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Author: Subject: My buggy build (Zephyr I)
jantie


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[*] posted on 4-7-2020 at 11:40 AM


:thumbup::thumbup::thumbup:

looking good..!!






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Jack.Oh


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[*] posted on 4-14-2020 at 11:14 AM


I now am trying to figure out how to hold everything square.
I made a fixture from things I had around the garage. It is lining up Ok.
I still need to trim the back of the rails a bit. The one on the right side is not angled correctly.

Zephyr 19.jpg - 64kB

I am hoping to finish up this week. Then I will need to figure out the fork.

Thanks for looking.




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Jack.Oh


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[*] posted on 4-20-2020 at 07:53 AM


Ok, here is more progress. I was unhappy with the way the fixture was holding the buggy parts. So, I decided to change a few things... Now, I did not want to spend money on a fixture that probably will only be used one time. :rolleyes: (we'll see) Anyway, here is what I came up with after scavenging some parts which have been laying around my garage and at work.


Fixture1.jpg - 54kB Fixture2.jpg - 54kB Fixture3.jpg - 34kB




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Jack.Oh


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[*] posted on 4-20-2020 at 07:57 AM


Here are the parts loaded into the fixture.


Zephyr 22.jpg - 46kB Zephyr 21.jpg - 45kB Zephyr 20.jpg - 39kB




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Jack.Oh


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[*] posted on 4-20-2020 at 08:01 AM


After welding the side rails, I borrowed the seat from my other buggy just to see what it would look like.


Zephyr 23.jpg - 45kB

Zephyr 24.jpg - 38kB




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eric67m


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[*] posted on 4-20-2020 at 02:05 PM


Looking good. It's fun to see your progress and what you use for holding everything in place. Keep your fixtures or good photos for when you build your next one. N+1



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rtz


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[*] posted on 4-20-2020 at 07:27 PM


Looks awesome. I like the look of the wide axle and those tires.

Where did you source the wheels or what is their standard application?




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Jack.Oh


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[*] posted on 4-21-2020 at 06:34 AM


Thanks all for the encouraging words.

The rims are....
https://www.bmikarts.com/8-x-7-Rim-with-Bead-Lock-_p_10510.h...

The bearings....
https://www.ebay.com/itm/6304LLUNR-NTN-Standard-Small-Ball-B...

If you are willing to go with a 25mm or a 3/4" axle you can find the bearings for less. I really wanted to stay in the kite buggy "standard".
Which seems to be 20mm axles.

The tires are....
Carlisle Straight Rib Lawn & Garden Tire - 18X9.50-8 4 ply...
I think I got them on Amazon.

It was really difficult to put the tires on the rims. I had help from my sons (Kyle and Tyler). I could not have done it alone.





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Jack.Oh


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[*] posted on 4-21-2020 at 09:35 AM


Quote: Originally posted by rtz  
Looks awesome. I like the look of the wide axle and those tires.

Where did you source the wheels or what is their standard application?


It's funny you should mention that. Because the tire size is what started this whole build. I saw Claude's VTT Black Widow at the Wildwood Buggy Bash last fall with this size tires on it. The tires were mounted on a wider rim, I think the rims were an 8 x 8 Sysmic. Well to buy Sysmic was a lot of $$$ with shipping. Then I found these rims, I was originally thinking of putting them on my custom Flexi wide axle.

(http://www.powerkiteforum.com/viewthread.php?tid=36640)

But the buggy would have been too high up. So, I finished that build with Midi tires. And made the decision to build from scratch.




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jantie


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[*] posted on 4-21-2020 at 11:09 PM


Looking very good so far.
When you finished it, how are you going to treat it?
Galvanized or powder coating or....?






to visit my Youtube-channel.


kite-movies about me on other channels:
kitebuggy-tandem movie
duobuggy movie
side-ride + tandem buggy







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Jack.Oh


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[*] posted on 4-22-2020 at 06:36 AM


Quote: Originally posted by jantie  
Looking very good so far.
When you finished it, how are you going to treat it?
Galvanized or powder coating or....?


Thank you...

As far as finishing I am not sure yet. I was thinking of primer and paint.
One of the main reasons for paint is... I am not sure if I will need to change some thing, make any adjustments, new parts, or modify existing parts.
So, paint will make it easy to strip / repaint and mach parts.




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eric67m


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[*] posted on 4-22-2020 at 09:46 AM


This exists. I have never used it. It is a generic version of "steel-it" a weld through paint.

https://www.amazon.com/Stainless-Steel-Protective-Spray-Pain...




Flying A mixed quiver of Flysurfer Peak kites.

