17th, 2005, 10:10 PM
damn I need to have some space and time like that.

looks like it will be a nice buggy, big as hell but nice :P

PhantomD AKA Zach
August 17th, 2005, 10:40 PM
Centrally mounted cooler... AWESOME! just be carefull of all the stuff falling out on off camber stuff, that cold ice could shrink some things :eek:

Zach

Yotaporvida
August 17th, 2005, 10:43 PM
PVC pipe is a great mock up tool and you can bend it with those little benzomatic hand held torches just a thought when incorporating bends.

formatt
August 17th, 2005, 11:46 PM
damn I need to have some space and time like that.

looks like it will be a nice buggy, big as hell but nice :P

mark, clean that garage and lose 1 or 5 of the fridge's in there and you will have the room. :)

Looks like a really cool start. i want to build a super small single seater so freakin' bad right now.

flashover
August 18th, 2005, 08:49 AM
Time and space? I can't say I have a whole lot of either. I am able to get about an hour or two's worth of work done every night, but I have been collecting parts for almost two years. All those parts take up the majority of the space in my little garage.

For a size comparison, the buggy without tires is roughly the same length and width as an XJ.

Sean Dogg
August 18th, 2005, 01:23 PM
For a size comparison, the buggy without tires is roughly the same length and width as an XJ.


Dats a big ol' buggy for just 2 people! I'm assuming this isn't for comps then?

Lubes
August 22nd, 2005, 11:41 AM
Haha! That's a sick lookin wood structure! I love the idea!
Can't wait to see this thing finished man, I love watching how some of you crazy fawkers think! Mad props!

Rex Ashton
August 22nd, 2005, 05:12 PM
Saw your thread over on Pirate....Nice job on the mock-up; Not many would take the time to do all that. Hell, you might could sell the wood-chassis to someone looking for an extreme budget build and is not afraid of getting splinters during a roll :cool:

jamescj7
August 22nd, 2005, 11:44 PM
really nice mockup....now comes months of work. I finished my buggy early this summer and started the project just after christmas. so about 6 months. I didn't have a mockup but the actual chassis went together pretty quick the thing that took freaking forever was putting everything on the chassis. Since i chose to make all my own tabs and well i probabily made a half million of the stupid things it took forever. If you have the money, get an a&a manufacturing catalog and buy up as many as possible...it will save you tons of time. is this your first buggy?
If you have any questions about the process let me know.

just a fiew things i would have done differently

-designed more storage into the buggy....i didn't design any into mine and now i have to strap backpacks to the tubes with gear in them

-put insulaton under the floor so it isn't so damn hot in the sun

-made the dash closer to my arms so i can turn off the motor. As soon as i put in the 5-points i couldn't bend forward to turn off my motor...it would be nice to turn off you rig when it is rolled. wally saw that in action ha ha!

These were just some of the things i completely overlooked and just thought i would through them out incase you also overlooked them. Also i know where you can get that thing powder coated for about $300 when it comes time for paint. hit me up if you would like some info on that. If i can think of anything else i should have know during my buildup i will post.

-james

flashover
August 28th, 2005, 09:27 PM
Here's the last weeks worth of progress.
http://flashover4x4.com/buggy/buggy03.JPG
http://flashover4x4.com/buggy/buggy04.JPG
http://flashover4x4.com/buggy/buggy05.JPG
http://flashover4x4.com/buggy/buggy06.JPG
http://flashover4x4.com/buggy/buggy07.JPG
http://flashover4x4.com/buggy/buggy08.JPG
http://flashover4x4.com/buggy/buggy09.JPG
http://flashover4x4.com/buggy/buggy10.JPG
http://flashover4x4.com/buggy/buggy11.JPG
http://flashover4x4.com/buggy/buggy12.JPG
http://flashover4x4.com/buggy/buggy13.JPG
http://flashover4x4.com/buggy/buggy14.JPG
http://flashover4x4.com/buggy/buggy15.JPG
http://flashover4x4.com/buggy/buggy16.JPG
http://flashover4x4.com/buggy/buggy17.JPG
http://flashover4x4.com/buggy/buggy18.JPG
http://flashover4x4.com/buggy/buggy19.JPG

Jocko
August 28th, 2005, 09:31 PM
:flipoff2: Back at ya.


















Looking good

flashover
August 28th, 2005, 09:37 PM
I decided that since I have enough space, why not make it a three seater? It will make the placement of the fuel cell and radiator a little more difficult, but it should turn out pretty well.

flashover
October 9th, 2005, 09:09 PM
I haven't posted any updated pictures for awhile, so here they are:

Roof bars and rear uprights in place
http://www.flashover4x4.com/buggy/buggy20.JPG

Roof spreaders
http://www.flashover4x4.com/buggy/buggy21.JPG

http://www.flashover4x4.com/buggy/buggy22.JPG

Rear bracing
http://www.flashover4x4.com/buggy/buggy23.JPG

Transmission mount
http://www.flashover4x4.com/buggy/buggy24.JPG

Motor mount
http://www.flashover4x4.com/buggy/buggy25.JPG

http://www.flashover4x4.com/buggy/buggy26.JPG

Rear Cross
http://www.flashover4x4.com/buggy/buggy27.JPG

Door area
http://www.flashover4x4.com/buggy/buggy28.JPG

http://www.flashover4x4.com/buggy/buggy29.JPG

Unfortuneately, progress has been pretty slow, due to breaking my drill, then my notcher, needing to replace the transmission in my CTD, you know the usual stuff. And to top everything off, we are getting our first taste of winter weather for the season!!!

beanman
October 11th, 2005, 11:29 AM
The buggy pics look awesome. Where are you at in Severance? There seems to be alot of wheelers in this little area. I would like to stop by sometime to check that buggy out.

flashover
October 11th, 2005, 11:54 AM
I live In Timberridge at 855 Cliffrose Way. Stop by anytime, I'd be happy to let ya take a look.

formatt
October 11th, 2005, 01:11 PM
out of curiosity, how do you store the wood buggy? that thing is massive and I'm guessing that you're using it for reference while fabbing up the new one...

flashover
October 11th, 2005, 01:54 PM
We took it apart and put it back together in the basement. It was really only used for a couple measurements on the first two or three tubes, after that everything was fit around the actual dimensions of the engine, seats, etc.

flashover
October 16th, 2005, 09:18 PM
This weekend, the bottom was finally put on. Some smaller tubing will still be added to brace the skid plates, but the outside shape is there.

http://flashover4x4.com/buggy/buggy30.JPG

http://flashover4x4.com/buggy/buggy31.JPG

http://flashover4x4.com/buggy/buggy32.JPG

http://flashover4x4.com/buggy/buggy33.JPG

74BuckinBronc
October 17th, 2005, 04:29 PM
That's a big cage, but with those rockwells and 44's (?) it should look proportional. Nice fab work. That doubler should be a good setup for ya. Good choice for a motor!!How are you going to christen the buggy? Drive through the flaming wooden mock-up??

J.D.

flashover
October 30th, 2005, 05:50 PM
Latest update:

Floor bracing:
http://flashover4x4.com/buggy/buggy34.JPG

Internal support between the front and rear seats:
http://flashover4x4.com/buggy/buggy35.JPG

Front seat knee area:
http://flashover4x4.com/buggy/buggy36.JPG

creepycrawler
October 30th, 2005, 06:59 PM
Looking really good but the lawn mower is hanging way too low. You are going to be dragging it across everything. :D

flashover
November 8th, 2005, 09:05 PM
We have been making quite a bit of progress over the last week. The bracing for the skid plates has been completed. Work on the steering has begun and is moving quickly.

I got a 2.75x10" ram from Rockstomper along with everything else needed to turn these big meats (thanks Scott). Here is the ram mount:

http://flashover4x4.com/buggy/buggy37.JPG

http://flashover4x4.com/buggy/buggy38.JPG

http://flashover4x4.com/buggy/buggy39.JPG

I forgot to take pictures of the bracket that we made to hold the steering pump and idler pulley, but I will post some up later.

We also got a new toy that will make the final welding of the chassis so much better.
http://flashover4x4.com/buggy/welder.JPG

Trango
November 9th, 2005, 08:48 AM
That ram mount is captain crazy big. It's hot.

