We assemble a children's electric ATV with our own hands. We assemble an ATV homemade product from an oka car Do-it-yourself steering gear of an ATV
Quite a lot of hunters, fishermen, and just lovers of outdoor activities dream of their ATV. But the prices even for used equipment are too expensive for most, not to mention new equipment. Do not despair, because today we will learn how to make an ATV with our own hands! It is an excellent vehicle for household needs, for transporting trailers, with high maneuverability due to a short wheelbase, as well as easy to operate. But right away we want to say that it will take a lot of time to make a homemade ATV. As practice shows, a project can take from 6 to 12 months on average.
Preparatory stage
So let's get started. Prepare your tools and equipment first. It will take a lot of welding work, for which manual arc welding is quite suitable. Choose electrodes for welding critical and vibration-loaded structures, which will be the ATV frame. By the way, this very frame can be cooked with your own hands from ordinary water pipes. These are easy to find at the nearest scrap metal reception, or metal warehouse. Choose a pipe diameter from 25 to 32mm, and the wall thickness should be around 3mm. To bend such pipes, it is desirable to have a pipe bender, but if it is not there, then you can also manually bend the pipes for the frame frame using a lever, heating the desired bend with a gas burner, or better with a gas-oxygen torch.
Selection of main parts
The next step will be the selection of the necessary parts in the first place, namely:
- engine
- wheels
- shock absorbers
- rear axle
If you want to build a simple lightweight quadric with a drive only to the rear axle, then it is preferable to choose an engine from a motorcycle of an average cubic capacity, from 250 cubic meters and above. Depending on the construction budget, this can be almost any motor from a Soviet motorcycle, preferably with a chain drive, due to which it will be quite easy to make a rear axle drive. The axle can be made from a structural steel tube. In the center, weld the flanges for attaching the driven star and disc brake, and on the sides, install wheel bearings from the car, having previously pressed them into the housings made in advance.
The housings are used to fasten the complete axle to the pendulum. The swingarm can be left as standard by further strengthening it and making a new mount for the disc brake caliper. Also, do not forget to make the brake hose mounts along the swingarm.
Our next task is the choice of wheels. And the ideal option not only in terms of accessibility, but also in size will be the wheels from the Oka. The main feature is that such stamped discs are very light, will perfectly fit into the proportions of a home-made ATV, and most importantly, rubber from factory ATVs is perfect for them, which will significantly improve cross-country ability. How it looks can be seen below:
Donor selection for a new frame
How to make an ATV even easier to manufacture? You can simply use a donor frame, for example, from the Ural motorcycle by welding the rear axle to the standard swingarm and just slightly change the front suspension! The thick frame of the Urals is made of good steel and has an excellent margin of safety. And an engine with a high torque is just right for such a purpose. As for the gearbox, it is better to use it from the Dnepr motorcycle. It is designed for good loads, is characterized by precise gear changes, and the most important thing is the presence of a reverse speed, which is an indispensable function of a full-fledged ATV. Photo example of a homemade ATV from the Urals below:
Steering
Do-it-yourself ATV assembly is not an easy task. And, perhaps, the most difficult thing is to make the steering. To do this, first weld the frame of the front of the ATV, then you will need steering knuckles from the car, for example from the Niva, but any others will do. Then you need to build the suspension arms. Pay special attention to the design of the attachment of the levers, since they are coupled with the frame, heavy loads arise, so additional stiffeners will not be superfluous. Levers are usually bolted through silent blocks. This is a rubber-to-metal hinge that is an indispensable link in the suspension. It dampens wheel vibrations, preventing vibration from being transmitted to the frame. Levers can be made according to these drawings.
Go ahead. What is the front suspension without shock absorbers? Here you can apply 4 motorcycle shock absorbers, one for each arm in the front, and two for the swingarm to shock the rear axle. Rear shock absorbers from Izh are suitable, but if you are ready to fork out for gas-oil with pumping, then this will give you the opportunity to adjust the suspension to road conditions, which is very handy for such equipment as an ATV!
