I am a junior student at Turkey. After i learned Solidworks and 3d sketching methods, i started to planning it by myself. I got really helpful tips from the qualified work-mans when i get stuck and they handled the most of the building work like welding, cutting etc.. After really hard working effort, our first prototype was ready, of course with some deficient parts...
Mostly inspired from Chris Kraft's awesome creations, a.k.a 'Rather B welding' on youtube. Specially GS500 is my favorite.Thank you him from here for giving me ideas.
Chris's GS500 buggy : https://www.youtube.com/watch?v=4aDVCqYMWgY&t=602s
For the test drive :
Step 1: Assembling the Ready Parts
First step was buying parts that we can't build with high efficiency. We bought the parts of Lx200 ATV vehicle (wheels, suspension, brake system, top and bottom swings, hubs, rods, etc.)
The second step was assembling the parts that we bought in order to design that we had planned as seen in the picture. After assembling, we realized that the shaft of the ATV wasn't rigid enough as we wanted, then we strengthen the shaft with shrink fit technique.
Step 2: Creating Front Chassis
After assembly, the measures of front chassis is determined. We sketched a 1:1 technical drawing and cut the parts according to dimensions.
Second step was creating the ears for suspensions.
After welding the cut parts, the front chassis is formed.
Step 3: Creating Middle Chassis
We watched to same steps as we did in the front chassis.
Step 4: Creating the Upper - Middle Chassis
After some measurement which is depending on seat, engine place etc.. We started to create upper part of the middle chassis which we are going to attach one edge of suspensions. Back support point.
Step 5: Mounting Engine
We used Loncin G420FD cc gasoline engine (15hp-2600rpm) and we used the dual clutch transmission and 1:1 reverse transmission for engine. I bought them online from a shop which manufacturing/selling hobby stuff for creators.
Step 6: Power Transmission and Steering Box
We connected to engine - 1:1 transmission - shaft by using the chain power transmission which has 1:2 ratio because it is an off road vehicle we need a higher torque.
After that, we bought a scrap steering box and other steering parts, which belong to a FIAT UNO, we cut it the dimensions as we demand.
Step 7: Gear Shift
We designed a basic gear shift system which has reverse and drive. Then we created it on a CNC machine.
Step 8: Creating Top Chasis
After finishing the design and painting of the top chassis, we assembled it with the main chassis.
Step 9: Final
At the end we have 2 different painted, top chassis.