87xjco
November 9th, 2005, 05:05 PM
Man that Rockwell is beefy. Nice low unsprung weight, just what ya want.

How are you cutting your steel? That would take a massive chop saw for those angled cuts.

JOHN LEU
November 16th, 2005, 10:18 AM
Any updated pics? I have to see the finished product.

flashover
November 16th, 2005, 11:08 AM
How are you cutting your steel?

Depending on the cut, we are using a portaband for small straight cuts, hole saw notcher to notch the tube, and a plasma cutter for anything big or complicated.

I will post some updated pictures after this weekend. Over the last week, we have been making good progress on getting everything finish welded. We fabricated a gas pedal and mounted the brake pedal and master cylinders. We will be taking the frame off of the table for the first time this weekend so it can be flipped over and the underside welded. I hope to get a lot of the skidplating done this weekend as well.

TubeWerx
November 17th, 2005, 10:27 AM
lookin' good!!! :thumbsup: that over-the-top truss/ram mount is a little 'quirky' looking...but other than that it all looks killer!! Keep up the good work man!!!! Nice build so far!! I frickin' dig that front engine compartment with the tube wrapping the motor like that, that's the coolest part about the whole project IMHO........ :thumbsup: :D :hail:

JOHN LEU
November 17th, 2005, 03:03 PM
Go big or go Home! I want to see the tank!!!!

Clod Hopper
November 17th, 2005, 04:16 PM
that over-the-top truss/ram mount is a little 'quirky' looking...

axle is on its side. truss will be in front of axle.

Looking really good Flashover!

TubeWerx
November 17th, 2005, 05:19 PM
axle is on its side. truss will be in front of axle.

exactly, it's on its side. but the truss will actually be toward the t-case, not "in front" of the axle. I was giving a second look simply for weight and bulk.....seems a Rockwell is heavy enough without adding alot more weight...don't know what gauge that flat stock/rect. tube is though...more importantly it just seemed kind bulky to arrange driveshaft, suspension and steering components around. Whatever works though, its all good.:D

flashover
November 17th, 2005, 08:26 PM
TubeWerx, you are right, the steering truss is in the back of the axle. It is built from 2x6 3/16 wall tube. Since the rockwells are top-loaders, there will not be any driveshaft issues. It is going to take a little bit of work to get the lower link to fit just right, but it will still work well with the truss. Compared to the axles, the added weight of the truss is minimal. Mostly the reason it is so big, is that is the tube I had, and it will be more than strong enough to resist the force of the 53's. Thanks for the comments everyone.

TubeWerx
November 17th, 2005, 10:42 PM
TubeWerx, you are right, the steering truss is in the back of the axle. It is built from 2x6 3/16 wall tube. Since the rockwells are top-loaders, there will not be any driveshaft issues. It is going to take a little bit of work to get the lower link to fit just right, but it will still work well with the truss. Compared to the axles, the added weight of the truss is minimal. Mostly the reason it is so big, is that is the tube I had, and it will be more than strong enough to resist the force of the 53's. Thanks for the comments everyone.

:thumbsup: right on man....I guess when 53" tires are in play, most anything goes. That's gonna be one BEEFY rig!!!

flashover
November 20th, 2005, 07:41 PM
This weeks update:

We got the gas pedal built. The throttle cable still needs to be made though.

http://flashover4x4.com/buggy/buggy40.JPG

http://flashover4x4.com/buggy/buggy41.JPG

It finally made it out of the garage :D

http://flashover4x4.com/buggy/buggy42.JPG

http://flashover4x4.com/buggy/buggy43.JPG

It is really not too much bigger than an XJ. It is actually not quite as long.

http://flashover4x4.com/buggy/buggy44.JPG

http://flashover4x4.com/buggy/buggy45.JPG

flashover
November 20th, 2005, 07:42 PM
The bottom was covered in 3/16 steel for the skid plates. There is plenty of bracing behind it, so I am not too concerned with it getting dented.

http://flashover4x4.com/buggy/buggy46.JPG

http://flashover4x4.com/buggy/buggy47.JPG

We also got the link mount for the front wishbone done. It is made of 3/8 plate with 3/16 gussets.

http://flashover4x4.com/buggy/buggy48.JPG

http://flashover4x4.com/buggy/buggy50.JPG

Thanks for all the comments every one!!!

87xjco
November 21st, 2005, 07:49 AM
Really nice work Flashover. Can't wait to see it on wheels.

flashover
December 8th, 2005, 08:11 PM
Well, my suspension joints are all here, so now I can really get started on getting the axles placed. I am using 1 1/4 x 3/4 evolution heims for the frame ends of the lower y links, and FK 3/4 x 3/4 heims for the uppers.

http://flashover4x4.com/buggy/buggy54.JPG

I spent the weekend after Thanksgiving machining a couple of plugs to be used in the back end of the main frame. These will serve to close the ends of the tube to hold the coolant, as well as my rear recovery points. I used a friends combo mill/lathe. I started off by turning 5" of a 8" length of 2" round bar down to 1.5" diameter to fit in my 1 3/4 x .120 tube. I then used an end mill to machine the flat surfaces on both sides for a 2" length. I drilled a 15/16's hole to hold a shackle in the end.

http://flashover4x4.com/buggy/buggy51.JPG

http://flashover4x4.com/buggy/buggy52.JPG

http://flashover4x4.com/buggy/buggy53.JPG

TubeWerx
December 20th, 2005, 09:06 AM
keep the pics coming as progress continues....i'm interested to see some of the latter stages of this build!

flashover
December 20th, 2005, 09:13 AM
Unfortunately, I have not been able to get much done lately. I am waiting on a bunch of parts to show up before a whole lot more progress can be made. I have drawn up all of my suspension tabs, and am waiting on the laser cutter to finish them. Their machine was down for a couple of weeks, and I am pretty low on the priority list, so it will be a little while on them still. I need to get a driver's seat so the interior mounts can be finished up and a floor built. I will start building the fuel cells shortly. The steering is finally completed though. I will try to remember to post pictures of it tonight.

Phazertwo A.K.A Brenden
December 20th, 2005, 02:33 PM
your skinny pedel isn't very skinny!

flashover
December 20th, 2005, 09:32 PM
your skinny pedel isn't very skinny!
That's cause it's the one I plan to use! Screw that sissy brake crap.

flashover
December 20th, 2005, 09:38 PM
Anyways, as promised earlier, here are a couple of pics of the completed steering on the axle. I may do some further boxing in of the upper tab on the steer arm.

http://flashover4x4.com/buggy/buggy55.JPG

http://flashover4x4.com/buggy/buggy56.JPG

My buddy that was getting my suspension tabs laser cut called me this morning and let me know that my tabs were done early. All of the tabs are 3/8" thick

http://flashover4x4.com/buggy/buggy57.JPG

flashover
December 20th, 2005, 09:40 PM
We got the frame end of the front upper links tacked on tonight. The tabs are twisted a little bit in relation to each other in order to get the bolt to run at a 5 degree angle from vertical. This will allow the link to get a little more droop before it binds. The way it is set now, the link will hit the frame on bump before the joint is limited, and it has more droop than my shocks will be capable of. The brackets are just tacked together for now until the links are completed and the suspension can be cycled to check for any problems.

http://flashover4x4.com/buggy/buggy58.JPG

http://flashover4x4.com/buggy/buggy59.JPG

We also finished mounting the rear seat. The front brackets are tied into the gussets for the main X brace of the chassis.

http://flashover4x4.com/buggy/buggy60.JPG

http://flashover4x4.com/buggy/buggy61.JPG

sonofmayhem
December 20th, 2005, 10:06 PM
b e a utiful, i wish i had the money and time to build a buggy.

87xjco
December 21st, 2005, 02:18 PM
Nice Flashover, but....

Why would you laser cut tabs. That's so..... not right.

If you did like me, spend 20 hours cutting, grinding and using 50 cut-off wheels at 'bout $1 ea, then progressively drilling each hole. You'd get brackets that look half as good as those, and holes that mostly line up, a sore elbow and black dust all over everyting including the inside of your lungs.

My way is so much better.

flashover
December 21st, 2005, 02:23 PM
Nice Flashover, but....