Four-wheel drive and car engine
How do you create a 4-wheel drive ATV yourself? Above, we have considered the simplest option. But an option is possible not only with an engine from a motorcycle, but also with a car engine! And then we will tell you how to make an ATV with an Oka engine. In the case of an all-wheel drive ATV with a car engine, things are much more serious. Here it is no longer possible to use a motorcycle frame as a basis; it will have to be welded completely from scratch for a car engine. By the way, it can be not only from Oka, but also any other, depending on your desires and capabilities. Don't forget about the liquid cooling system right away. Calculate the frame design so that the radiator and fan are located in a protected area from forest branches. The engine with the gearbox should be mounted along the frame so that the drive shaft from the gearbox is directly directed to the rear axle. To distribute the rotation of the wheels to each wheel, you will need 2 identical axles, for example, from the Zhiguli. But for installation you have to shorten them. To increase the cross-country ability, if desired, a lowering chain reducer can be made, combining with a standard gearbox. In this case, the driving gear should be slightly smaller than the driven one. By simple calculations of the ratio of the diameters of these gears, you can find out by how much the maximum speed will decrease and the thrust will increase. If the ATV is not planned to be used for driving on public roads, then this will be a very significant technical solution.
Increased functionality
Now that the frame and chassis are assembled and the engine is installed, you need to think about the secondary structures that will make the technique practical. The fuel tank will fit well from a Ural motorcycle. Its impressive capacity will be enough even for a car engine. An important modification will be the snorkel installation. Since the engine is located quite low in the frame, the air filter also draws air from the bottom accordingly. To prevent water from getting into it when overcoming the fords, it is highly recommended to do this. The exhaust system also needs to be completely redone, with the exhaust gas outlet at a fairly high level so that water does not get inside either. Also, for an ATV you need a large wide seat, moving the body weight, it will be possible to achieve better control while driving. Aluminum sheet metal can be used for underbody protection to protect the front suspension arms and engine. A winch installed in the front will not be superfluous in the forest. Car fog lights can be used to illuminate the road.
Work on the appearance
In conclusion, you need a body to get a proper ATV look and feel. To do this, you will need ED-20 epoxy and fiberglass. These components can be purchased at a hardware store or hardware store.
To give this shape, first you need to cut out a blank from dense foam, which is also sold in large hardware stores in the form of 1 m2 plates, which is very convenient for creating such projects. Then fiberglass is applied in several layers, while each layer is coated with resin. The more layers, the stronger the case. Do not forget about the metal fasteners, which must be inserted between the layers, in the future for which the body will be attached to the ATV frame. After drying, it can be primed, sanded and painted. This fiberglass body is lightweight and very durable.
With a serious approach to business, such an ATV will be little inferior to the factory one, and in terms of assembly costs, it turns out to be many times cheaper. Despite the fact that you can assemble such a thing for yourself and get a lot of driving pleasure.
At first glance, it may seem that assembling a homemade ATV is not an easy task. In fact, everything is much easier than it sounds, with the necessary parts and tools. An off-road vehicle of this type is usually constructed from parts found on any unused motorcycle that is in decent working order.
Required set of tools
To assemble the device with your own hands, you may need the following tools:
Welding machine.
Bulgarian.
A good set of box and socket wrenches.
Other small tools like pliers and screwdrivers.
To assemble an ATV, you will need a small room with good lighting and heating. If you assemble in the summer, you can sit under a canopy.
Engine and transmission
Engines from Soviet-made motorcycles such as "Ural" or "Dnepr" are suitable as a power unit for a home-made all-terrain vehicle. For lighter and more maneuverable vehicles, you can use units from motorcycles like "Java" or "IZH", which were equipped with single-cylinder two-stroke engines.
To simplify the design of the future ATV, together with the engine, it is better to use the same transmission and drive with which they were originally equipped. To construct a car with four-wheel drive, you will need to install an additional gearbox. This is extremely rarely used in home-made devices, since it will be difficult to implement an additional unit without a sharp addition in weight at home.
Frame and suspension
The frame for a homemade apparatus is usually made by yourself from scratch. You can use blanks from an old motorcycle as material for the frame. The pipes from which they are made are lightweight and have the necessary strength and flexibility. As a last resort, you can choose the material yourself. Here the main parameter will be weight. Excessively thick tubes or profiles will make the ATV very heavy and overwhelming for fast and agile riding.
