Project Outline - Off-Road buggy

I have always wanted to build a go-kart.  being raised surrounded with all sorts of neat machinery and a father who is both a mechanical engineer and a hobby machinist created a desire to make something that could come to life.

While reading Dad's old "Dirt Bike" magazines, I caught a glimpse of an ATV that was unlike the typical bikes and the odd trike that was common in those magazines. The driver sat very low in the vehicle and, since the few pictures I saw were the "Crash and Burns", looked very sturdy.  I memorized the model: The Honda Odyssey.

It turns out the Honda Odyssey was a model of a line of buggies Honda made between 1976 to 1990 (Apparently recycled from an abandoned snowmobile project).

While popular on the sand dunes, the high price kept customers away and eventually killed the line.

The two rather unique things about these machines are the transmission and its controls - the machine uses a CVT (continuously variable transmission) for power delivery, a feature that is not very common for wheeled vehicles at the time, and all the controls are on the steering wheels - no pedals.

The Hondas enjoy a cult following, but I feel it would cost prohibitive for me to actually own one. Parts for it are getting harder to find and more expensive.

So, I propose a project:

PROJECT BUGGY

Outline: To build a go-kart that is as similar to the Honda Odyssey/Pilot as possible

Component areas:

• FRAME: Metal tube construction - Dimensions will copy the Odyssey frame, with some deviation for both length and height in the driver's compartment (I'm 6' 4")

•  SUSPENSION : A-arm suspension using nitrogen-charged snowmobile shocks.

• WHEELS: Quad tires, with wide rear tires and narrow fronts.

• BRAKES: Front will use spindles from a 2WD quad (Preferably with disc brakes), the rear will have a large disc on the gearbox output.

• ENGINE: From my dumpster diving last summer, I have both an Rotax 340 and Rotax 440 engine.  I will need to tear them down to determine if they are salvageable.  May need to find an exhaust pipe.

• TRANSMISSION: It seems the RPM Gearbox is a very bulletproof "FNR" box, capable of handling up to 300 horsepower while providing flanges for constant-velocity shafts.  It's also really expensive, with the average sale price around $2,000usd.  The other best option I heard of is the Spicer H12 FNR gearbox commonly used on UTVs and golf carts. They are around $1,600 brand new (Even less on the used/surplus market), but can only handle around 30 horsepower.

• STEERING: Unassisted tie rod assembly.  the steering wheel might be another expensive purchase if I go for a Honda steering wheel, unless I experiment with casting aluminum and make my own.

• ELECTRICAL: The alternators on the two snowmobile engines I have are likely 6 volt.  if I cannot make another coil work, I may either consider an external alternator or look for another engine.

• LIGHTING: Four floodlights up front, reverse triggered flood and taillight out back.  Have a DRL system to turn two lights on for visibility on the logging roads. 

•  BODY: Fenders fashioned from old quad fenders, roof molded out of fiberglass.

Building phases:

• Design Phase: Acquire dimensions of a Honda frame and other major components, design frame in CADD program

• Acquisition Phase:  Gather up the necessary parts and tools as funds allow. Prepare parts that are already in possession.

• Fabrication Phase: Build the parts that the design calls for. test fit the components

• Assembly and Test Phase: Assemble the machine and test to eliminate bugs.

• Cleanup Phase: Strip the machine back down, paint

 Right now, this is a long-term project, along the lines of "Nice to do, but there are more important things in life".  The design phase would be simple enough to do, I would just need at least some of the frame measurements.