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| FrankenBuggy Tech Unconventional and Home Built Buggy Tech Forum |
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#1
05-21-2018, 12:56 PM
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Coolster 250cc single seater
I bought this buggy a couple years ago and have slowly been transforming it to accommodate an adult.
Here's some pictures from the seller when I bought it:   
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#2
05-21-2018, 12:59 PM
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The electrical was a nightmare so I cleaned it up a bit and made brackets for the solenoid, CDI and rectifier.
 
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#3
05-21-2018, 01:08 PM
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Next I removed the craptastic exhaust and started mocking up a new one.
  
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#4
05-21-2018, 01:14 PM
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Next I flipped the rear wheels around for maximum width and added aluminum wheel spacers
 I wanted to add a temp gauge and fuel gauge  cardboard dash:  
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#5
05-21-2018, 01:23 PM
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Nice. I haven't worked on my buggies much this year, but if I ever get the time and good weather I will.
__________________
2010 Carter Interceptor GTR 300 2010 Hammerhead 250 SS 2015 Kandi 49FM5 110cc 2015 Hammerhead GTS 250-SOLD 2008 Kazuma Coyote 150-SOLD |
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#6
05-21-2018, 01:25 PM
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Aluminum dash:
   decided to ditch the temp gauge in favor of a tachometer 
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#7
05-21-2018, 01:32 PM
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Realized I wouldn't have enough head room so I made it a convertable
  Cut off the roll cage from another kart and got it mocked up 
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#8
05-21-2018, 01:41 PM
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Added some tube
 Thought I'd mount the engine to the chassis and cut the engine in half in order to get the gear box on the same axis as the swingarm pivot   
Last edited by 707offroad; 05-21-2018 at 01:50 PM. |
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#9
05-21-2018, 01:48 PM
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Took some measurements off the old swingarm and temporarily mocked up the new rear shocks
  I had some rusted box tubing I wanted to use to make a new swingarm   Decided to try to remove the rust with electrolysis. I used a little battery charger and mixed up a solution of sodium carbonate and water to remove the rust. 
Last edited by 707offroad; 05-21-2018 at 02:00 PM. |
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#10
05-21-2018, 01:50 PM
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made some temporary aluminum spacers and pieces of steel tubing for swingarm bushings and shock mounts
  Then started laying out the parts for the new swingarm     
Last edited by 707offroad; 05-21-2018 at 02:07 PM. |
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#11
05-21-2018, 02:01 PM
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Holesaw through the swingarm for multiple swingarm mounts
     New swingarm bolted up, radiator and gas tank relocated   
Last edited by 707offroad; 05-21-2018 at 02:15 PM. |
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#12
05-21-2018, 02:08 PM
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Cleaned up the reverse box and put some fresh grease in it
  
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#13
05-21-2018, 02:28 PM
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started mocking up new motor mount and reverse box mount
      I got to this point and I didn't like where the project was headed so I let it sit for a year. |
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#14
05-21-2018, 02:54 PM
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After thinking about it for a year I concluded that i should go a different route with the engine. I had a new in the box Chinese 200cc 4 stroke 5 speed manual with electric start that I bought for another project and decided to use it on this buggy project.
I started by making an engine cradle mount with a jackshaft. This gave me tons of gearing options and gave me the clearance I needed for the shifter linkage.       I couldn't find a shaft mount sprocket that matched the pitch of the countershaft sprocket on the engine so I made my own out of two sprockets.  I had to anneal the larger sprocket in order to bore out the id.     
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#15
05-21-2018, 03:09 PM
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made plates for the pillow block bearings to bolt to
 Then made a plate on the swingarm to mount the engine. 
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#16
05-21-2018, 03:22 PM
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Made a paddle shifter
      
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#17
05-21-2018, 03:46 PM
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bracket for shifter cable and mounted the rectifier
 bracket for coil, cdi and solenoid             and all finished with the electrical components attached  Next I moved on to some wiring  
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#18
05-21-2018, 05:00 PM
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I wanted reverse on this buggy and was thinking about rigging up an electric reverse with an starter motor and small ring gear from a geo metro. I was just about to buy the parts when I found a 200cc like the one I had except with reverse for $300.
 then found a cheap 250cc piston/cylinder kit       
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#19
05-21-2018, 05:37 PM
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Made an intake manifold
       
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#20
05-21-2018, 08:58 PM
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Holy Smokes ! Awesome Build ! , Thanks a Lot , I Feel About As Useless As Tit's On A Bull Now ! Wait , I'm Old and Wore Out , Yea That's It ....
 Wear Your Helmet !!! 
__________________
2011 BMS KING COBRA 150 Sold YERF DOG SPIDERBOX's Sold YERF DOG 3203's. Sold MANCO SILVER FOX. Sold 2009 POLARIS 500 HO SPORTSMAN 4X4 2002 POLARIS 500 HO SPORTSMAN 4X4 2000 POLARIS MAGNUM 2X4 HALF A DOZEN CHEVY 4X4's NEED-MO-BUGGY
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#22
05-22-2018, 12:59 PM
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Quote:
 Quote:
I didn't like the front suspension and some of the frame cage I built had to be redone.    So I got a Honda TRX400 front end  And started making some brackets       
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#23
05-22-2018, 01:02 PM
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Then got the front end tack welded
      
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