V6 Engine in to 2wd comp safari buggy project.

offroad 68

I have a self built 2 wheel drive buggy that I use in comp safari events, It has had quite a few different engine/transmission set ups in it and last year I raced it with a 2.0 toyota MR2 engine and manual box in it but was very over geared with off road tyres on it.
I have decided to put a V6 engine in it for the extra torque and am well on with the project in fact I hope to give it a run this weekend all being well. I build my vehicles very much on a budget and never spend money on bling of any sort (even paint Laughing

) this buggy is constantly under develpoment and only when it starts to win events outright will I think about smartening it up.
A few videos.
http://www.youtube.com/watch?v=e68Idpqoiwg
http://www.youtube.com/watch?v=tCb1jAIlMOg

To see the build up until one week ago look here link removed

offroad 68 · Posted: Wed Jan 12, 2011 8:24 pm Post subject:

I have since done some work (with the help of Tony a good friend of mine and my dad who is co driver in the buggy) on the loom to get rid of a lot of the not needed parts of the car loom, this went a lot better than I thought it might and got very lucky when fixing the damaged speedo sensor plug got rid of all 5 fault codes I had Smile

Today I have been fitting plastic boxes to the rear of the fire wall to put the ecu, fuse box and immobiliser in to keep them dry. I still have some work on the petrol tank to do, finish off the wiring and finish the clutch pipe off along with a few other odds and ends, then see how it goes Very Happy

Kitesurf · Posted: Wed Jan 12, 2011 11:02 pm Post subject:

Awesome!

Who says that IFS doesn't give enough ground clearance. Nice buggy.

Diesel Destroyer · Posted: Thu Jan 13, 2011 8:04 am Post subject:

Was quick before Lee.. should be fab when its finished Cool

baloo · Posted: Thu Jan 13, 2011 6:14 pm Post subject:

Lee
do you have some pics of when i was a rolling chassis/cage in your work shop, they show more of how it is constructed

offroad 68 · Posted: Thu Jan 13, 2011 7:32 pm Post subject:

Hi Baloo, I will post some more pictures.
Done more work on it today, the wiring is almost all done now ( thanks again to Tony) I have done work on the petrol tank so it now takes the peugeot V6 pump, sorted out the accelerator cable which is fly by wire, done the clutch pipe and bled it. Just need to re fit the tank, fire wall, seats and harnesses etc then give it a run, If it does not go like stink I will set fire to it. not putting any more engines in it again

Diesel Destroyer · Posted: Fri Jan 14, 2011 7:58 am Post subject:

Dont set it on fire Lee.. Laughing

Your build is very impressive and it handles and drives very well..

I understand your frustrations.. but Im sure this new engine will transform it.

I look forward to seeing it in first place Wink

offroad 68 · Posted: Fri Jan 14, 2011 5:59 pm Post subject:

I had a quick drive down the road in it today and it goes very well, lots of torque and very smooth with no flat spots which is exactly what is needed for a 2 wheel drive off roader.
When I got back to the workshop I was revving it up to get the temp up to check the fans were kicking in, The fans kicked in and at the same time a hissing noise started, The noise was air blowing out of what looks like some sort of diaphram in the inlet manifold (see pic) This did not happen the other day when I got the fans to kick in. Any ideas??

The wife keeps on asking where all the sandwich box's have gone Embarassed

muddyoffroader · Posted: Sat Jan 15, 2011 1:35 pm Post subject:

Take it down the track lee give it a going on the bottom end!

offroad 68 · Posted: Sun Jan 16, 2011 8:51 pm Post subject:

I am planning on taking it up to a motocross track tomorrow to give it a run, I will have a closer look at that valve first though.

baloo · Posted: Sun Jan 16, 2011 9:00 pm Post subject:

offroad 68 · Posted: Sun Jan 16, 2011 9:13 pm Post subject:

baloo · Posted: Mon Jan 17, 2011 7:50 pm Post subject:

well how did it go Lee ? wheres the pics Laughing

offroad 68 · Posted: Mon Jan 17, 2011 10:37 pm Post subject:

http://www.youtube.com/user/tonybkr3#p/a/u/0/yb-gTRkE0oA
Lots better, much more torque, I have the broken in half drive shaft to prove it Evil or Very Mad

The long shaft I had made last year that solved my problems broke right in the middle, it is around 600mm long and looks like it might be "wapping" if that is the correct word, about a bit in the center which as caused it to brake. Going to make another one about 3mm bigger in the center tapering down to the ends with a rubber damper on it like the standard shafts have.
Thanks again to Tony for the help with this project and for filming and putting the video together.
Lee.

baloo · Posted: Tue Jan 18, 2011 7:21 am Post subject:

Nice Lee done

certainly looks like it goes better, are you happy with the engine power ?,
you seemed to be airborne more than usual

Andy

offroad 68 · Posted: Tue Jan 18, 2011 8:15 am Post subject:

Yes very happy with the power, loads of torque, I had it pulling up as steep hill in second gear at 1700 RPM

I just hope it is not going to restart more drive shaft problems.