Rollin in the Popeye The Welder Playa buggy.
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Jack.Oh


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[*] posted on 4-27-2020 at 05:37 AM


Quote: Originally posted by eric67m  
This exists. I have never used it. It is a generic version of "steel-it" a weld through paint.

https://www.amazon.com/Stainless-Steel-Protective-Spray-Pain...


Thanks for the link. I think this might be a good option.




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Jack.Oh


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[*] posted on 4-27-2020 at 05:50 AM


Ok, started working on the front fork. I did not have a final design in mind. So, I did not put anything on paper, just started working to see where it was going to end up. I knew I wanted some adjustment in the fork for trail and for the foot pegs. With that in mind here is what I have so far. It is only tacked together at the axle plate and at the foot peg plate, the rest is still loose. If anyone is interested, I can get some measurements and post them.


Zephyr 25.jpg - 45kB Zephyr 26.jpg - 48kB Zephyr 27.jpg - 55kB




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jantie


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[*] posted on 4-27-2020 at 07:16 AM


Nice...!!!!!!!!

Looking forward to the end result.







to visit my Youtube-channel.


kite-movies about me on other channels:
kitebuggy-tandem movie
duobuggy movie
side-ride + tandem buggy







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ColinW




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[*] posted on 4-27-2020 at 08:24 AM


I like the curved fork tube surrounding the axle mounting plates. Looks good and stiff for speed.
I am slowly cleaning my garage back to the corner where the welder is buried. I keep discovering little projects on the way. Even though I am going back to work, I hope to keep this project in sight.
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Jack.Oh


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[*] posted on 5-4-2020 at 06:51 AM


Ok here is this weeks progress.

I tacked the fork together. And I made a back rest. The back rest is not my design. I found a YouTube video by Popeye the Welder, the back rest turned out nice. Thank you Popeye for your contributions.

Zephyr 28.jpg - 41kB Zephyr 29.jpg - 40kB

So, then I put the seat on again and sat in it. It was really flexi... the side rails 1.25 tube .125 thick still really bouncy??? I could not let that go. I am a bigger guy, and it felt like it would not hold up with me riding in it. So, I made struts to stiffen the rails. At this point all is tacked into place and the buggy will stand on it's own, with out any supports.

Zephyr 30.jpg - 43kB Zephyr 31.jpg - 45kB Zephyr 32.jpg - 44kB

Things left to do..... Finish the foot pegs, finish welding, paint, make seat, make side rail covers, and bag.




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Jack.Oh


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[*] posted on 5-18-2020 at 09:44 AM


Foot pegs....


Zephyr 33.jpg - 28kB Zephyr 35.jpg - 30kB


I was hoping to finish all welding/grinding this weekend but I ran out of welding wire. Hoping to finish up in the next few weeks.

Also, I found this to use as padding..
https://www.zoro.com/tundra-pipe-ins-poly-1-18-in-id-6-ft-6x...

This insulation is 3/4" wall, the center is to size and it is more firm then the stuff at Home Depot.

Here is a side by side.


Zephyr 36.jpg - 43kB Zephyr 37.jpg - 22kB




US417
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3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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jantie


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[*] posted on 5-23-2020 at 10:10 AM


:thumbup::thumbup::thumbup:





to visit my Youtube-channel.


kite-movies about me on other channels:
kitebuggy-tandem movie
duobuggy movie
side-ride + tandem buggy







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Jack.Oh


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[*] posted on 7-22-2020 at 11:09 AM


OK, Jacks back......

It has been a while since I had any time to work on my buggy.
This week I finally got some time in.

Here is the long story... Finished the front fork.

Zephyr 43.jpg - 20kB If you notice, I put supports in in the middle. Once I did that I could not take the fork of the Swan Neck. The wall of the yolk was a bit taller then the bearing. Both on top and bottom. Here is a picture hopefully you can see what I mean. To get the fork off, I had to grind the top and bottom of the yolk.

Zephyr 39.jpg - 15kB

Now, I also noted that the bottom tube of the swan neck was a bit too long, about 4 inches.

Zephyr 38.jpg - 41kB

So, I ground the top and bottom of the yolk, shortened the bottom tube, and I added a sleeve in. The sleeve will, down the road, give me a place to tie / hook off an AQR. Here are a couple pics.

Zephyr 40.jpg - 37kB Zephyr 41.jpg - 21kB Zephyr 42.jpg - 26kB




US417
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3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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Jack.Oh


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[*] posted on 7-22-2020 at 11:17 AM


Next up, I will be making some wheel spacers. As rtz pointed out they are needed and are not optional. And really it is not that much work to make them. Thanks for setting me on the right path.



