How to Build Off Road Buggies

Build a scaled-down or full size off-road buggy.

For the off-road enthusiast, few things are more exciting than hitting the sand dunes or remote dirt roads in a custom-built buggy. You can build a two-seat or four-seat buggy with parts from auto salvage yards and accessory outlets, or purchase a kit that includes a tube-steel frame, axles, steering components and the suspension. Those with welding expertise and fabricating equipment can design and build the frame, roll bars and mounts for the various components. An expert do-it-yourself enthusiast with mechanical skills can obtain a ready-made frame and build an off-road buggy.

Things You'll Need

• Tube-steel frame with roll bars
• Jack stands or wood blocks
• Auto mechanic’s tools
• Rear axle and differential
• Floor jacks
• Steering and suspension components
• Brake system and hand levers
• Nylon ties
• Transmission, linkage and floor-shifter
• Engine hoist
• Air-cooled engine and throttle components
• Coolers, lines and filters
• Lights, wiring and battery
• Seats belts and seats

Instructions

Steering, Suspension and Brakes

1. Support the tube-steel frame above the floor on jack stands or wood blocks. Roll the rear axle and differential into place under the rear of the frame using two floor jacks. Raise the jacks and bolt the rear axle to the mounts on the frame with U-bolts and lock nuts.

2. Bolt the steering arms, steering box and the steering column to the mounts at the front of the frame. Attach the front wheel-plates with spindles to the steering arms.

3. Install the master cylinder at the mount below the steering column. Install the drum brakes at each wheel and plumb the front brake lines to the master cylinder.

4. Install the dual brake levers for the rear wheels at the mounts between the front seat mounts. Connect brake cables between the levers and the corresponding rear brakes. Secure the loose sections of the cables to the frame with nylon ties.

5. Fit the front shocks into place between the shock towers and the mounts on the front axle. Fit the rear shocks into place at the shock towers and mounts at each end of the rear axle. Mount the front and rear wheels and off-road tires with locking lug nuts.

Transmission and Engine

1. Bolt the transmission to the mounts above the rear axle. Connect the drive shaft to the CV joints at the differential and the transmission.

2. Install the floor-shifter between the front seat mounts. Route the transmission linkage along the underside of the frame and connect the linkage to the floor-shifter.

3. Connect the arm of an engine hoist to the top of the air-cooled engine. Lower the engine into place at the rear of the frame. Align the engine and transmission. Bolt the engine to the motor mounts on the frame and the bell housing on the transmission.

4. Attach the oil cooler and transmission cooler to the mounts on the frame. Plumb the corresponding lines to the oil filter and the transmission. Connect the throttle linkage from the carburetor to the accelerator pedal. Bolt the tube-steel engine cage in place above the engine.

5. Install the fuel cell or gas tank at the mounts behind the seats. Install an in-line fuel filter and connect the fuel line between the cell or tank and the fuel pump on the engine.

Lights and Seats

1. Attach off-road lights at the top of the roll cage and the front of the buggy. Attach brake lights at the rear of the buggy.

2. Route a pair of wires from each light to a terminal bar you mount near the steering column. Route the brake-light wires to the brake-light switch at the base of the brake pedal. Connect a pair of wires between the terminal bar and a light switch you install at the driver’s compartment.

3. Secure a 12-volt battery in the battery box on the frame with a battery strap. Connect a ground wire between the negative terminal and a bolt on the frame. Connect the positive and negative battery cables to the appropriate terminals on the bus bar.

4. Bolt the metal stays for each seat belt to the mounts on the frame and the roll bar. Bolt the seats to the mounts on the frame.

5. Roll a floor jack under the differential and raise the rear of the buggy enough to remove the jack stands or wood blocks. Lower the rear of the buggy. Raise the front of the buggy with a floor jack, remove the stands or blocks and lower the front of the buggy.

Tips & Warnings

• Have the compression checked before purchasing a used engine.

• Test the brakes before taking the buggy off-road.

References

• Petersen’s 4Wheel & Off-Road; “Off-Road Rock Buggy Build”; Fred Williams; 2009
• Rorty Design: Buggy Building Photos