Why would you laser cut tabs. That's so..... not right.

If you did like me, spend 20 hours cutting, grinding and using 50 cut-off wheels at 'bout $1 ea, then progressively drilling each hole. You'd get brackets that look half as good as those, and holes that mostly line up, a sore elbow and black dust all over everyting including the inside of your lungs.

My way is so much better.
I have built some of the other tabs on this thing that way. It sucks, and they look like crap. My hole drilling skills (at least getting the holes in the right spot) are horrible. On the other hand laser cutting is not cheap. Nice yota? build by the way.

flashover
January 9th, 2006, 09:48 PM
Well time for an update. My brother welded up the spider and side gears for the rear axle. I don't think that I will have to worry about these coming apart.

http://flashover4x4.com/buggy/buggy62.JPG

We got the rear differential shaved. I think we brought up the clearance about 1 1/2-2" or so. There is now 3/8" clearance at the bull gear.

http://flashover4x4.com/buggy/buggy63.JPG

The upper link mounts are all installed now. Front axle:

http://flashover4x4.com/buggy/buggy64.JPG

The driver's side mount is welded to the axle on one tab, and bolted to the differential on the other.

http://flashover4x4.com/buggy/buggy65.JPG

Rear axle:

http://flashover4x4.com/buggy/buggy66.JPG

Once I finish the links up and make sure this thing doesn't bind, I will be boxing in the upper link tabs, and possibly running some gussets down to the axles as well.

flashover
January 9th, 2006, 09:49 PM
We also built the frame end of the upper link tabs for the rear axle. I am pretty pleased on how these turned out.

http://flashover4x4.com/buggy/buggy67.JPG

http://flashover4x4.com/buggy/buggy68.JPG

Phazertwo A.K.A Brenden
January 13th, 2006, 11:58 AM
faster faster!

rocktoy85
January 13th, 2006, 04:02 PM
That things gonna be huge, keep up the good work, can't wait to see it finished

flashover
January 13th, 2006, 04:08 PM
Unfortunately, progress has been very slow lately. I do have allof the parts to build my suspension links now though. Look for an update after the weekend with some progress.

Brokeagain
January 13th, 2006, 06:53 PM
How many miles to the gallon will you expect? Not really!
It's looking good!

Thanks again for bending the tube for my YJ. It worked out perfectly and the whole tire carrier thing works great.

Moab in May?

BLOODBANE
January 13th, 2006, 09:14 PM
Nice build-up. Worst thing about the C-6 is, its such a HP pig(I run one in a 84 Ranger with a carbed 302), they are stout though and for crawling I wouldn't trade it for anything. With your HO302 and doubler you probably won't even notice though. get that thing done so we can see finished pics.....:hail: :hail:

flashover
January 22nd, 2006, 09:52 PM
OK, finally time for an update. Over the last two weekends, we finished the suspension links and mounts. The upper link tabs will be boxed in before it is considered done. The axles have way more flex than I will be able to use with my coilovers.

http://flashover4x4.com/buggy/buggy69.JPG

http://flashover4x4.com/buggy/buggy70.JPG

http://flashover4x4.com/buggy/buggy71.JPG

http://flashover4x4.com/buggy/buggy72.JPG

I am very pleased with the way the rear lower mount turned out.

http://flashover4x4.com/buggy/buggy73.JPG

http://flashover4x4.com/buggy/buggy74.JPG

http://flashover4x4.com/buggy/buggy75.JPG

http://flashover4x4.com/buggy/buggy76.JPG

The links:

http://flashover4x4.com/buggy/buggy77.JPG

Rear links.

http://flashover4x4.com/buggy/buggy78.JPG

http://flashover4x4.com/buggy/buggy79.JPG

We played around with the coilover mounts this afternoon and have a pretty good plan of attack to finish them off.

87xjco
January 23rd, 2006, 08:00 AM
Looking good. Nice work!

74BuckinBronc
January 23rd, 2006, 09:42 AM
Wow, coming along well. Are you going to be able to use the full axle articulation or will the coilover limit the travel? That's one solid carrier and spider gears. Looks like one solid peice. If someone want to know what "lincoln lock" is, that's what you're aiming for! Looking forward to come poser pics!!

J.D.

sonofmayhem
January 23rd, 2006, 04:56 PM
whats next after the suspension? you gonna finish the engine and tranny work? or axles? or misc.?

Excellent work. still going with the 50s or 52s?

2LoudDodge
January 23rd, 2006, 07:20 PM
awesome work so far. keep upt he great work...


Think your buddy would be interested in some more work? I need a couple things Laser/cnc cut for my project. Mainly my crossmember and some tabs for the front axle.

Phazertwo A.K.A Brenden
January 23rd, 2006, 08:16 PM
:drool:

flashover
January 23rd, 2006, 09:43 PM
awesome work so far. keep upt he great work...


Think your buddy would be interested in some more work? I need a couple things Laser/cnc cut for my project. Mainly my crossmember and some tabs for the front axle.
Thanks for the compliments. Unfortunately, I called in a couple of favors in getting those brackets cut. I am not saying that the place I used would not do it for you, but I think you would be looking at a long lead time and a pretty big expense. They are a major structural fabrication shop and little things like this don't rank to high with them.

The next step will be to finish off the coilover mounts. We have gotten a start on them, and should hopefully have them done this coming weekend. The suspension will easily handle all of the travel of the shocks. I am using 16" travel in the front and 12" travel in the rear. I got a good deal on the 12's used, otherwise I would have gone with longer for the rear. With some creative mounting, they will still offer plety of flex though.

The rear spiders should certainly define "lincoln locked." It glowed for nearly half an hour when it was done being welded.

sonofmayhem
January 23rd, 2006, 10:54 PM
i should be picking up a lincoln her shortly, just hope it doesnt chew the tires to bad.

flashover
January 29th, 2006, 09:45 PM
We got a lot done this weekend. First, the rear coilovers were finished off. The fronts will require a little more work still. Anyway, here are the pics.

http://flashover4x4.com/buggy/buggy80.JPG

http://flashover4x4.com/buggy/buggy83.JPG

We also mounted the front seats. Each of the mounts pivots at the front so the space under the seat can be accessed. The battery will be mounted under the driver's seat and part of the fuel tank will be under the passenger seat.

http://flashover4x4.com/buggy/buggy81.JPG

http://flashover4x4.com/buggy/buggy82.JPG

We finally finished mounting the drive train. The transfer case mounts were all that was left to build. We built a similar arm to the torque mount at the front output side.

http://flashover4x4.com/buggy/buggy84.JPG

Lastly, we built a battery mount. It is pretty simple, but it will work well.

http://flashover4x4.com/buggy/buggy85.JPG

Ryan

Steven_Mc
January 30th, 2006, 07:16 AM
Looks Great!! Are those rear springs going to be able to support the weight of that rig? They look awful skinny. :eek: Keep it up, and keep those pictures coming!

Oh, and I dig the frame table, very nice!!

flashover
January 30th, 2006, 08:33 AM
The spring (singular) that is on the rear right now is just one of the ones that came with the coilovers when I picked them up used. I am using it to make sure that there will not be any interferences with links, body, etc. As far as the diameter goes, however, I will just be using regular 2.5" springs for 2" coilovers.

The frame table was nice, but it was cut apart yesterday. The chassis is far enough along, where it need not be on the table any longer. I discovered that we could not get the engine in and out of the chassis with the axles mounted and the chassis on the table, it just made everything sit too tall. My engine crane hit the garage door before the engine cleared the tube work. So we cut the table apart, but left it whole enough that it could be reassembled fairly easily.

Ryan

87xjco
January 30th, 2006, 10:55 AM
I really like the angles on that chassis, especially around the windshield area. That's some sic work!!

