How to make a raptor buggy out of oki. Oki buggy is easy. "Zaporozhets" for buggy, ready-made version
Now 28-year-old car service worker Denis Kostomarkin cuts through the Tula off-road in a mini-SUV.
The idea to make a buggy with my own hands came to me when I read in "Sloboda" about a motorcycle enthusiast Dmitry Sytin, who assembled an ATV himself, ”says Denis Kostomarkin. - Although I haven't done such things before, but still I work in the service, I can do something ...
Denis had no heart for ATVs and tricycles - he liked 4-wheeled vehicles with a roof more. Denis bought an old "Oka" for 15 thousand rubles - and the rework began!
“The Oka was in such a state that it was simply unrealistic to drive it,” says Denis Kostomarkin. - On the same day, I ruffled her like a tuzik to a heating pad.
The stretcher and "engine" from the car, as well as the suspension and gearbox, went into action. In total, it took about six months to build the buggy, and the car enthusiast finished the work just a few days ago: he is already going to start a new job.
- Plans for the future - to sell the buggy for a hundred thousand, - Denis laughs. - Otherwise, my wife Julia does not allow me to start a new job until I deal with the old one. Also in the plans - to make from the car "Oka" something like a two-seater jeep, with good acoustics and without a roof. It will be something like a golf car, like in foreign films.
Tulyak Denis Kostomarkin made his buggy from Oka in just six months.
BODY assembled from pipes, to which the lining was welded and painted.
PRICE: 5000 rubles.
WHEELS Dunlop stamps were removed from the ATV, the discs were cut for them, inserting an additional strip of metal.
PRICE: 2000 rubles.
AIR INTAKE serves to cool the engine, which is located behind the driver of the buggy.
SEAT driver removed from the car "Oka".
 | STEERING WHEEL the buggy was previously installed on a VAZ-2108 car. DASHBOARD- from the car "VAZ-2106". |
| TANK volume of 14 liters was borrowed from the motor scooter "Ant". |
| ENGINE took from the car "Oka", went through, put new pistons, rings and so on. PRICE: 6000 rubles. |
| MUFFLER I got the "Prosport" brand for free, a mesh was welded into it so that it worked quieter. |
| Mirrors rear view removed from an old scooter. |
| FOG LIGHTS, for which the brackets are made, are borrowed from the Toyota Camry. |
| SHOCK ABSORBERS used to stand on a Ural motorcycle. PRICE: 2000 rubles. |
OUR REFERENCE
Buggy(English buggy - convertible, light stroller). Initially - a sports carriage, a phaeton in equestrian sports. Now used for the name of an SUV for driving on sand. For the first time, buggies appeared in the 50s of the last century in the United States.
TECHNICAL SPECIFICATIONS BUGGY
Engine power: 36 HP
Engine displacement: 630 cc cm
Maximum speed: 100 km / h
Fuel consumption per 100 km: 6 liters
Tank volume: 14 liters
Consumed fuel: А-92
Drive: rear
Ground clearance: 30 cm
Dear Readers! Have you assembled a car from available tools, painted your car entirely, or made a cool exterior / interior tuning? Call and tell us about it by phone 23-55-99. Heading Leader Sergey BIRYUK.
If you decide to make a buggy with your own hands, you should know that there are two types of drawings: sports (racing) and tourist. When assembling the structure, do not forget that certain proportions must be observed, the parts must correspond to one another in size, weight, load, etc. Self-assembled machine should be light (about 300 kg).
The racing model must have a reinforced tube frame. A secure frame is required to protect the driver in the event of collisions or overturns at difficult distances. Such a car is made for one. The tourist buggy "dresses" in the body and has two seats.
What tool do we need
Before you start assembling at home, you need to prepare everything you need. You will need a set of tools in your work:
Welding(for the initial setting of the frame elements and the final welding of the pipes). Remember! During welding, metal stress arises. Therefore, make sure that the frame does not lead.
Bulgarian(pipes will need to be cut, and the edges will need to be leveled for welding).
Pipe bender(they are different both in price and in the amount of work that they can perform: manual, manual hydraulic, electro-hydraulic, electric). The pipes will have to be bent in different places, according to the drawing.
Attention!When buying a pipe bender, ask what diameter and thickness of pipes it can work with, what is the maximum bending angle and the accuracy of the bending angle.
Drill.
Bars and trims of boards(for raising or fixing various elements during construction).
Milling machine.
Metal crown.
Frame material:
Pipes(about 50 m of pipe, diameter 40 mm, wall thickness 3 mm). Pipes can be seam or seamless.
