Dave's la(te)st buggy build...

Ok, some history first, I've attempted to build a buggy five times, and always given up due to lack of time and.or funds. I've asked Father Christmas for a Polaris RZR buggy for the last few years, but apparently he can't afford one. And lastly, I've drooled over the Ford EX Concept vehicle for many years too -



And recenty I found this Brazilian buggy, more of an ATV size but more of what I was thinking of in terms of inspiration...



So, last year I started looking for a cheap soft-top to be a winter project to try and create a buggy inspired by the above two photos, but more for the British climate, so retaining the windscreen and front soft-top roof section for some protection from showers...

Eventually I found a good donor from the one and only James Priestley (J999PRE on here) and he dropped it off for me -



Here it is on the drive with S200KYS in the background...

I then set about stripping it -





And in the meantime had a trip to Leeds to pick up a set of five Grand Vitara 16" alloys and had them shod with 235/70/16 Malatesta Camel tyres...

I then started on the rear suspension and transmission -



Rear lift done. The suspension lift is basic, I bought new front springs to go front and back with the fronts having a pair of my 1.5" spring spacers on top, just enough lift with the bigger tyres without getting into steering wobble / vagueness territory - KISS - Keep it Simple Stupid!



Rebuilt axle with a Lunchbox locker built into a VVT diff to correct the gearing for the bigger tyres, TrailGear shafts, new bearings, seals, SuperPro bushes. Monroe Adventure shocks with spacers / repositioners and shock guards, panhard rod, bump stop spacers and cones (most of these parts came from JimnyBits) and spring clamps holding the new front springs in place...



Radius Arms cleaned up, couple of coats of hammerite and then SuperPro bushes pulled in.



Even fitted my own bearings and collars this time with some seamless tube and a lump hammer.



And with the axle being repainted, it had to have a nice smiley face which will be visible from behind!



The Lunchbox Locker (same as a Lockright only cheaper) going in.

Lately I've been making a mount for the rear winch and battery -



A Black Raptor winch, again sourced from jimnyBits, with an Odyssey PC1200 battery cradle I had in the garage, mounted right at the back of the chassis for weight distribution, and so that it can be used to winch forwards and backwards - the rop will run forward through a couple of donut fairleads at either end of a seamless tube that goes under the passengers (Alan's!) seat and down the side of the engine, and to winch backwards you take a loop off the drum through a huge fairlead and use a snatch block in the loop of rope.

The mounting tray bolts through the chassis (no chassis mods! Been there, done that!) -





And due to the damage to both shock mounts on my S200KYS Jimny I also braced the shock mounts by fitting long bolts running through a 5mm steel bar brace.



From the back you can see the big fairlead (off a Warn 8274), the lovely tread pattern on the tyres, and the removed back.

That's as far as I've got so far, I was struck down ill at the end of last year and spent most of January in hospital recovering from pneumonia with some diabetic complications thrown in for good measure, so I've spent February recovering at home and am itching to get back to this project as soon as I feel fit and able enough...

... that said, this is a long-term project with no deadline, it'll be done as and when I have the time, inclination and funds

Speaking of funds... money is tight at the moment, particularly with Bits4Vits and ZookBOB being shut for January while I was ill, but I have already amassed a load of parts, so I figure my progress will be with what I've got already, so -

Finish the rear winch mount first.

For the front axle / suspension I have a pair of new front springs with spring spacers on the top, Monroe Adventure Grand Vitara (rear) shocks, shock guards, a new panhard rod, SuperPro bushes to go in the radius arms, a VVT diff and the rear diff that came out of the back to convert it into 26 splines to take some front TrailGear shafts that I've yet to save up for... And it'll need new bearings and seals for the rebuild of the transmission, so I'd better start scrimping for a bit!

I've a new pair of bucket seats to go in too...

Then it's onto modifying the bodywork to resemble a mix of the two inspirational photos above. more like the yellow one that the Ford EX...

Progress updates as things happem, but don't expect a fast build!

The eventual aim? A fun summer greenlaning vehicle, capable of driving most of the type pf 'lanes we already drive, but open top wind in your hair, flies in your teeth (hence keeping the windscreen!). It'll work out cheaper than a Polaris RZR and be more capable, much better ground clearance and a locker in the back

AND, fulfil one of my bucket list items of actually finishing a buggy project in my lifetime :lol:

Good stuff as always Dave, you'll get there mate.

sniper

That's going to be awesome!

Slow and steady wins the race Dave
I hope you see this one through till the end matey
Will be a very capable machine and a real head turner

Jack

:laugh:

I wondered how long before this turned up on here :silly:

Superb progress (especially considering the unexpected hospital excursion). Im really looking forwards to updates on this one...

The winch is a clever idea, also keen to see how it routes through to the front. What are these 'donuts' you speak of? Like a pillow block bearing, but for rope?