4WHEELRAY
February 8th, 2006, 09:28 AM
Wow!! Fun Building In A 2car Garage Aint It? Thats How I Built Mine And Dont Think I Want To Do That Again. Good Luck With It.

sonofmayhem
February 8th, 2006, 07:25 PM
man where are the new pics???? i love reading about this, it prepares me for my retired life.

flashover
February 19th, 2006, 09:24 PM
Well not much progress has been made over the last week or two. We finally got the orbital valve mounted.

http://flashover4x4.com/buggy/buggy86.JPG

and the steering wheel mounted to the valve/

http://flashover4x4.com/buggy/buggy87.JPG

http://flashover4x4.com/buggy/buggy88.JPG

The original goal was to have the buggy completed in order to take with us to Moab in early May. In addition to completing the buggy, we need to complete the XJ with new axles and a cage, new seats and tube doors for the TJ, and fix the cooling of a friends CJ before the trip. At this point, we just don't think it will be possible to get all of that done, and done well, before the trip. Therefore, the buggy is getting put aside until after we get back from Moab. I rented a POD storage container and loaded the buggy inside. The rear axle clears the interior supports by about 1/2". It is really not fun to put inside of one of these things when the temps are as cold as they were yesterday. I will continue to gather the parts that are needed to complete this thing until we get back at it. Thanks for all the kind words and encouragement.

http://flashover4x4.com/buggy/buggy89.JPG

Ryan

DADA_JEEP
February 20th, 2006, 01:31 AM
sucks to have to put the project aside, but at least you fond some place to put the lawn mower! ;)

homegrown
April 7th, 2006, 11:16 AM
i love how you did the steering wheel. i dig that.

later tj

flashover
April 7th, 2006, 03:56 PM
i love how you did the steering wheel. i dig that.

later tj
It gets it trucker style! It will probably take some getting used to, but it really frees up the dash.

Ryan

TerryHowe
April 8th, 2006, 12:40 PM
It gets it trucker style! It will probably take some getting used to, but it really frees up the dash.

Won't it be hard to hold a beer between your legs when you are driving with that steering wheel?

co_spgs_jeepr
April 11th, 2006, 10:09 PM
awesome buggy, that looks like its coming together extremely nice. im an engineer, and for a long time i have toyed around with the idea of designing a buggy using solidworks. i have access to both solidworks, and cosmosworks (cad, and stress analysis software). i am curious, when you start building your buggy, is there any analysis before, i see a wood frame, which you probably used to check for displacement/flex and stiffening the chassis in its high displacement areas, but are there ever any calculations run to ensure that you get the strongest setup with the least material, or is it just built so stoutly that you may be sacrificing unneeded weight for unquestioned strength? i understand not everyone has the luxury of using this design software as its not cheap. i just see a lot of potential for a truly enhanced buggy, and cant say i wouldnt mind making money off of something i love!

SUPERGILDO43
July 5th, 2006, 10:47 PM
whats goin on with this thing, i want to see it finished!!!!

flashover
July 6th, 2006, 09:23 AM
We have a ford truck to strip for some parts this weekend, and then it will come back! Look for some updates here in a week or two.

rockfrog
July 9th, 2006, 08:39 PM
Looks good. But don't you think you are overbulding it a little? I mean 1/4" for a battery mount! Any idea how much this will weigh when it's all done?

82'CJ7
July 20th, 2006, 12:10 PM
Waiting......

flashover
July 20th, 2006, 12:39 PM
It made its way back to my garage last Sunday, but it has been too damn hot to work on it. We did get the front chunk pulled out to weld the spiders and shave the axle a night or two ago. All my parts to build the brakes and rebuild the axles are on their way. In addition, the fuel cell should be started relatively soon.

Ghettojeep
July 23rd, 2006, 09:42 AM
, but are there ever any calculations run to ensure that you get the strongest setup with the least material, or is it just built so stoutly that you may be sacrificing unneeded weight for unquestioned strength?
:lmao:

flashover
August 20th, 2006, 09:03 PM
Finally time for an update!

I have finally gotten my wheels painted. They are 20x10 heavy duty wheels from Stazworks. They took awhile to get, but man are they nice.

http://flashover4x4.com/buggy/buggy90.JPG

http://flashover4x4.com/buggy/buggy91.JPG

Last weekend Joel and I got the fuel tanks built. There is not space in the chassis to fit a single tank that is large enough. Therefore, we built two. The front tank is about 8 gallons and the back is about 9. Should be plenty of capacity for a weekend of fun. The tanks sit under the passenger seat and foot space. Each tank will have a pickup that does not allow it to suck air if it is not submerged. There is a connecting tube between the tanks to make sure that the fuel level stays about the same between the two.

http://flashover4x4.com/buggy/buggy92.JPG

http://flashover4x4.com/buggy/buggy93.JPG

Yesterday, we got the exhaust mostly done. No aftermarket headers would fit in the space that is available. The stock Mustang headers discharged straight into the upper link mounts, which obviously wouldn't work. What we came up with won't have the best performance, but it will work.

http://flashover4x4.com/buggy/buggy94.JPG

http://flashover4x4.com/buggy/buggy95.JPG

http://flashover4x4.com/buggy/buggy96.JPG

http://flashover4x4.com/buggy/buggy97.JPG

http://flashover4x4.com/buggy/buggy98.JPG

flashover
August 20th, 2006, 09:10 PM
In addition, today we got the driveline end of the transfercase shifters built. I am using push-pull cables to simplify the linkages. Once the floorboards are done I will start on the dash and get the handle end done.

http://flashover4x4.com/buggy/buggy99.JPG

http://flashover4x4.com/buggy/buggy100.JPG

http://flashover4x4.com/buggy/buggy101.JPG

Ryan

Clod Hopper
August 21st, 2006, 05:57 AM
Where did you get the shift cables from?

Trango
August 21st, 2006, 07:31 AM
That's so nice and clean - looks great.

74BuckinBronc
August 21st, 2006, 08:15 AM
Those are some big tires! Are you grooving them yourself?

Those headers are something else...You do what you gotta do, but I'd think in the near future you may be looking to have some made for you...

Keep up the good work!

J.D.

flashover
August 21st, 2006, 08:33 AM
Where did you get the shift cables from?
McMaster Carr. I will be using a three handle setup from Speedway motors for the actual shifters.


Those are some big tires! Are you grooving them yourself?

Those headers are something else...You do what you gotta do, but I'd think in the near future you may be looking to have some made for you...


I am going to be grooving the tires myself, but really not looking foward to it. We will see how the exhaust does, if it is really hampering the performance I will look into building a set of real headers, but those are a huge pain in the butt.

Bob, thanks for the compliment.

Ryan

87xjco
August 21st, 2006, 08:53 AM
Nice to see some more work done on this project.

Great job on the tanks!

Those headers may be a little restrictive, but that would mostly only effect high rpm's.

DADA_JEEP
August 21st, 2006, 08:12 PM
www.hanksvillehotrods.com custom mabdrel bent for any application, and he's a member here

flashover
August 21st, 2006, 08:31 PM
Thanks for the recommendation, but custom headers = $$$. Given enough time and j-bends I could probably come up with something. :flipoff2:

Ryan

Ghettojeep
September 21st, 2006, 04:54 PM
Updates?

SUPERGILDO43
October 19th, 2006, 04:28 PM
the forever build?

flashover
October 19th, 2006, 04:36 PM
the forever build?
Yeah, pretty much. Since we picked up a trailer, I have actually been trying to wheel a little bit while the weather is still nice, and I've had a bunch of other stuff going on as well. I know, nothing but excuses.

I will try to get some more pictures put up. The driveshafts have arrived from High Angle Driveline. We built a mount for the carrier bearing of the front two piece shaft. The yoke for the front diff interfered with one of the down tubes at the front of the chassis, so the chassis had to be modified a little bit. The front axle has been shaved the same as the rear. We have started mocking up the floor boards. The radiator has been installed. A bunch of other little stupid stuff that I can't think of has also been done.

Ryan

Matt
November 12th, 2006, 05:23 AM
Any updates?