What we take as a basis
You can assemble the buggy yourself, taking as a basis the supporting frame of a motorcycle, "Oka", "Zaporozhets", "Niva" or VAZ. You need a body, frame, wheels, fuel tank, engine, brake system, shock absorber, exhaust pipe, air filter, steering wheel (can be taken from the racing kart), seat (preferably equipped with a headrest). This is far from full list everything you need.
V homemade model the buggy will not have a hood, trunk, doors. Windshield you will be replaced by a metal fine mesh.
Attention! Motor and fuel tank separated from the driver's seat by a partition made of refractory material. On the right side of the driver, a fire extinguisher is fixed (one branch pipe is directed towards the engine, the second towards the driver). The fire protection must be triggered from both sides (from the two levers).
Motorcycle buggy
If we take an old motorcycle IZH or Ural as a basis, then the assembly can result in a compact buggy of 300 kg, which can travel on off-road at a speed of 80 km / h. To assemble a buggy, you need a motorcycle engine (although this is a somewhat noisy option) and parts from a small car.
"Oka" is a good donor for a buggy
Oka is a very profitable buggy donor. Oka engine with liquid cooled, and therefore protected from overheating, the hubs are lightweight, the steering rack with a sufficient margin of safety. The braking system and shock absorbers from "Oka" are suitable for your buggy.
Attention!When disassembling the car into parts for a buggy, do not forget to keep the certificate of deregistration.
The Oka seat is only suitable for extreme sports (it's too hard). It is best to look for a seat with good lateral support during disassembly. At the same time, we must not forget about the headrest - this is the protection of your cervical vertebrae during off-road driving. The Oka-based buggy is characterized by high cross-country ability.
"Zaporozhets" for buggy, ready-made version
If we take "Zaporozhets" as a basis, then it will turn out to be a ready-made rear-engined model. The motor must be secured backwards (this will improve cooling and evenly distribute the weight along the axles). The differential will have to be flipped (swap the right and left sides). Redesign the gearshift drive (since the gearbox stem turns towards the rear bumper from the driver - and this complicates the linkage system).
Make a buggy from a VAZ
If you are afraid of problems with electronics, then it is better to take a carburetor VAZ as a basis. The motor, as in all buggies, is attached to the rear of the driver. Front axle shafts and VAZ hubs are used to drive the rear wheels. The axle shafts are attached to the trimmed bridge from the VAZ 2106.
Trunnions on rear axle fixed without the ability to rotate. And the front ones are like a car. The differential is blocked (for uniform transmission to the axles). If you take the front struts with springs from the 41st "Moskvich", then the stiffness of the rear suspension will increase. The upper part of the buggy frame will need to be welded from seamless water pipes (section 30 - 50 mm).
Buggy based on "Niva"
If you are going to use the buggy as a transport for fishing or in the forest, then you can take the "Niva" as a basis. On the basis of "Niva" you can build an all-wheel drive buggy. Both front suspensions from the "Niva" are taken as a suspension (the entire front suspension assembly weighs 130 kg). On overcooked disks from "Niva" they put Uaz tires. To increase travel, the suspension arms can be lengthened as much as possible (the track can be increased to 1550 mm).
Choosing a suspension
Independent suspension is a great option for a buggy. The levers are suitable longitudinal and transverse (you can take the front suspension from Japanese cars). This is a triangular lever: one side of it is attached across the machine through one silent block, and the other serves as a jib that takes over the load. On sports buggies it is recommended to use a single trailing arm suspension. This option is the simplest and easiest. With such a suspension, body roll will be minimized, and the weight of the machine is evenly distributed.
Good to know! If you plan to drive buggies on public roads, you will have to put headlights, bumpers, direction indicators (just like on a regular car, so as not to violate traffic rules).
In an independent candle-type suspension, a spring acts as an elastic element, which moves along vertical guides at the ends of the bridge beam. If the buggy is on the driving wheels independent suspension then the cardan joint is used to transfer torque from the final drive to the wheels. The most commonly used cardan joint is with two joints. On simpler structures in the axle shafts, one cardan joint is placed.
Front
The front suspension of the buggy is best done in the form of the letter "A" on long wishbones... It is this design that gives a large travel to the wheels and allows you to change the angle of inclination of the spring with a shock absorber (thus adjusting the stiffness of the suspension).
