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Old 09-12-2013, 11:57 AM   #1
freqster
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Join Date: Feb 2013
Location: League City, TX
Posts: 39
Default PVC Buggy

I have been working on a neighborhood cruiser made from PVC pipe for a few months now. I mainly did it as a proof of concept idea to see if I could. It has turned out pretty well so far and It has help up better then expected.

I have a build log on DIY Go Karts website here: http://www.diygokarts.com/vb/showthread.php?t=21082

I thought I would share it on this site. So here is my build log from the begining until now.

I got the idea from http://www.americanspeedster.com/ I bought a set of the plans and was really disappointed in them. The plans were a few pages of mostly text, with a few pictures made using a word program. I mean, I could have hand drawn better pictures!!

So I came up with my own design borrowing some of the ideas from the americanspeedster design. I love Google SketchUp so I spent a lot of hours drawing up my design.

Here is a link to a Intro video I made about the idea and some of the PVC parts I used:

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File Type: jpg No Riders.jpg (72.6 KB, 0 views)
File Type: jpg Frame Wheels Engine.jpg (103.7 KB, 0 views)
File Type: jpg Engine and steering.jpg (180.3 KB, 0 views)
File Type: jpg Rear Axel trough PVC.jpg (128.7 KB, 0 views)
File Type: jpg Body Panels.jpg (137.0 KB, 0 views)
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Old 09-12-2013, 12:02 PM   #2
freqster
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Join Date: Feb 2013
Location: League City, TX
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Default PVC Buggy

I used a 110cc 4-stroke engine out of a little Chinese quad that I found on craigslist. It is electric start, automatic with Forward, Neutral, Reverse. I used as many parts as I could from the quad. Here are a few pictures of it in different stages.

I spent a lot of time cleaning up the motor and labeling all the wires to make sure I know how to put it back together.
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Old 09-12-2013, 12:08 PM   #3
freqster
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Default PVC Buggy

Since I decided to use PVC, I had to come up with some ways to reinforce some of the areas of the build.

I decided to make a cage for the engine to mount in. That gave me some strong points to attach things like bearings and axle, brake caliper, exhaust, ect.
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File Type: jpg New Motor Cage.jpg (76.4 KB, 0 views)
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Old 09-12-2013, 12:16 PM   #4
freqster
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Default PVC Buggy

The frame need some steel reinforcement too so I borrowed the idea from the americanspeedster plans and used the top rail from chain link fence materials, that fit inside the 1 1/4" pipe. I made some drawings with the some of the PVC clear so you can see where the steel reinforcement is.

I had originally planned on making some spindles out of pipe couplings but I decided just to use the spindles that were on the little quad. It worked out better anyway because it was easier to set up my steering geometry.
Attached Images
File Type: jpg Steel suppor locations.jpg (139.1 KB, 0 views)
File Type: jpg Steel front axle.jpg (149.6 KB, 0 views)
File Type: jpg Spindle Idea 2.jpg (90.1 KB, 0 views)
File Type: jpg Spindle Idea.jpg (178.5 KB, 0 views)
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Old 09-12-2013, 12:24 PM   #5
freqster
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Default PVC Buggy

At this point I finally decided to start the build. I went to the local Home Depot and bought my PVC pipe, and got to work.

If anyone has worked with PVC glue, you know that it sets pretty fast. So I had to make sure I had a build order so I could ensure I assemble it properly. I opened up my drawings and changed the color of the different lengths of pipe. I exported 2D drawings of the different stages and basically just followed the pictures.
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File Type: jpg 3.jpg (92.2 KB, 0 views)
File Type: jpg Cut List.jpg (158.8 KB, 0 views)
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Old 09-12-2013, 12:29 PM   #6
freqster
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Default PVC Buggy

Since I had a few curved sections of pipe to deal with, I set up sort of a pattern to follow and used a heat gun to bend the PVC. I took a video of me bending one of the sections.

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Old 09-12-2013, 12:36 PM   #7
freqster
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Default PVC Buggy

I decided to use bicycle wheels for their light weight, and cost. I found a guy on craigslist selling 15 bikes for $100 bucks. I was able to salvage some 48 spoke rims, inner tubes, and tires, and I got a little radio flyer tricycle and a starter bike for my son!
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Old 09-12-2013, 12:47 PM   #8
SCLakes
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Default Re: PVC Buggy

very cool
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Old 09-12-2013, 10:11 PM   #9
freqster
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Default Re: PVC Buggy

I wanted both sets of rear wheels to drive, so I needed a differential. I found a peerless 100 differential on eBay for $60.00 that worked out pretty well. I just had figure out a way to make one of the axles longer.
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Old 09-12-2013, 10:22 PM   #10
freqster
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Default PVC Buggy

Next, I had to figure out how to adapt the bicycle wheels I planned on using, to the rear live axle. I found a instructables post here: http://www.instructables.com/id/26-w...-for-pedicabs/ where a guy used "bore hubs" and mounted them inside the wheel hub. I used a 3/4" axle so I had to get bigger bore hubs. I turned them down a little on my lathe and welded them to the bicycle hub. I used a 3/4" hardened drill rod to keep everything straight when I welded them. I used another bore hub for the brake disc.
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