Love'n the progress so far.

van7559
November 12th, 2006, 09:52 AM
update update update

CUBoulder96XJ
November 12th, 2006, 01:27 PM
wow, i just ran into this post...awesome build! cant wait for the next update:drool:

flashover
November 19th, 2006, 09:47 PM
It's getting close! Work has been progressing, but at this point there isn't a whole lot new to see. It seems that I can work for a couple of weeks and not have anything look any different. Oh well. Here is the radiator mount. They are polyurathane vibration isolators that I got from McMaster. The radiator is a 3 core aftermarket unit for a TJ, so it should have plenty of cooling capacity. The trans and steering coolers will be mounted to the face of the radiator.

http://flashover4x4.com/buggy/Buggy102.JPG

We also got started on the body this weekend. What a pain in the butt.

http://flashover4x4.com/buggy/Buggy103.JPG

http://flashover4x4.com/buggy/Buggy104.JPG

http://flashover4x4.com/buggy/Buggy105.JPG

http://flashover4x4.com/buggy/Buggy106.JPG

Ryan

Mark
November 19th, 2006, 10:29 PM
Ryan - what are you guys using to break the body panels with? Looks like at least a couple of them have bends in them. Also, what are you using to attach the 'permanent' sections (rivets, bolts, welds?) versus skins, if you're going that route?

Looking good as usual! :thumbsup:

SUPERGILDO43
November 19th, 2006, 10:54 PM
i dont want the pictures to stop.


is that bad?

Steven_Mc
November 20th, 2006, 08:49 AM
It's getting close! Work has been progressing, but at this point there isn't a whole lot new to see. It seems that I can work for a couple of weeks and not have anything look any different. Oh well.

Ryan

No kidding, I can relate to that. People tease that my jeep looks the same as it did when I ripped it apart a year ago, but I swear I've gotten stuff accomplished. :flipoff2:

Love the build. Question; so after you get the thing built are you going to tear it all down so you can paint the chasis? If so I admire your patience. The work is fun, but I much prefer having the thing on the road so I can wheel it.

flashover
November 20th, 2006, 09:33 AM
Mark, all of the body panels, floor boards, etc. bolt to the chassis. I am going to get some U-nuts to hopefully make the process a little quicker, especially since I can't get to the backside of some of the bolt holes. We have a box and pan brake to bend the skins with. It was certainly a worthwhile investment for this project.

Steven, yes I am going to tear everything down and paint it after all the assembly and fab is done. At this point I want to have it running/driveable at Christmas when my parents are coming to town, so it will most likely be unpainted or partially painted at that point. Once the weather warms back up in ths spring, I will do a full paint job.

Ryan

Trango
November 20th, 2006, 10:10 AM
Mark, all of the body panels, floor boards, etc. bolt to the chassis. I am going to get some U-nuts to hopefully make the process a little quicker, especially since I can't get to the backside of some of the bolt holes.

Hey Ryan,

What about using riv nuts/nutserts? If it's just for body panels, those have worked well for me in the past.

Bob

flashover
November 20th, 2006, 10:29 AM
I like the ability for the u-nuts to move around a little bit so my alignment doesn't have to be spot on. I am not all that great at getting my holes to line up 100% of the time :p The u nuts are cheaper and easier to install too. Thanks for the suggestion though.

Trango
November 20th, 2006, 10:46 AM
No worries.

Dude for lining up holes, use transfer punches and step bits... I'm sure you know this, but I had a brainstorming session with Chris Dunn (occasionally posts here) and I've since had excellent results in getting lineup. :)

Swat
November 20th, 2006, 01:07 PM
Cool build! Got Tire garooooover???

Tire groover for sale bud: http://www.colorado4x4.org/vbb/showthread.php?t=80601

Trango
November 20th, 2006, 01:15 PM
Oooh that's a good deal. If my XL's weren't older than dirt already and just waiting to die, I'd steal that. :)

Damian
November 26th, 2006, 06:52 PM
Sweet fuel cell idea!

flashover
December 10th, 2006, 10:29 PM
Alright, time for another update. It is getting close. We got a few more body panels done. Here is the hood, and rear seat surround. In addition, the rear axle winch is mounted below the radiator. It is setup to do multiple line pulls more for winch brake capacity that the pull capacity.

http://flashover4x4.com/buggy/buggy107.JPG

http://flashover4x4.com/buggy/buggy108.JPG

http://flashover4x4.com/buggy/buggy109.JPG

http://flashover4x4.com/buggy/buggy110.JPG

http://flashover4x4.com/buggy/buggy111.JPG

http://flashover4x4.com/buggy/buggy112.JPG

Also, the front winch is finally done. I am using a Warn 9.0Rc so I can have the shorter drum, plus it already comes with a rope intead of a cable. I have some serious lack of space issues in the front and the only place that I could put the winch without risk of the axle hitting it on flex was on the axle between the link mount and the center section. As you can see the clearances are still pretty tight. A box was built to provide enough bracing to mount the winch with the foot foward and to hold the fairlead in front of the link mount so the rope would not rub on things. You can also see the beginnings of some boxing of the upper link mounts. This was doen on the rear two upper mounts as well and really finishes the look of the axles.

http://flashover4x4.com/buggy/buggy113.JPG

http://flashover4x4.com/buggy/buggy114.JPG

http://flashover4x4.com/buggy/buggy115.JPG

I am happy to say that other than paint, the axles and suspension are fianlly done! The big things left at this point are wiring, plumbing, and the completion of the body.

Ryan

Sean Dogg
December 11th, 2006, 02:11 AM
Sweeeeeeeeeet!!! You gonna have this beast done by EJS?

RockRash
December 11th, 2006, 08:18 AM
Ryan- I realize that you are going to be running enormously huge tires and the front disk brake will be 3 feet in the air, but have you thought about putting a guard of some sort on the front disk brake (for rocks, trees, etc.)?

Looking good... your buggy has come a long way since the first time you showed me the wood mockup in your basement. Almost time for paint!

flashover
December 11th, 2006, 08:40 AM
With any luck, it might be done (minus paint) this month. I am not holding my breath for that though.

I am not sure what to do for brake protection, if anything yet. The plan is to get everything put together and drive it for a while and see if it may be an issue. If it looks like it will get bashed on everything, I will make a guard of some sort for the front, and may move the rear brake to the front side of the rear axle for a little added protection. I think it will fit there, but I may have some interference at full bump on the rear axle.

toycrawler1
December 11th, 2006, 09:16 PM
it's too big and heavy, won't fit on any trails, how you going to fit it on a trailer, blah blah blah. looks great! When you get it finished, come to Montrose and i will help you break it in

BigE
December 11th, 2006, 09:48 PM
it's too big and heavy, won't fit on any trails, how you going to fit it on a trailer, blah blah blah. looks great! When you get it finished, come to Montrose and i will help you break it in
:laughing:
You should not pass a trip up with the Proffitt guys there chit is BIG STUFF!
It was a blast watching those guys last time we were on cactus.

flashover
December 12th, 2006, 02:42 PM
it's too big and heavy, won't fit on any trails, how you going to fit it on a trailer, blah blah blah. looks great! When you get it finished, come to Montrose and i will help you break it in
Actually, it probably will be to big for the easy trails on this side of the divide. I guess I will be forced to come see what you guys on the western slope have to offer. I certainly plan on heading out to Montrose, GJ, Farmington, etc when this thing is done.

Ryan

Damian
December 12th, 2006, 03:17 PM
Good Gravy that thing is huge. Only question, why didn't you put a bench seat up front ~ it could be a 6 seater! ;)

JK, looks great, keep the pics coming.

toycrawler1
December 12th, 2006, 06:33 PM
open invite. same for the minion crew. you guys are a riot !!! I was on my best behavior with a new group of folks, but I promise it won't happen again.
quick question! rear steer or not. 126 w/rear steer should be tits. Mine is 119 and I wouldn't mind if it was a little longer. chad

Damian
December 12th, 2006, 10:38 PM
For that long of a rig, definately rear steer. Its going to be a bear manuvering it otherwise

sonofmayhem
December 26th, 2006, 06:07 PM
update?

Mcstiff
December 26th, 2006, 06:45 PM
The headers do not look that bad, they look like a lot of log style turbo headers. High end may not be the best but they should not be too bad overall.

Matt
March 19th, 2007, 01:24 PM
Updates??

I need to get my fix. :D

flashover
March 19th, 2007, 01:31 PM
Damn you. I get enough reminders of this thing everytime I walk into the garage. :flipoff2:


I have a few more body panels taken care of. Most of the floor is built. Axles are painted and installed, but I cannot get the front end to go together. The bronze bushings that the knuckles ride on at the kingpins will not go together for me and I have not had a chance to do a lot of research into it. In addition, as I was cleaning the front axle shafts before assembly, I noticed that my short side inner has a hairline crack at the u-joint yoke. So I have to find a new shaft before I can wrap up the front end.