The problem I thought I had with the inlet pressure relief valve was not a problem, it turns out it was the cooling fan blowing air in that area which made it feel like it was coming out of that valve. I should have noticed that it was only doing it when the fans were running Embarassed

Got to wait 2 weeks now for a new shaft to be made Crying or Very sad

Diesel Destroyer · Posted: Tue Jan 18, 2011 8:18 am Post subject:

Looking good Lee..

Wink

offroad 68 · Posted: Tue Jan 18, 2011 6:05 pm Post subject:

Now that I have some torque to play with I will have to learn how to use the accelerator properly, watching the video it looks like it is either on or off. We even washed it when we got back to the workshop Wink

offroad 68 · Posted: Sun Jan 23, 2011 7:01 pm Post subject:

Not happy:evil: . I can partly excuse the long shaft breaking and sort of see why they made it so thin but I would think it would have been better a bit thicker in the middle because of wapping but I agreed to pay the full amount for a new one.
On saturday I was looking at the cv cup that was a torque shaft that the same company shortened and re splined for me, and I noticed that the shaft has started to twist on the inside edge of the splines Shocked

so no doubt this would have broken soon any way. The the cv cup shaft on the other side is the same size and same splines but has not been modified and that is fine.

With a normal open diff (which it has) both drive shafts will see the same amount of load no matter which wheel is getting a hammering but I spoke to the guy who did the work for me and he was saying anything he could to try and move the blame off him all of it bull s**t. I will be taking it to him tomorrow and I can just see me falling out with him over it.

So a standard Mr2 drive shaft with standard peugeot cv cup one side which is all fine and on the other side around £400 of work done by a company who say they know what they are doing but the shaft has broken in half and the splined shaft on the re splined cv cup is twisted! I will see how tomorrow goes and if need be name and shame!

baloo · Posted: Mon Jan 24, 2011 5:49 pm Post subject:

so hows the driveshaft saga then ?

offroad 68 · Posted: Mon Jan 24, 2011 6:34 pm Post subject:

Well it looks like it has been heat treated correctly which is worrying because it will see more shock load in events than it got last week and it had the smaller tyres on Crying or Very sad

Not sure what to do now.

4x4rick · Posted: Mon Jan 24, 2011 7:42 pm Post subject:

offroad 68 · Posted: Mon Jan 24, 2011 8:57 pm Post subject:

Twisted cv spline

offroad 68 · Posted: Thu Aug 11, 2011 9:27 pm Post subject:

well with no muddybuggy and minibuggy not working I will have to get my buggy fix here Laughing

Update to this thread.
Had more drive shaft problems but seem to have if fixed now, You CAN join drive shafts and have them work ok and you can buy cheap new shafts that last and less than half the price of top notch shafts that break after a few laps!

Done quite a few comp safaris with some problems but goes well when it stays together, I still have problems with it dropping in to limp mode on start up and the engine will not rev, I have a fault code finder in the cab to clear the problem which is fine but a bit of a pain if I stall it on a lap because it takes around 20/30 seconds to clear the codes.

I did a round of the BCCC british championship at Radnor forest a few weeks ago, I think they thought the scrap metal man had taken a wrong turn when I turned up with my buggy with all the big money vehicles that take part in these events, After a few runs I was getting quite a few favourable comments from spectators and my times were on a par with some in the bottom end of the championship class.
My steering has always been on the heavy side because it is less than one full turn lock to lock and with the wider all terrain tyres and a bit more offset on the front wheels this made it even harder , I was hanging on tight to the wheel all the way around the track, on the fast stuff because it was very nervous (adjusted the tracking later which helped a bit) and trying to stop the wheel being ripped out of my hands on the rough stuff. I usually do events with a lap time about half what it was at Radnor so my hands were cramping up in the second half of the lap. I am currently fitting a corsa power steering colum to help with the problem.

A few videos, yellow buggy number 235.

http://www.youtube.com/watch?v=r_eOkrNl8AA&feature=feedlik

http://www.youtube.com/user/tonybkr3#p/u/4/ENjj_3_op18

http://www.youtube.com/user/tonybkr3#p/u/7/gwTlZY0AKmk