When assembling the pendulum arm, pay attention to the material and quality of the welds, as this part is subject to very heavy loads. Levers count on the maximum width of the base of the letter "A" (this will extend the life of the silent blocks). The width of the lever must not interfere with the rotation of the wheel. The design flaw is that the stroke of the pin of the lower ball joint in its socket is limited (up or down, it will not be in the place where we would like).
Back
For the rear suspension of the buggy, we choose a trailing arm that keeps the wheel from shifting (the wheel on the cardan sits rigidly). True, there is one flaw: wheel camber changes for the worse.
To achieve stability in motion, variable values of the angle of inclination of the wheels are needed. The levers will allow movement in two planes. If there is such a suspension on the rear axle, then the front suspension can be any. If in such a suspension the swinging axis of the lever passes through the center of the semi-axle cardan, then there is no need to install a second cardan at the wheel hub.
My friend offered to make a buggy, real in the right way smile.gif After a little thought, I agreed to his provocation. A friend purchased 99.9% of parts on a buggy, and I helped with welding-ideas-tools with a room and, most importantly, a company (one cannot do it all alone)
So here is the uprooted motor with a box. Heart so to speak ...
Start. So, as usual, the soul demanded rational decisions, so a buggy from the Soviet magazine "Modelist Constructor" was taken as a basis, it was called AB-82, and had most of the spare parts from the kindest gear in the world with a motor, ZAZ 968, i.e. Zaporozhets.
For a while, we found tools, did a mega-cleaning in the garage and looked for a donor. The tools (the most necessary) were found You can work in the garage (cleaned up, made the lights, etc.) Purchased ZAZ 968, rear-engined red coupe.
So we drove the ghost around the city, it drives, it is alive. In the garage, they butchered it (there is no photo of butchering, apparently we were very keen on the process)
We arrived at the garage, cleaned up, made light, it seemed like decent, more or less working conditions came out ... We bought ordinary iron profiles at a metal warehouse, (profile pipe) And began to sculpt welding machine means ... Art
Art expanded, at first the bottom was welded, here the drawings were observed by 90%. The frame was made a little larger than in the drawings.
Somewhere in the process, a rear suspension appeared. These are native Zaporozhye levers with hubs, and on their own "ears", carefully opened in advance from the donor's body. There was an opportunity to move to my garage, which we did. Worked so that there was light, order and beauty, nothing happens for free.
As it was
How did it become
Pay attention to the high-tech technology for painting walls (they thought to make it lighter, like beauty and light are reflected) The technology is this, one paints chaotically in one place, the second in another, the paint suddenly ends (sellers are such sellers ... they promised that for the whole garage 10 layers is enough for a bucket .. but really ...) and this event is over))
The front arms and suspension were made.
The pipes of the rods are the rods from the rear suspension of the VAZ classics. With silent blocks.
Ears on the frame for homemade silent metal 2mm.
The ball mounts at the bottom are a piece of the VAZ front arm.
Ball vases of course.
Above, there is a releasable vase tip instead of a ball.
The bushing for adjusting the camber is welded into the upper arm (the bushing was made by the turner)
The turner also made a spacer for the upper ball-tip (they have different cones)
Initially, IZHP 4 shock absorbers were installed, but this is too weak an option.
Later they changed.
The rubber is still there to roll.
Suspension I must say was not welded from the bulldozer. The kinematics of the levers are measured in such a way that the contact patch of the tire with the road is always maximum. Checking the suspension travel. This is already a very interesting moment when the structure can be rolled at least somehow! Joy like 7 year olds.
Fiery heart, engine i.e. Trying on. The mountings for the motor and gearbox remained original, with minor modifications.
A general photo with a suspension and a homemade metal bucket 0.8 according to drawings from our wonderful Internet (what would we do without it ?!)
Again erotic fantasies on themes with a roof ... Design and engineering (from the word engineer or fig?))
Time has passed. We chose how beautiful it will be.
Space gravity. An intermediate, meaningless, cool snapshot.
By the way, here's the motor mounts closer. Just in case)
We began to make pedals, mounting tanks, cylinders. Alas, there are no high-quality photos of the process, either written or in between, like here. But the main thing is there is gas)) The steering rack is also fixed offhand. This moment is adjusted for a long time so that the balls in the steering rack are in a certain place relative to the suspension attachment lines. In short, what would you steer the car, and not she steered you over the bumps. Steering rack OKA (1111) Steering gimbals VAZ 2107, very comfortable, and for safety + Steering tips VAZ classic.