In addition, we have been working on the XJ a lot over the last two months. It has taken a precendence over the buggy, as it's first WE ROCK competition is in less than two weeks. We have shaved the rear axle, installed a doubler, made a couple of roll cage changes to meet the rules, installed a fuel cell, new wheels and tires, and a whole bunch of other little stuff. It is a lot of work to get a rig comp ready for the first time. :D Hopefully it will be finished this week so we can get a test run this weekend before we head to Globe, and then Hannibal two weeks after that. I will see if I can convince Joel to get some new pics put up.

Ryan

flashover
July 23rd, 2007, 08:40 AM
Finally time for an update! We have been getting a lot done, althougth it seems like very little. The fab work is 99.9% complete. We built the skins. They are made from expanded sheet and flat stock.

http://www.flashover4x4.com/buggy/buggy116.JPG

Then it was time to flush out the tubes that are being used to carry the coolant. A garden hose was hooked up to the top of the tubes through a schrader valve that is used to bleed air. An olde piece of firehose was used at the back to get the water out of the garage.

http://www.flashover4x4.com/buggy/buggy117.JPG

http://www.flashover4x4.com/buggy/buggy118.JPG

With the coolant tubes flushed, we could finally weld in the rear recovery points, build the fan shroud and rear lighting.

http://www.flashover4x4.com/buggy/buggy119.JPG

And we pulled the engine and got the saddle for the motor mount built.

http://www.flashover4x4.com/buggy/buggy120.JPG

Unfortunately, I forgot to take pictures of the shifters that we built.

flashover
July 23rd, 2007, 08:41 AM
We also gussetted the main halo of the cage.

http://www.flashover4x4.com/buggy/buggy121.JPG

Then came one of the worst ideas that we have had in a long time. It was time for paint, so the chassis needed to be cleaned. It had a lot of dirt, dust and grease in it from the months that it has spent in my garage. So, we decided to tow it a couple of blocks over to the pay-n-spray to wash it out. Unfortunately, the front axle is still not put together, so we just took it off and made the buggy a big trailer.

http://www.flashover4x4.com/buggy/buggy122.JPG

My parents are out visiting, and somehow, I was able to sucker Dad into doing the dirty work with the pressure washer. I got in and scrubbed the inside of the skid plate with a stiff brush.

http://www.flashover4x4.com/buggy/buggy123.JPG

http://www.flashover4x4.com/buggy/buggy124.JPG

It was towed back home, and put in back in the garage. We should start paint next weekend.

http://www.flashover4x4.com/buggy/buggy125.JPG

newracer
July 23rd, 2007, 09:01 AM
I bet you got some wired looks going to the car wash. That thing is sweet!!!

Mark
July 23rd, 2007, 09:31 AM
http://www.flashover4x4.com/buggy/buggy124.JPG

Sorry guys, needs more triangulation. :flipoff2:

Coming along nicely, btw. :thumbsup:

BradC
July 23rd, 2007, 01:54 PM
Great work!!!

74BuckinBronc
July 23rd, 2007, 02:10 PM
I want to see how you hooked it up in the XJ? Looks interesting to say the least, but you gotta do whatcha gotta do!

J.D.

flashover
July 23rd, 2007, 02:59 PM
I want to see how you hooked it up in the XJ? Looks interesting to say the least, but you gotta do whatcha gotta do!

J.D.
Thanks for the compliments. We didn't get any really good pictures of how we coupled the buggy to the Cherocar, but basically we hung the nose of the buggy from one of our trailer tie down straps to the top node of the XJ's cage, and chained between the XJ's bumper and the buggy motor mount tubes to limit the amount it could swing. A real good idea? No, but it was not too stupid or dangerous.
Ryan

Haire Ball
July 23rd, 2007, 05:28 PM
Glad to see your still at it! Thanks for the update.

Looks great!

ThePagan
July 26th, 2007, 08:23 AM
Good thing the car wash is only a 100 yards away....

74BuckinBronc
July 26th, 2007, 08:30 AM
At least it wasn't this:
http://i62.photobucket.com/albums/h103/Ozman2/Untitled-1copy.jpg

J.D.

ThePagan
July 26th, 2007, 09:09 AM
lmao....


<sorry hijack>
Here's another one
http://southernhighrollers.com/trails/images/may_201.jpg
<end hijack>

DADA_JEEP
July 26th, 2007, 11:01 AM
whats wrong with the first one??? i see no big deal........

ThePagan
July 26th, 2007, 01:21 PM
Sorry should have used <sarcasm> - I was giving flashover crap, nothing more, nothing less.....

flashover
July 26th, 2007, 03:07 PM
Shawn, we're moving out of the garage to the driveway again tomorrow evening in preparation for paint on Saturday. If you want we can just drag it over to your place instead. :flipoff2:

ThePagan
July 26th, 2007, 04:29 PM
flashover I may just have to stop by and laugh in person.

- Shawn

flashover
July 26th, 2007, 04:36 PM
Come on by. We've got plenty of cold :beer: if ya like.

Loobz
July 30th, 2007, 07:36 PM
Buggy's lookin good guys, can't wait to finally, and I will repeat FINALLY, see it out on the trails!! :D

flashover
July 31st, 2007, 08:17 AM
Well, the chassis is painted, the engine, trans and t-cases are reinstalled. With any luck, I may be able to try getting this thing to fire up by the end of the week. We'll see.

Rhino95
August 2nd, 2007, 09:59 PM
Pictures?

89minitruck
August 4th, 2007, 09:01 PM
At least it wasn't this:
http://i62.photobucket.com/albums/h103/Ozman2/Untitled-1copy.jpg

J.D.


Some sort of Darwin Award here ... :idea:

74BuckinBronc
August 6th, 2007, 07:57 AM
It gets worse if you see the closeup, but I didn't want to take over this thread.

J.D.

flashover
September 19th, 2007, 01:27 PM
I apologize, my home computer died on me, so I have been lacking in posting any updates, so here it goes:

We hauled it out of the garage the same as we did for the cleaning, put the front on jackstands, and sprayed it. Primer:

http://flashover4x4.com/buggy/buggy126.JPG

Paint:

http://flashover4x4.com/buggy/buggy127.JPG

Paint on the trans/t-cases:

http://flashover4x4.com/buggy/buggy128.JPG

And driveline installed:

http://flashover4x4.com/buggy/buggy129.JPG

http://flashover4x4.com/buggy/buggy130.JPG

Let the fun of wiring begin. I have set up the Taurus fan to automagically switch itself from low to high as needed, or be turned to high manually. In addition, I have brake lights, running lights, rock lights, and winch controls to be run to the back. I didn't get a picture before everything was installed, but as you can kinda see here, there isn't much room for anything more. This took about 8 hours to wire.

http://flashover4x4.com/buggy/buggy131.JPG

I am using a jet ski safety switch as a master disconnect for everything electrical. Obviously, it can't hand the amperage draw of winches, and all of the other items being used, so I have set the safety switch to trigger a couple of big continuous duty solenoids. When the solenoids are off, so is everything else except for the Ham radio and the clock.

http://flashover4x4.com/buggy/buggy132.JPG

All of the wiring eventually ends up in the panel between the front seats. I still have quite a bit to do here, but I did wire it up enough to be able to start the engine. I temped in the oil pressure and water temp gauges to keep an eye on things while it is running.

http://flashover4x4.com/buggy/buggy133.JPG

http://flashover4x4.com/buggy/buggy134.JPG

But the big news is, IT RUNS! I took a semi educated guess at the distributer position, and got it to start on the first try. After a little bit of timing adjustment, it starts and runs even better than I had expected. As soon as I get the coilovers mounted, finish painting the floors, and complete the dash wiring, it is finally time to go wheeling!

Ryan

74BuckinBronc
September 19th, 2007, 01:44 PM
Ryan - I got a certain bronco that could use new wiring from headlight to tail-light and it has a similar engine in it as your buggy. I wouldn't even car if it took us 12 hrs... Got a hankering to make a trip to tropical San Antonio?