As a suspension, you can use shock absorbers with springs from the same motorcycles. The suspension itself is made in the form of the letter "A", and is movably fixed to the frame. Shock absorbers and springs should be selected to support the weight of the future machine and provide a smooth ride with good control over bumps and holes.
Steering and wheels
The steering can be partially used by motorcycle, with the addition of two-wheel drives. The drive is carried out by adding levers and ball joints to the design, which can be borrowed from the car. The main task of the steering is precise and comfortable steering.
The wheels for an all-terrain vehicle are best used from a car, as they are wider and will increase the vehicle's cross-country ability. The diameter of the wheels must be calculated in such a way that the homemade ATV can develop sufficient speed and also has a harmonious appearance.
Body and electronics
To install attachments, a gas tank and controls, you can use a motorcycle frame, which is structurally connected to the ATV frame. In this case, special attention should be paid to the stability of the all-terrain vehicle, its appearance and the convenience of the driver's landing.
Do not forget about installing all the necessary lighting and outdoor alarms on a homemade ATV. The headlights, taillights, and direction indicators can all be used from the same bike from which everything else was taken.
See what a homemade ATV is in use!
The popularity of four-wheeled vehicles is growing steadily - nowadays on the roads almost every day we meet people rushing at high speed on roaring ATVs. This fun is not available to everyone. But the ATV can do it yourself.
Idea to build ATV in your hands and appears among many fans of auto-moto technology. And if you figure it out, then this is not a very bad option to occupy yourself with something interesting and, as a result, get your own personal unique ATV... Yes, and it will be much more convenient and enjoyable to ride it, since you yourself are its author and creator, and you also know how each of its units is built, which is important and very useful when repairing or modifying. First you need to decide on the type of ATV and its main dimensions. This will affect the design of the frame and suspension of your ATV.
Here is a translation of the manufacturing instructions homemade ATV, drawings and specifications
Introduction.
The main purpose of this guide is to provide you with the necessary specifications, material lists, calculations, drawings and all the necessary information material that you will need to constructing own ATV.
The compilers of the manual have tried to simplify this project as much as possible, but you will need basic knowledge in the field of technology and mechanics, as well as skills in working with hand tools and a welding machine.
Perhaps you will also be interested in making a homemade children's electric card - the description is on the link.
The materials used or changes in calculations are entirely your choice, you can use materials not recommended by us, but some others. However, you are solely responsible for the result. For example, the material we chose for the Main Frame in the drawing is 1 "x 1" square profile. 083. We have tested this material on several models and it has proven to be reliable and easy to work with.
We will show you step by step how to make a frame in your own garage without any special tools.
Frame.
The main detail is not only ATVs, and any technique - the main frame.
Frame specification:
Material: 1 "x 1" square profile. 083
Overall length: 50 inches
Overall height: 29 inches (landing level)
Overall height: 33 inches (handlebar level)
Wheelbase: 41 ``
Axle spacing: 27 inches
Axis tilt: 14 degrees
Front tires: 41 inches (from the outside edge of the tire to the outside edge of the other tire)
Rear tires: 44 inches (from the outside edge of the tire to the outside edge of the other tire)
Ground clearance: 7 inches (with 16-inch rear wheels)
Calculation of speed by the formula:
The total is 33.91 miles per hour, or about 54 kilometers per hour.
Drawing:
Note:
Main Frame - Main Frame
Swing Arm - swing arm for rear suspension
General view of the frame:
Materials:
Square profile:
9.75 meters - 1 "x 1" square profile. 083
Pipes:
1.22 meters - 1 "x .065
1.22 meters - 3/4 "x .065
0.3048 meters - 3/4 "x .125
0.915 Meters - 5/8 "x .125
0.61 Meters - 1/2 "x .083 6061 T6 Aluminum Tube
Rent:
0.61 meters - 1 "x 3/16"
0.915 meters - 1 1/4 "x 1/4"
0.61 meters - 5 "x 1/8" (This plate is needed to mount the engine and bearing hangers)
After you assemble and weld the metal profile, pipes and all the rest details ATV according to the diagram and attach to the wheel frame, you should get something of the type shown in the photo
You will also need spring dampers for the rear and front suspensions.
Engine:
Now you need to securely mount the engine to the frame. The engine is best used from a moped. After screwing it to the frame, connect the motor shaft to the gear on the rear axle with a simple chain drive. After that, bring all engine controls to the handlebars and secure the pedals and levers to your frame.