The first descents from the hill, the steering wheel is on a stick with electrical tape, there are no seats, there are no brakes, there is nothing ... Do not do this, it is dangerous for everything in general)))) Of course, the ocean of joy. Front wheels are normal, vaz, rear zaz (vazovskoe is a temporary dummy for a photo, really only zaz wheels per zaz hub)
Bottom. For it is dangerous to skate without him. Sheet metal, 0.8 in my opinion. Initially, it was fastened to self-tapping screws with a drill, but as practice has shown, they are not suitable for these purposes, they fall out from vibration, and are often cut off by the ground when jumping and so on. And then another mystery who will collect them with wheels ... Later, the bottom was welded with dots. By the way, from the start, the project was cooked with electrodes. And with the move to a new home, the machine was created only with a semiautomatic CO2 and a 0.8mm wire. It is more convenient, faster, lighter, there are a lot of advantages for this type of welding.
After the first trials, the hopes for compact lightweight shock absorbers disappeared. We put two of these on the side, it became better, we drove them for a while, but not that. By the way, out of the corner of your eye you can notice that there is a gas cable, clutch tanks, brakes, brake pipes and a high-quality steering rack. Such moments require a lot of thought and creativity, so they forgot about the photo campaign. On the floor of the buggy - linoleum)) Type was domesticated temporarily.
Nothing is more pleasing than a high assessment of the results of the creation of one's own hands and personal achievements. Automobile sport is not only a competition for the professional qualities of race car drivers, teams of technical equipment and preparation for the performance of cars also enter a sharp struggle for the championship.
A special category of sports car racing is occupied by competitions using models of the "buggy" type. Having appeared in 1950 as a race on cars converted from worn-out and unusable "cars", this sport, even with the development of professional models, has not lost amateurs who create their exclusive samples of high-speed highly maneuverable all-terrain vehicles for cross-country competitions from serial products of the automotive industry. Often, to create their masterpieces, they use not used cars, but rather fresh versions with a high stock of still unused motor resources.
Recently, interest in this type of machine has increased not only from professional athletes. With the onset of warm days, walking variants of the "buggy" can increasingly be found not only in off-road conditions, but even in the city crowd. Not one fancy hatchback or an expensive crossover is able to provide the youth category of lovers of drive and adrenaline with that feeling of freedom and power over speed and space like a motorcycle, scooter, and now a "buggy". The appearance on the domestic market of factory serial samples for a wide category of users does not stop those who want to assemble their unique car from Zhiguli or Zaporozhets parts, practical and reliable buggies are obtained from Oka.
The pages of various sites and forums are full of these models, because to assemble a buggy from the Oka, an accessible list of equipment is required, and such a minimal list of the most basic parts is taken from the car that you can save money on purchasing a full-fledged car, limiting yourself to the main units and mechanisms from a second-hand automobile. In pursuit of minimizing costs, it is worth remembering the stingy, which pays twice, and not getting carried away with the acquisition of large components and assemblies of dubious quality.
For the version of the buggy with your own hands from the Oka, you can take, in addition to the engine and gearbox, parts of the suspension, it will fit well into the "interior" of your car dashboard domestic runabout. Some craftsmen manage to remake native VAZ (SeAZ) -1111 ("Oka") disks for wide tires, but it is less troublesome and much safer to use ATV wheels than to cut out its central part from the disk for subsequent welding of two into one.
With an abundance of ready-made drawings of design solutions and instructions on how to make a buggy out of the Oka, the beauty of "homemade" lies in the ability to experiment and customize the future car to suit your needs. But you should not get carried away with fantasizing and it is better to completely abandon excessive initiative in terms of ensuring security, distributing the masses and the principles of building governing bodies. These moments should be taken for special control of compliance with the quality and precision of manufacture.
Usually, as the easiest to assemble, single-seat designs with a rear engine are used. But as a walking version of the buggy from the Oka, two-seater cars look very attractive, because the power of a 33-strong motor is quite enough for traveling on sand and off-road not only for two pilots, but also for transporting their luggage, although an increase in linear dimensions will require additional reinforcement of the structure body frame.
The main skills that buggy assemblers must master are bending the base material for the car body frame. With patience, you can get a fairly respectable version of the buggy, capable not only of confirming the skill of the manufacturer, but also worthy of performing in the competition.
As a rule, having achieved the first successful results in the production of buggies from the Oka, the home-grown masters of the "garage auto industry" do not stop there. Thanks to the AvtoVAZ conveyor, which has produced a huge number of its various variants and modifications in 21 years of production of an inexpensive ultra-compact subcompact, the buggy's adherents have received a full supply of material for their hobby for many years of creativity.