You've done a nice job. I can't wait to see how she'll look with the front axle under her. We need some video as you pull it out of the garage under it's own power.

J.D.

flashover
September 19th, 2007, 02:07 PM
I've got video of starting the engine (the 3rd time, not the 1st), and will try to get some of it leaving the garage.

The wiring for only the rear end took 8 hours. I probably have about 30-35 hours in wiring right now, and another 5-7 to go.

RockRash
September 20th, 2007, 08:30 AM
...

But the big news is, IT RUNS! I took a semi educated guess at the distributer position, and got it to start on the first try. After a little bit of timing adjustment, it starts and runs even better than I had expected. As soon as I get the coilovers mounted, finish painting the floors, and complete the dash wiring, it is finally time to go wheeling!

Ryan

Just say the word and I am up for your maiden voyage. I'm sure that ThePagan, OlBlueCJ7, Thompster, Jdogg, jtw2, and other 'locals' would join in.

Moody/Crystal is close for some test and tuning...

74BuckinBronc
September 20th, 2007, 08:38 AM
I've got video of starting the engine (the 3rd time, not the 1st), and will try to get some of it leaving the garage.

The wiring for only the rear end took 8 hours. I probably have about 30-35 hours in wiring right now, and another 5-7 to go.

Oh ok, but still I'd put you up for a week, feed you well and we can use the neighbors pool... J/k

Looking forward to that video.

J.D.

flashover
September 20th, 2007, 08:46 AM
Just say the word and I am up for your maiden voyage. I'm sure that ThePagan, OlBlueCJ7, Thompster, Jdogg, jtw2, and other 'locals' would join in.

Moody/Crystal is close for some test and tuning...
I was actually thinking about Kelly Flats, hopefully on Sunday. We will have to see how Saturday goes though. There is a lot left to do in order to get it driveable.

newracer
September 20th, 2007, 09:32 AM
Definitely post up when/where. I want to see this beast in person.

flashover
September 22nd, 2007, 04:42 PM
Just got back from it's first trip around the block. We are definatly on for Kelly Flats tomorrow (Sunday). http://www.colorado4x4.org/vbb/showthread.php?p=885372#post885372

-Joel

Steven_Mc
September 28th, 2007, 07:55 AM
You've had it out of the garage, around the block, and on a maiden voyage and still no pics of the completed buggy?

This is a good build thread, but without final pics for closure...
:worthless:

74BuckinBronc
September 28th, 2007, 08:18 AM
I was thinking the same thing just before I clicked the link to this thread! I don't care if you had to winch it back on the trailer, let's see 'em finished pics! :)

J.D.

flashover
September 28th, 2007, 09:45 AM
Alright, here you guys go.

The floor installed:

http://flashover4x4.com/buggy/buggy135.JPG

The beginning of the skins:

http://flashover4x4.com/buggy/buggy136.JPG

A few more need to be put on still, but I need different bushings to hold the coilover reservoirs first, as the ones I have now will hit the skins.

Front coilovers installed, but the axle not aligned yet:

http://flashover4x4.com/buggy/buggy137.JPG

Switch Panel:

http://flashover4x4.com/buggy/buggy138.JPG

http://flashover4x4.com/buggy/buggy139.JPG

http://flashover4x4.com/buggy/buggy140.JPG

And now for the exciting stuff. It comes out of the garage, but just barely. The rear tires need to be completely empty of air in order for it to fit.

http://flashover4x4.com/buggy/buggy141.JPG

http://flashover4x4.com/buggy/buggy142.JPG

The rock lights:

http://flashover4x4.com/buggy/buggy143.JPG

http://flashover4x4.com/buggy/buggy144.JPG

flashover
September 28th, 2007, 09:49 AM
And here it is at the Kelly Flats trailhead:

http://flashover4x4.com/buggy/buggy145.JPG

http://flashover4x4.com/buggy/buggy146.JPG

And for the sad part of the story, this is as far up a hill as it can make it. I have some transmission issues, but at this point am not sure what they are. With my foot to the floor, the engine will get to the stall point of the torque converter but not move the rig. It sure does build a ton of heat in the trans though.

http://flashover4x4.com/buggy/buggy147.JPG

Ryan

Gotlift91
September 28th, 2007, 11:25 AM
Man that thing looks sweet!:drool: And good gravy is that thing HUGE:D I dig it man, I hope you get your tranny issues figured out soon that way you can wheel the CRAP out of it:beer:

Scooter
September 28th, 2007, 12:50 PM
Super Job! That thing is sick! Hope to see it on the trail soon.

Did you consider AMMCO...:flipoff2:
Man, I just had to do it.

Scott@Rockstomper
September 28th, 2007, 01:21 PM
C6?

flashover
September 28th, 2007, 01:27 PM
C6?

Yeah. Unfortunately, I made a rookie mistake in the chassis design, and made it so I pretty much have to take the WHOLE thing apart in order to access the trans. Troubleshooting will be difficult at best when I get around to it. At this point, my best guess is that one or more of the clutches is slipping, or that I got crud in the valve body while rebuilding. I don't think my symptoms indicate any torque converter problem, which is too bad, since I can get to it much easier than the bottom of the trans.

Scott@Rockstomper
September 28th, 2007, 02:17 PM
Unfortunately, I made a rookie mistake in the chassis design, and made it so I pretty much have to take the WHOLE thing apart in order to access the trans.

Rookie like, have to pull the seats, then the floor, then the floor supports, then the tunnel, then the skidplates, then the driveshafts, then the transfer case, then the tranny mount, then the exhaust, then the tranny fluid, then the dipstick assembly, then the tranny itself? And OBTW, do all that while origami-folded into the interior.

<-- fellow rookie.

I've got a spare, but it takes me two days to change it. :eek:

And at least it's not as bad as pulling my engine... do all the above, then take off all the accessories and end-mounted stuff down to bare timing cover on the front, and block on the back... and then it just barely wiggles out.

flashover
September 28th, 2007, 02:48 PM
Yeah, that's about it. But mine does not need the skid plates pulled, but does need a substantial portion of the wiring removed, and has to come out with the engine. The engine itself however, is pretty easy. Just undo the engine harness, drain water, steering fluid, etc, support front of trans and pull out.

I got your PM. Let me think about it, I'll let you know.

Damian
September 28th, 2007, 09:44 PM
Hope to see that thing in tomorrows RockRace!

formatt
September 29th, 2007, 10:14 PM
http://www.flashover4x4.com/buggy/buggy125.JPG


AND you just had to install a clock... what's wrong with you two?! :D

Joel... got a PM coming your way. Found that info regarding those tiny engines we talked about when you stopped by.

BIGNICK91K5
September 30th, 2007, 12:51 AM
I just looked at this thread

Amazing !

I wanna see this thing back on the trails.

Jake_Blues
October 1st, 2007, 05:01 PM
I thought the buggy build was missing something, so I added my own mod...

http://omgwtf.kicks-ass.org/Images/gunbuggy.jpg

Ahh, much better! :D

-E

Phazertwo A.K.A Brenden
October 1st, 2007, 06:26 PM
I thought the buggy build was missing something, so I added my own mod...

http://omgwtf.kicks-ass.org/Images/gunbuggy.jpg

Ahh, much better! :D

-E

I think the warthog turret would go much better on that rig! Maybe even put master chief in the front seat!

redtj98
October 6th, 2007, 06:46 PM
I love your buggy, but not to be asshat what truck tralior are you going to tow it with? Cuz dammmmm that thing is big . I hope you have a f450 and a gooseneck . agin I dig the beast and I cant wait to se it wheel I'll have to just watch cuz I wi'll just be wheelin my oj bronco.


Keep up the good work!!:beer: :beer:

James
October 6th, 2007, 10:45 PM
http://flashover4x4.com/buggy/buggy137.JPG

Is that Joel in the back of the garage with only a mustache?!? :spit:

flashover
October 6th, 2007, 11:39 PM
Yeah, new job doing some HAZMAT work means no more beard.
-Joel

Loobz
October 11th, 2007, 01:50 PM
Dis big bitch runnin yet?!? I love the green under there! That's rare for me...