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eric67m


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[*] posted on 7-22-2020 at 09:23 PM


I like your pierced bottom of the swan neck. I have had my rope slide off of the rod that it is tied around. Good thinking.



Flying A mixed quiver of Flysurfer Peak kites.

Rollin in the Popeye The Welder Playa buggy.
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[*] posted on 7-23-2020 at 09:44 AM


Completely agree with Eric - I've had to come up with several work around solutions to keep my AQR webbing from sliding off the stinger and this would be a nice solution.



Born-Kites:
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NasaStar-4 (2.5m, 4.0m, 5.5m, 7.0m)
NasaStar-3 (custom 3.2m)

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Peter Lynn BigFoot+ nose & tail; midsection VTT rail & seat kit; home-brewed AQR

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eric67m


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[*] posted on 7-23-2020 at 11:56 AM


This also means your swan neck needs to extend back underneath you. I don't believe I have space to fit a tube or a wedge section of a tube. Other people's buggies will vary...



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Jack.Oh


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[*] posted on 7-24-2020 at 06:17 AM


I have not used an AQR system. I am actually still getting comfortable with using a harness with my power kites. I have a homemade harness and a PL Divine. The swan neck extends about two inches into the seating area when the buggy is adjusted for me. That puts the thru hole just in front of me. I will put a grommet around the front area of the seat to allow for access. I know the object is to get as close to the release point as possible. Well if it dose not work having the sleeved hole there wont effect anything.



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3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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Windstruck


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[*] posted on 7-24-2020 at 07:35 AM


Quote: Originally posted by Jack.Oh  
I have not used an AQR system. I am actually still getting comfortable with using a harness with my power kites. I have a homemade harness and a PL Divine. The swan neck extends about two inches into the seating area when the buggy is adjusted for me. That puts the thru hole just in front of me. I will put a grommet around the front area of the seat to allow for access. I know the object is to get as close to the release point as possible. Well if it dose not work having the sleeved hole there wont effect anything.


The extra hole may come into play when attempting to set a PB. :evil:




Born-Kites:
RaceStar+ (3.0m, 5.0m, 7.0m, 14.0m)
RaceStar (9.0m, 11.0m)
NasaStar-4 (2.5m, 4.0m, 5.5m, 7.0m)
NasaStar-3 (custom 3.2m)

Buggy:
Peter Lynn BigFoot+ nose & tail; midsection VTT rail & seat kit; home-brewed AQR

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SWATK Member UT0003
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[*] posted on 7-24-2020 at 06:56 PM


Anyone else have a fetish for new tyres with spikes or just me ? Great build. :thumbup:
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Jack.Oh


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[*] posted on 8-5-2020 at 07:34 AM


Quote: Originally posted by Windstruck  
Quote: Originally posted by Jack.Oh  
I have not used an AQR system. I am actually still getting comfortable with using a harness with my power kites. I have a homemade harness and a PL Divine. The swan neck extends about two inches into the seating area when the buggy is adjusted for me. That puts the thru hole just in front of me. I will put a grommet around the front area of the seat to allow for access. I know the object is to get as close to the release point as possible. Well if it dose not work having the sleeved hole there wont effect anything.


The extra hole may come into play when attempting to set a PB. :evil:


And brown pants:lol:




US417
Flexifoil buggy
3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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Jack.Oh


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[*] posted on 8-5-2020 at 07:43 AM


Quote: Originally posted by RedSky  
Anyone else have a fetish for new tyres with spikes or just me ? Great build. :thumbup:


Time to make wheel spacers...

Look at them spikes .... :yes:
Zephyr 53.jpg - 38kB

Thanks!




US417
Flexifoil buggy
3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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Jack.Oh


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[*] posted on 8-5-2020 at 08:15 AM



Ok, I am sure that all of you people here know about wheel spacers.

This is just the next step to the build. I am using 1" steel tube /.083" wall, this was left over from a fork I made for my other buggy. (pic above)

First take the bearings out, setup a flat surface, place the wheel on it, and measure the hub. It measures 3.250".
Zephyr 45.jpg - 39kB Zephyr 46.jpg - 35kB Zephyr 47.jpg - 41kB

Next, setup the bearing, measure it and do some math.
Zephyr 48.jpg - 36kB Zephyr 49.jpg - 33kB
Hub - Bearing seat times two = Spacer length
3.250-(.450x2)=2.350

I do not have a mill or a lath so sawzall and a belt sander.
Zephyr 50.jpg - 48kB Zephyr 51.jpg - 33kB

Job Done!




US417
Flexifoil buggy
3m Flux, 4m Flux, 4m Skim, 5m Skydog, 6.5 Adam
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