Body kit:
Body kit parts or ATV body the best and easiest way to make from fiberglass. After manufacturing on wooden or plasticine blanks, the elements of the aerodynamic body kit are adjusted relative to each other, polished and then painted in the desired color, after which they are already attached to the ATV frame. Ideas, as well as some ready-made elements, for example from a broken car (of course, if you have them available), options for an external body kit can be taken from any serial models.
Important:
Remember that in order to operate the ATV on public roads, you will need to register it with the traffic police, where it is necessary to register any vehicles with an engine over 50 cc and a maximum design speed of over 50 km / h. Therefore, if you do not want to register, we recommend not using engines with a volume of more than fifty cubic centimeters. We also strongly recommend that you remember about safety precautions: MANDATORY! wear at least a helmet.
Unfortunately, not every person has the opportunity to purchase an ATV in the store. All more or less interesting models are now quite expensive, and buying a supported ATV is always a certain risk. In this regard, many motorcycle enthusiasts advise to make a four-wheeled all-terrain vehicle with their own hands, using an engine and spare parts from some old Soviet motorcycle. Earlier, we have already told you about how to make an ATV from a Ural motorcycle. In today's article, we will talk about other donors that you can use if you decide to assemble an ATV with your own hands.
Why is it worth assembling an ATV with your own hands?
Assembling a four-wheeled all-terrain vehicle with your own hands definitely helps to solve several problems. The first reason people decide to make a homemade ATV is of course a small budget. If you analyze the market prices for ATVs, then you can understand that such vehicles can be considered almost a luxury. Prices for the simplest and low-power models start at 150 thousand rubles, for example, the Yamaha Blaster YFS200. In principle, such a single "quadric" will be enough, but the power will always be in short supply.
But models of ATVs with engines with a volume of 500-800 cm 3 will cost much more, about 500 thousand rubles. You can also consider Chinese models, such as the Russian manufacturer Stels, but they will have to be well monitored. New all-terrain vehicles of this brand will cost about 300-400 thousand rubles, but the engines are already much more interesting - 45-70 hp.
Nuances in the operation of a homemade "quadric"
If you definitely decided to make an ATV with your own hands, then you should know about the intricacies of its operation. Basically, if you need an all-terrain vehicle to ride in impassable places, where there have never been patrol cars, then there is probably nothing to worry about. You will have to face problems if you plan to drive even in small settlements, which are sometimes visited by patrol cars. Having caught you without documents for this vehicle, then with a probability of 99% they will take it away from you. The whole difficulty lies in registering a homemade ATV, because the traffic police will most likely refuse you. In an amicable way, you can register a homemade product, but it is extremely difficult to do this. Therefore, assembling a homemade ATV only makes sense if you operate it in some wilderness.
Decide on the choice
So how to make a do-it-yourself ATV? When creating a homemade ATV, we need to decide on a donor, that is, a motorcycle that will form the basis of our project. Old Soviet motorcycles are perfect for a four-wheeled all-terrain vehicle. From them we can borrow an engine with a gearbox, a frame, a steering wheel and, if desired, such details as a tank, a seat and other elements. Since we already had an article about a homemade ATV from the Ural motorcycle, in this review we will talk about how to make an ATV based on the IZH motorcycle.
For our purpose, almost all motorcycle models from the Izhevsk plant are suitable for us. The only thing that is important to understand is the engine power. Still, the end result will be a fairly heavy structure, so the best solution would be to use the latest models - IZH Jupiter 5 or IZH Planet 5. It makes no sense to consider more interesting models, like IZH Planet Sport, because it is quite difficult to find them, and if possible , it is better to restore them, because the motorcycle is quite rare and interesting. Let's move on to the main thing, how to make an ATV and what is needed for this.
Rear suspension
Once you have decided on a donor, in our case it is IZH Jupiter 5, you need to completely disassemble the motorcycle. After disassembling, we need a frame on which everything was held, including the engine. It is quite logical that in order to increase the reliability of the structure, the frame must be strengthened in several places.
