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Coolster 250cc single seater - BuggyMasters.Com - An On Line Mini Buggy Forum and Go Kart Forum
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FrankenBuggy Tech Unconventional and Home Built Buggy Tech Forum

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  #1  
Old 05-21-2018, 12:56 PM
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Default 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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Old 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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Old 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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Old 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  
Old 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.
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  #6  
Old 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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Old 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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Old 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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Old 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  
Old 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  
Old 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  
Old 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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Old 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  
Old 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  
Old 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  
Old 05-21-2018, 03:22 PM
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Made a paddle shifter













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Old 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  
Old 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  
Old 05-21-2018, 05:37 PM
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Made an intake manifold















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  #20  
Old 05-21-2018, 08:58 PM
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Cool

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 !!!
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  #21  
Old 05-22-2018, 07:00 AM
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Glad to see this posted here. The other site doesn't seem to be working, and I want to see this project when it's done.
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  #22  
Old 05-22-2018, 12:59 PM
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Quote:
Originally Posted by OLDKID View Post
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 !!!
Lol. Thanks man

Quote:
Originally Posted by liduno View Post
Glad to see this posted here. The other site doesn't seem to be working, and I want to see this project when it's done.
Yeah, I wonder what happened to the other forum? I'm getting closer

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  
Old 05-22-2018, 01:02 PM
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Then got the front end tack welded













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  #24  
Old 05-23-2018, 04:30 AM
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Pretty cool, been looking to do the same motor swap on my son's 150. I'm old school and just like a good manual gears over a CVT.
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