4 Wheel drive lightwieght buggy

Baloo

Member
l may as well start this thread as l have started the biuld,
l dident particually want a 4 wheel drive buggy 2 wd would have been fine, l have a honda pilot and where that will go offroad never ceases to amaze me, l have come by a subaru justy which just happens to be 4 wheel drive, they also come as 2wd and if this one had been 2wd then the buggy would have been 2wd with out a doubt, but never look a gift horse in the mouth or some thing like that, so 4 wd it is, unless a 2wd gearbox falls in my lap and it might all change  ::)
one of the things l like about this justy is the cvt gearbox, rubber band drive like the old daff variomatics, well steelband really,  so you get a gear stick with basically 2 positions forward for forward and backward for backward, simple huh, but its the way it transmits its power to the ground that siuts an offroad buggy, they seem to bite more and get constant traction with no shifts to unsettle the grip, the pilot uses the same sort (ish) of drive
 the engine is a 3 cylinder 1200cc about 75 hp, most of the other components are also on the small side diff drive shafts etc all siutable for a light wieght buggy
the engine in the justy is mounted at the front with 2 drive shafts feeding the front wheels like a mini, but it also has another out put on the gearbox facing the rear and from here a prop runs to a diff mounted at the rear with another pair of drive shafts feeding the back wheels, this rear prop can be engaged and disengaged at will by pressing a button mounted on the gear stick, so its normally front drive with the rear brought in when required  :(
it would be better if the engine was mounted behind the seats diving the back wheels normally and the front switched in when wanted ? but reverseing the engine also reverses the drive  and l will end up going backwards  :)   so some more thinking to do on that bit

heres a pic of the drive train
justy001.jpg

as you can see it has subframes front and rear, this makes it nice and easy for fabricating the new chassis,

made a start today and stripped  most of the car down, pics to follow

Andy
 

Baloo

Member
heres a pic of what l think the buggy  l am going to biuld out of the justy is going to look like,
subarubuggy-1.jpg

well some thing like anyway, perhaps not so blingy for me, just army green would do for the paint work, just fancy a 2 seater for  change, the honda pilot l have is great but it would be nice to take a pal out for a spin now and then  :eek:, clearly this isent going to handle or jump like a pilot with its limited suspension travel
20090311-231603.jpg


but it should be reasonable offroad with its lightwieght and 4 wheel drive,



stripped the car down to a bare shell,
justyshell002-1.jpg


justyshell004.jpg


justy010.jpg


cut the roof off, flipped it upside down in the garage and started to make a jig that picks up with all the suspension points
rustyjusty020.jpg


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once l had all the bolt holes tagged l lifted it out cut the car into 3 bits and waved it goodbye on the back of the local scrap mans truck

justyjig005.jpg


justyjig006.jpg


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justyjig010.jpg


gave it a good wipe over with thinners and a quick coat of red oxide andl am now ready to start the chassis proper

justyjig036.jpg


thinking of using 14g 2" box for the chassis ?,  l am intending to make the chassis in the jig using all the bolt holes drilled and tapped and then lift the chassis out and bolt the subaru subframes straight on to it, maybe ,

heres the engine and box
justyjig042.jpg


justyjig045.jpg


what l like about the justy is every thing is pint sized and more fitting for a buggy like the axles
justyjig040.jpg


justyjig041.jpg


probally start the chassis over the weekend

Andy  
 

Baloo

Member
as l havent updated this for a while l may miss somthing here but l will let the pics do the explaing

justychassis003.jpg


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justyrollcageshape005.jpg
 

Baloo

Member
l have been hard at it, well perhaps not that hard but l have made progress, a bit anyway,  l started with the standard justy steering column, mounted it where l wanted it  and then decided that as it was non adjustable l could do better, so l did it all again with a toyota mr2 column this time, at least this one adjusts up and down, would have liked in and out as well but beggers cant be choosers,
steeringcolumn004.jpg


mounted the clocks in there as well, wiring dosent look to bad as its a carb motor

justy8001.jpg


started making up the "tranmission" tunnel, l have made it a little on the large side as l might have to run the exhaust down it as well as the water pipes if l go for a rear mounted radiator, the high tunnel also gave me somewhere to mount the auto gearchange

justy8003.jpg


next is the propshaft centre bearing mount, once that is sorted l think l will connect up the exhaust and fuel lines and then get it running and weed out all the wires l dont need

justy8007.jpg
 

Baloo

Member
managed to get another couple of hours on it tonight, l have re made the transmission tunnel a different shape, which meant re fitting the gear shifter, also made a fancy bracket for the hand brake lever to bolt to,
l might mount the radiator as in the pics below ( but facing the other way of course ) or l might mount it behind the seats l havent made my mind up on that one yet, just got the steering rack mounts and the exhaust to sort and then its time to fire it up l think

justy9006.jpg


justy9005.jpg


justy9003.jpg


justy9006-1.jpg
 
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