Now it is necessary to weld the rear axle so that instead of a wheel, a bearing block with a chain drive can stand on the axle. An example, you can see in the photo. As a suspension, you can use ordinary shock absorbers from a motorcycle, and parts from an old Zhiguli car are suitable for the rear axle. You can go a more complicated way and install a monoshock, but then again you will have to look for spare parts from the car, for example, from the same Zhiguli or Oka.
Front suspension
Once the rear suspension is complete and in place, you can move on to the front of the bike, which is a little more complicated. In the case when we were dealing with the rear suspension, we had the opportunity to choose how much the shock absorber will be installed. When creating the front suspension, we only have one option - to use two shock absorbers.
Oka's car is perfect for the role of a donor for the front of the ATV. From it we need shock absorbers, swivel assemblies and a steering linkage. However, be prepared for the fact that the parts will still have to be changed - to weld on, saw off, saw off something. Also a good and simpler option would be to install a monoblock with fixed wheel surfaces. Then you don't have to look for a steering linkage, couplings, hinges and other spare parts.
A monoblock is a really simple option, because it literally takes an hour to install. The only drawback of this design of the front suspension is the heavier mechanism. The steering wheel will be slightly more difficult to turn than with a suspension with shock absorbers.
Engine
Many wondering how to make an ATV with their own hands, understand that it is worth starting with the engine. Indeed, the main detail in the future ATV is the engine. The final result, and the whole structure in general, depends on how powerful it will be. Of course, you can leave the engine from the donor's motorcycle, but in the end, the "quad" will not be as powerful. If you are a little more serious about creating an all-terrain vehicle, then installing a more powerful engine would be an excellent solution. We hope we have answered your question on how to make an ATV yourself.
I started working on my project about a year ago. I assembled my homemade ATV mainly after work and on weekends for 2-3 hours, no more.
And now, after 11 months, all the big work was completed (there were minor improvements in the form of electrics, an ignition switch and other little things) and I decided that the prototype was already ready for testing and the first photo session.
The engine for my brainchild was a used motor from the Oka. A two-cylinder, thirty-two strong unit, according to my calculations, should have done an excellent job with a light quadric.
The basis of the ATV was the old Oka
Spatial frame, welded from steel water pipes. The upper and lower pairs of spars are made of VGP-25 pipe (25x3.2 mm) for auxiliary elements (crossbars, struts, etc.), I decided to do with VGT-20 pipes.
All side members are bent on a pipe bender. I bent the lower spars in the horizontal plane, the upper ones in the vertical. I welded the mountings for the levers and shock absorbers right after the frame was made; I welded and adjusted everything else as it was assembled.
ATV drawing
The car is made according to the all-wheel drive scheme, but without a transfer case. This happened due to the fact that the Oka engine was able to unfold along the frame and direct the output shafts from the checkpoint directly to the front and rear axles. To reduce the horizontal angles of the longitudinal hinges, the power plant with the clutch and the box had to be shifted to the left (relative to the longitudinal axis of symmetry).
The homemade transmission is assembled from factory units from the domestic "classics" with some modifications. For example, to increase the torque from the gearbox from the Oka, the main gear pair was removed and replaced with a chain drive. Differential locks and reduced no.
Kinematic transmission diagram
An extended gear shift rod was made, with outlets on both sides of the gearbox. It has two fixed positions - one for shifting 1-2 gears, the second 3-4 and reverse.
Cross-axle gearboxes were made from the rear axles of the VAZ. The original axles were redesigned: the axle shafts were removed and replaced by the shafts with CV joints, which I borrowed from the front-wheel drive "classic" model. By the way, I used the same CV joints in the transmission as intermediate shafts.
Management is implemented as follows. The upper part is a lever and a shaft, the lower part is with steering rods, as in a car, but with one bipod. Initially, the steering wheel was used from the Minsk motorcycle, but later it was replaced by the Ural one, due to its great strength. The steering shaft of the upper part is made of a 20x3mm tube with a travel stop at the bottom.
The lower part of the shaft is inserted into the support bearing, the middle part is fixed in the bracket-sleeve. From steel sheet 8mm I made a T-shaped bipod. The bipod ears are bent down so that they are almost parallel to the rods.
The steering shaft is inserted and welded into a 20mm hole at the edge of the rack, and tapered holes are drilled in the ears for the ends of the steering rods and reinforced with welded washers.