72BajaBen 2 Seat Buggy Build

[72bajaben]

So I wanted to start a new thread for the 2 seat buggy frame I picked up. Its going to be its own project...so I figure why have this and my baja build mingling and confusing. So here it is...The 2 seat Buggy Build.

First of all, I never intend to have a 2nd project...much less a 2 seat buggy. But here I am. I have a family of 5, my oldest son being 20 now. He's getting ready to start his own buggy build. So a 2 seat buggy just doesn't quite fit in. But it was a smokin deal and I've already fallen in love with it. My you8nger kids are already calling dibs on it to drive to school. They are 4th and 6th grade. hahaha

So here it is, I got a 75% buggy project for a screaming deal.

002 # Rib
Frame
2 Bins full of parts
Fiberglass Body kit
Spun Tank
Seats and belt
The list goes one.

Here are some Pics.







And my plan is to run the good ole trusty T4 2.0L Bus motor. Which has been spruced up.


The project needs a few things. But its one hell of a jump start.

[72bajaben]

I sprayed the entire chassis down with Ospho, and its received a coat of rattle can black to help keep the rust down. This frame has been garage kept for a long time. I dont have space for it in my shop yet, so its under a tarp. Hopefully the Ospho and paint will keep the rust at bay.

After the Ospho treatment.


And Painted:


I also got a set of stock pedals and a steering box from a buddy.

Pedals going for a dip in Evapo-Rust.


And the steering box all cleaned up.


I also got a set of seats from a Honda...but they don't quite fit. So we will see what we can do about that. My buddy Dave hooked it up.

[72bajaben]

I dug out the old headers for the T4 and cleaned them up. I had to cut the old exhaust off. No big deal.


And here is an updated pic of the T4.

[Ol'fogasaurus]

Looks to be a good start. Side bars for safety, the cage and supports look good, a widened front beam and the 002 bus trans all are good things to have. The only thing I see that has to be done are floors .

4-seaters while they are OK but they can get noisy and there is a lot of additional weight and length there too.

Going to be fun to watch the build.

Lee

[72bajaben]

Hey Lee

I have full diamond plate floors for the 2 seater. So thats a bonus!

-Ben

[Ol'fogasaurus]

For some reason, the diamond plate floors doesn't surprise me. Are the diamonds on top or under the floor? It's been a while but if remember correctly the diamond pattern on top can get a bit slippery due to the smaller "hoof to metal" contact. Also, dirt doesn't slide off as easily.

Lee

Also, it can cause your tootsies to hang up on the raised area if your heels are in contact with the floor when you operate the pedals. One of the reasons to justify hanging pedals as your feet are not in contact with the floors except for maybe the "loud" pedal.

It's a funny situation as some people like the pattern up while some don't. There are also several other materials used for the floors which also have pluses and minuses by people. Some of it is what media you are driving in that can make the difference; for what it is worth, sand is one of them as the front wheels can throw it around and it collects on the floor, so some kind of mesh I've seem added in places or the whole area. A lot of yes and no here.

Lee

[Ol'fogasaurus]

Ben, if you wanted to, you could get an after market floor mounted pedal assy and easily convert it to hanging pedals.

Here are some pix of hanging pedals in a glass dune buggy.

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In this case there are bell cranks of sorts or the old style of bell crank involved.

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When I was looking at the brake and clutch system in the black buggy I mocked up the cheaper ones with the mount upside down and the master cylinders rotated (and depending on the size of the cylinder) they may have to be switched. I decided not to go this way but I still debate doing it this way at times. Got more complicated in ways and not so in other ways.

Lee

[72bajaben]

Right now stock pedals were free. Haha

[Ol'fogasaurus]

Right now stock pedals were free. Haha

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Electric power steering included.

You have a lot of very good (but $$$) options if you want to head in that direction.

I run a 6-rib bus trans and will use a hydraulic clutch setup in my black buggy. My blue buggy is a 6- rib bus trans with stock clutch cable. It works OK but they are prone to wear too (so is "juice" equipment too)

Lee

[72bajaben]

I got the header all cleaned up. If you guys haven't tried Evapo-Rust yet...you have to get a bucket. Its magical.

I didn't take a before Pic...but here is the after. All of the rust just melts away. Then I spray it down with Ospho.


I bought some rebuild parts and got the pedal cluster built. Still waiting on a boot and push rod. But its ready to go.cc


I also re built the shifter. New springs, lock out plate and a dip in Evapo-Rust and its looking pretty good. Its just a stock shifter but it will work fine.


This is something I have been working on for a few weeks while its been either too hot or raining too much to be outside. I scratch built a console/dash for the buggy.






I'm not ashamed to admit it took me 4 tries to get it to work the way I wanted it and to fit everything.


My plan is to weld it in the center of the windshield bar. I initially tried to plan it to have a radio in the dash...but there's no way it would fit. I'm running pretty much everything on a relay with thermal circuit breakers on the dash. Should work out pretty good I think.

[72bajaben]

No work updates. I'm waiting for the body of the baja to get moved out of the way in my shop so I can bring this is. Which should be in the next week or so.

But I did get new seats in for it.

[72bajaben]

So I was gathering pics for an update post....and it doesn't seem like a lot of progress, even though Ive done a ton of work. I have to continue to remind myself to document the progress.

My goal is to take this buggy riding Labor Day weekend. So time is ticking.

What I have gotten done.

Front and rear disk brake kits are installed. Front beam has been gone through and new LP shims and nuts and bolts and what not have been installed.

Front pitman arm has been modified for center steering. I will eventually go with a rack and pinion...but for now stock box is what I got. I've also built L and R tie-rods.



Engine and trans are installed.


My buddy Dave came over this past weekend and we built driver seat mounts and a new rear cage. The one that came on the buggy was designed for a T1...and the T4 didnt fit.



And by the grace of the fabrication gods....I ran out of mig wire and gas at the exact same time. Not sure how I pulled that off.

Shes coming along. Next is the passenger seat mounts, steering, electric and pedals.

[72bajaben]

So I got the exhaust welded up and mounted. I have to make sure nothing hits and I will mount the rubber hanger and call it done. Its not really the most ideal place...but its what I got right now.



Im going to make a more 90-ish dump for the exhaust.

The new rear cage is all painted up and mounted. Next Im going to mount the rear lights and license plate.



I have not welded the gat tank mounts in yet. But I'm pretty sure this is where its going to go.





Next is wir3ing and getting the engine running. Im getting closer and closer.

[72bajaben]

So I had a shop project this weekend. Ultimately went really well and man what a difference. If anyone out there is dealing with sand or dirt out in front of your shop...Stop it and go with asphalt millings.

18 yards covered about 35'x22' anywhere from 3" to 8-9" thick. My yard has a slope to it so it got pretty thick on the man door side.






I also got the dash tacked in. Im pretty sure that location is going to be good...but I want to get the shifter and steering wheel hard mounted before I fully weld it.



I got the gas tank installed and I built a custom ammo can mount. I copied the gas tank strap mounts. It was pretty easy.






Next goal is to try and get the motor running.

[Ol'fogasaurus]

On the dash, two opinions:

I would put the dash on top of the crosspiece. Easier to see your gauges when driving for one reason; not having to look down from looking forward. Also... assuming you were using digital gauges, they take longer to read and assimilate than "needle" gauges usually do. The difference may not be that long, but it could be too long in some circumstances.

Also, the switches would be easier to see also and easier to find the one you wanted to use/change at the time.

Two, if you change your shifter (a bit longer new handle for instance) you could have interference.

Lee