Whas going on guy/gals? Ok so here we go...
Fabricate a 1 or 2 seater tube chassis that resembles a jeep but smaller, approx 9ft long and 4 ft wide and no taller than 4.5 or 5 ft tall. I want it to have full independent suspension and completely operable 4WD.
Parts in Hand:
I have a donor 4 wheeler sitting in my garage. It's a 2004 Yamaha 350 Bruin 4x4 automatic, and I have access to multiple shops with all of the tools I need to complete the job. Thank God for friends that are into racing and dune buggies.
I need help decided what kind of tubing to use for the chassis. So far I have looked at 4130 Chromoly 1 1/2" O.D. 0.083 wall with 1.334 I.D. which is 1.256 lbs per foot and also at some Aluminum tubing with the same specs but lb/ft is like .357. There is a huge weight difference per foot. I am unsure what kind of tubing to use to keep it light weight but yet strong enough to uphol dduring a rollover. Also with me wanting to keep the body looking like a Jeep should I make the main frame out of Square tubing so it would be easier to attach a sheet metal body to it and make the rollcage out of round tubing? My idea was to make this chassis resemble the outer jeep body so if it does roll the replacement "body panels" would be easy to replace. I've never fabricated a full Chassis and roll cage by myself. I've made repairs to my buddies odyssey's before, actually we had to make a new roll cage for it but we made it a bolt on incase he wrecked it again. That in mind should I make the roll cage and chassis as one piece or a bolt on set up? I was hoping to keep the weight of this build around 400 lbs give or take a few. Another problem is with the shape of the motor I'm using I won't be able to front mount the engine without sacrificing leg room. I can handle making it a rear mounted project and extending the 4x4 drive shaft and such. The exact build specs for like the motor mount and such will have to wait til I get home and take some measure ments. Any and all advice/tips/ideas/or even constructive critism will be appreciated. Keep in mind that this first build will be a trial build so It won't have to be perfect but I would like to keep it rather nice for my little brother.
I'm using this as an excuse to make him a toy and help me decide how big to build my personal mini jeep. I want mine to be made out of a 2007 Polaris Sportsman 800 EFI and so on, but for now Thats what I'm working with. I actually am still in Afghanistan for a couple more months and I get home just before summer so I was hoping to start and finish this project before the summer is up. I have had, and still have, some time left to do research and finish drawing up my plans. I am still waiting on my 3D and bend tech pro program to be shipped to me so I can turn these paper drawings into something worth looking at.
I want to keep this Mini Jeep Buggy 2WD/4WD with all of the electrical components of the 4 wheeler ie Electric start, push button 4WD, low/high beams, winch, and Automatic shifter. I have read about a few builds where some guys did the same with a 2005 Sportsman 700 EFI but they just built a chassis that looked like every other buggy. I know it's possible and I have enough time once I get back home to work on this project. I know I forgot to put some information in here like the suspension modifications to the A-arms and 4x4 drive shafts to make them adapt to the wider vehicle width.
Alright so I laid out everything that I could remember off of the top of my head. I'll post more later when I have a chance to look over my build write up I have going.