74BuckinBronc
October 11th, 2007, 01:55 PM
Is the green the duplicolor self ectching primer? I painted my bumper with that stuff and almost just left it...

J.D.

Action Jackson
October 11th, 2007, 11:21 PM
Any luck yet finding the problem? Congrats on a cool ride! I wanna see that beast crawl :eek:

kPs
October 12th, 2007, 11:14 AM
I wanna see that beast crawl :eek:

Xtheentireboard...:thumbsup:

Love this thing!

flashover
October 12th, 2007, 12:55 PM
The green paint is Duplicolor Grabber Green engine paint over Rustoleum grey clean metal primer. It turned out pretty good.

As far as the transmission goes, I have not done anything with it yet, as I need to recover a little bit $$ wise before I really tear into it. I am planning on starting with replacing the torque converter as that is only a one day job. If that doesn't take care of it, I will tear the whole thing down in order to get the tranny pulled and diagnosed.

And the chop with the gun, AWESOME!

Ryan

jeeplvr79
October 12th, 2007, 01:07 PM
Good luck, Ryan and keep us updated with the Beast's status :)

flashover
October 12th, 2007, 01:11 PM
I had to take the gun pic a little bit further.

http://colorado4x4.org/vbb/attachment.php?attachmentid=7252&d=1192216223

Trango
October 12th, 2007, 03:01 PM
IT's really impressive how low your rig is. My crank pulley is as low as it can get and it's still a bee's dick away from the chunk on the front axle. I guess I could move the engine back but hell if I'm going to rebuild.

mikey_d05
October 29th, 2007, 11:49 AM
Been following your build on Pirate, looks killer. Maybe I missed it but what did the WB end up at? :beer:

Jefe
November 11th, 2007, 05:18 PM
Any updates?

:popcorn:

Jeepin Dave
January 6th, 2008, 11:15 AM
That is one sweet rig. What do you have for a tube bender? I live in Windsor and need a few bends. Dave

redtj98
January 6th, 2008, 04:25 PM
So Whats new ???? Is the beast done?

Ps cuz yer a ford guy ,, do you know where I can get an AOD for my bronco??:thumbsup: :thumbsup:

POLLY
March 8th, 2008, 10:35 PM
Update much needed!!

So I just saw this haus of a rig being towed done 1-25 near Loveland. Looks finished, whats the progress status? I had my little bro give you a thumbs up as we passes but it was dark out and we failed to receive a reciprocated gesture.:tisk:

Whats the deal buggy's can't wave back at Pontiac Grand-Am's??:flipoff2:

flashover
March 9th, 2008, 08:33 AM
Update time indeed. I got a new performance torque converter from Art Carr to hopefully fix my transmission problems. Joel and I brought the buggy down to his office to perform the swap, since they have an overhead crane and a lot more space than we have at home, especially with the Burrito Jeep in the garage. I got lucky and was able to just remove the engine, while leaving the trans in place. This means I didn't have unwire the entire chassis or pull but a couple of the body panels. What a relief. Onto the pics:

Unwiring the engine, pulling the coolant lines and fuel lines.

http://flashover4x4.com/buggy/buggy148.JPG

Engine all hooked up the crane. The crane doesn't have a super fine up and down motion, so we put a chain fall between the crane and the load leveler for super fine control of the pitch and height of the engine for reassembly.

http://flashover4x4.com/buggy/buggy149.JPG

After getting the engine pulled and the the new converter filled with fluid, I discovered that I had been delivered the wrong converter. The spline count for the trans input shaft was too small, so obviously, the input shaft wouldn't fit :mad: So we put the engine and trans back together to sit until the right converter got here. Art Carr was good to deal with and sent the correct converter right away, so the only thing I lost was time. The new converter came on Friday and we got it installed yesterday. Surprisingly, everything bolted back up very easily.

Since we had access to the crane, we needed to actually flex the beast out.

http://flashover4x4.com/buggy/buggy150.JPG

http://flashover4x4.com/buggy/buggy151.JPG

And the rig had sat so long with no air in the rear tires, that the beads came unseated. With access to a forklift, removing these heavy pigs is nice and easy.

http://flashover4x4.com/buggy/buggy152.JPG

http://flashover4x4.com/buggy/buggy153.JPG

I am reasonably sure this fixed my issues. I was able to actually pull up onto the trailer last night, and a relatively steep hill next to the shop. I will find out for sure when I have a chance to get to a trail.

And finally, thanks for the wave. I would have waved back, but there are a lot of potholes there and I really don't like the idea of losing control of the truck with the trailer hooked up. Compliment appreciated. :thumbsup:

Ryan

87xj
March 9th, 2008, 10:23 AM
sick ride... When is it going to be street legal? haha looks like fun wish i could do the same but i think my apartment complex would get mad lol

Burrito Bob
March 9th, 2008, 06:40 PM
Surely, it can't be done! After only 2 1/2 short years.
Awsome.:hail:

The Burrito Wagon should be done by Christmas. 2010.:P

Jefe
March 9th, 2008, 08:13 PM
OMG!! SICK!! That thing looks like it sits 12' in the air!

RockRash
March 10th, 2008, 01:56 PM
Surely, it can't be done! After only 2 1/2 short years.
Awsome.:hail:

The Burrito Wagon should be done by Christmas. 2010.:P

Great moral support DAD!

:P

Burrito Bob
March 10th, 2008, 05:25 PM
Great moral support DAD!

:P

That's what they get when they work on the buggy and not my Jeep!

Matt
March 10th, 2008, 10:29 PM
I think that thing is bigger than my apartment.

Nice flex on the semiuggy.

sonofmayhem
March 16th, 2008, 11:44 AM
That is a monster. Toss some black on there and see if "Monster" then energy drink will support you.:D

flashover
March 22nd, 2008, 07:20 PM
Well we took it up to Carnage Boulder today and it ran great. No issues to be found other than a couple of loose jam nuts and hose clamps. Unfortunately we forgot the camera, so no pics. But it does run, finally! It will need a little bit of tuning on the shocks and spring rates and a couple of other little things, as would be expected.

Ryan

ThePagan
March 23rd, 2008, 04:25 AM
Cool.. I'll have to stop by and take a look.

- Shawn

RockRash
March 24th, 2008, 08:20 AM
Well we took it up to Carnage Boulder today and it ran great. No issues to be found other than a couple of loose jam nuts and hose clamps. Unfortunately we forgot the camera, so no pics. But it does run, finally! It will need a little bit of tuning on the shocks and spring rates and a couple of other little things, as would be expected.

Ryan

Waterfall? Guardian Rock? How did it do?

I realize no pics, but did it do well?

flashover
March 24th, 2008, 09:31 AM
Guardian rocks, what guardian rocks. It walked them like they weren't even there. A large (4'-5' tall) undercut rock had fallen into the approach path to the slab since the last time we had run this trail, but again, after getting a decent line on it, the buggy had no issues going over the rock or the relatively narrow spots caused by the rocks. However, I did not make the waterfall. So much ice had collected that the waterfall was only about 12" tall, but I could not get the tires to stick to anything. I would just sit there and spin. The flat rock to the west of the waterfall was no issue though.

It is much different wheeling a buggy than the jeeps that I am used to. Definitely a good time.

trailbuilt
March 24th, 2008, 09:54 AM
Almost 3 years I have been Following this build..... Finally get a shake down run and you guys forget the camera? WTF guys?:flipoff2:

jeepn4evr
March 25th, 2008, 08:18 AM
Hey my sister & bro in law lives like 6 houses from you guys, we have met before. At any rate I was up there on easter & saw it in person. All I can say is WOW :eek: . That thing if HUGE!! Since no one was around I didn't look real close, as I didn't want some neighbor callign the cops, but I did get some pics. Vey nice. My other bro in Law & father were equally impressed. I take it you don't get in trouble with anyone for parking it on the driveway, as it is way to tall for the garage.

Good job

flashover
March 25th, 2008, 08:24 AM
No one has ever said anything about it being in the driveway, so i guess its OK :confused: It actually does fit in the garage as long as I suck the rear suspension down all the way and take all the air out of the rear tires. I would keep it in there, but the Burrito Wagon is taking up that space right now.

Ryan