How To Build A Off-road Buggy

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Last Updated on June 16, 2022

I know, building an off-road buggy sounds intimidating. But believe me, building an off-road buggy is easy. If you follow proper instructions, you will be building an off-road buggy in no time.

In this article, I am going to explain the steps following which you will be able to build your off-road buggy. So, stay tuned with the article and start building your off-road buggy.

How To Build A Off-road Buggy

Before moving on to the construction part, there are some things to consider like what will be the raw materials for building your buggy. This is highly recommended to go for the metal. There is also an option for going wood though. However, make sure that the metal is high-quality and durable.

Then, you can make a blueprint or scratch of the buggy following which you will be building the buggy. In this case, you may ask an expert for any kind of help.

After getting the scratch, you may get started. For this, you need to bring the required tools and materials. I am providing a tentative checklist below:

Necessary Tools:

  • Bench grinder and Angle grinder.
  • Welder, solid wire or flux core wire, welding gas, gloves, welding helmet.
  • Hack saw and reciprocating saw.
  • Wrenches, Welder’s square, hammer, Magnetic welding holder, clamps, sockets, Vise grips, Vise and steel brush.
  • Chain Breaker.
  • Tape Measure.

Required materials:

  • 20 feet of 1″ and t 50 feet of 3/4″ conduit. Make sure that it is metal. You will find them in 10 feet section.
  • 1″ square tubing of 5 feet.
  • Stratton motor and Briggs of 6HP.
  • 2 pieces 5/8″ black iron pipe of one foot, 0.25-inch steel of one-foot stock pieces and 6-inch bolts.
  • 1/4″ steel rod of 10 feet.
  • Unused steel off old lawnmowers from pressure washer base, wire mesh, nuts and bolts.
  • 1/8″ steel cable of 10 feet.
  • 145/70-6 Balloon Tire with Rim
  • 15 x 6.00-6 Super Turf Tire & Rim (1″ Bore)
  • 1″ Rear Axle
  • 1″ Steel 45″ long Live Axle
  • Torque Converter for Chain, 3/4″ Bore
  • Multi-patterned sprocket hub made from aluminum along with sprocket with 1″ Bore
  • Chain 5 feet
  • Chain master links.

After having all the mentioned tools and materials ready, now you are set to go. For starting the construction process, you should follow the scratch or blueprint that you got earlier. This will make your task easy. Your construction task can be divided into three parts. The frame, Rear End Assembly and Front End Assembly.

The Construction Process

  • Frame:

Trust me, this task is really very easy and simple. According to my, building frame is the easiest part of building an off-road buggy. For building the frame, look at your blueprint and go ahead. While building the frame, make sure that you are following the proper measurement and design.

However, if you use Conduit, then you may have to cut the conduit for fitting over another one.

  • Rear End Assembly:

Well, for assembling the rear end, at first, you have to slide the bearings on the axle. After that, you need to attach the bearing housing to the bearings. Then, you need to find out where the bearings are going to be fastened. You need to tack welded it on the built frame and then measure again.

Here, if you find that all the measurements are done accurately, then you can start welding. However, if the measurements are not accurate, you have to adjust it first and then start welding.

  • Front End Assembly:

Wait, I mentioned that you can use the unused steel. But this is not necessary at all. You may purchase it from the market. No worries. In fact, after-market products are really good to use. But, while attaching the spindles, you need to make sure that you have welded the rear assemblies on the frame carefully. Otherwise, it can be the reason for a great hassle.

You are done. You can go for test driving. You may face some problems as this is homemade. But after a while of going through some testing, I hope it should be fine.

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About the Author: Brian Silvestro

Brian Silvestro is the founder and chief editor of OffroadersArena. He spends his free time tending to his BMW iX SUV and explaining its merits to anyone who'll listen.

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