Some of you may remember my last project, the Subaru Powered Peugeot 205 that sold a while back now.



So something different this time, It's a scratch build, and motorbike powered! Although still harnessing a Subaru drivetrain, or at least in some fashion.

This is something I've wanted to build for a long time, so here goes!

First off, the Build Bench!




I need something strong, and big enough to build the buggy frame on, and this is it, all marked out with 100mm squares to keep everything square and true.

 

This is a viscous lsd from a bug eye wrx, I've stripped it down, removed the tapered roller bearings and fitted sealed sleeve bearings so I can run the diff out of the casing.

 

Should be a fairly easy build, be like a rage buggy when done?

 

Similar mate yes, and for tarmac.

 

I've removed the crown-wheel, and had a sprocket cut to suite the flange and the bolt pcd on the diff.



This is a housing I've made to keep the diff sealed, I've fitted grease nipples so I can pump it full of grease to keep the internal gears lubricated.













The new sleeve bearings are fitted into the stock alloy bearing housings, and bolted onto the mounting plates, I can now build the rear frame around this.

 

After hours of modeling the rear frame, it’s time to start building.
I have designed the suspension geometry on the Racing Aspirations suspension calculator, it lets you input all the dimensions and run it through its travel and roll etc.
I'm using the Subaru rear hubs and Driveshafts.

 

The main hoop was bent with my new tube bender, and what a beast it is, so easy to use.

 

Subscribed

 

The rear frame is coming along nicely now, I’ve fabricated the rear wishbones, and knocked up a jig incase I need to make new ones.

 

Modeling the front end, to get all my pick up points spot on, note the threaded rod with the nut welded on the end, that's where my steering rack pivot point will be, it needs to be in right position to avoid bump steer.

 

Front lower wishbones fabricated, and I’ve started on the front frame, I’ve also fabricated my own pedal box to fit inside.

 

Starting to take shape.

 

 

Threads like this are what makes forums interesting. Great write up. Looking forward to the end result.

 

Thanks mate

 

holly molly!

 

Woo hoo! He's back with another great build. Most certainly subscribed!


Looking great so far.

 

Loved your last project, can't wait to see how this one develops!

 

Haha cheers guys!!

Shouldn't take long to finish after crimbo!

 

Looking forward to this project James!!!!

Looking forward to the first test at Curborough!!!

 

+1 will be following this thread closely, nice and neat alloy mig welding on the seat.

 

Subscribed. Really interested to see how this progresses. Good luck to you!

 

I’m back!! 3 years later😂

I’ve moved house twice since my last post, so the project was put on the back burner.

I’m finally settled again, so here goes for a massive update.

This project ended up being a lot bigger than I first thought, designing a frame that not only looked good, and was safe, but I could fit myself in comfortably, and package an engine, diff, fuel tank and all of the other components.

It’s certainly been a test.

I spent months researching and modelling my suspension geometry, and I quickly noticed that tweaking one thing, effected another thing, so I realised that there’s no such thing as the perfect geometry, and a compromise was needed. All that said and done, I think I’ve finally found a happy medium, and with lots of adjustability on the wishbones, and double adjustable shocks, I’m super confident it’s going to handle well.

 

Wishbones and the steering column fabricated.

 

Engine mounted and the exhaust fabricated.

 

I decided I wanted to fabricate my own alloy tanks, so I’ve completed a level 1 and 2 aluminium welding course, and treated myself to a tig welder.
I've made a start on the coolant tank, engine breather tank and the battery tray.

 

Radiator fitted and she’s rolling baby!!

 

The big strip down and paint.

 

Wishbones and hubs powder coated.

 

Quick release steering wheel fitted.