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My first Buggy build.

40K views 210 replies 55 participants last post by  Mr.Green 
#1 ·
I am a OTR truck driver working on a local contract in Fultonville, NY for who knows how long. I am saving up to buy a house outright while getting all the parts and tools around to build this rig once I am in that house.

I plan doing this in stages.

Work on design
Get components
Build Drive train
Mockup fuel
Run Drive train
Finalize design
Build frame/body(mock HDPE while building using cardboard)
Mock Drive train
Mock Steering
Mock Cooling
Mock Electrical
Mock Recovery
Mock Safety
Mock Fuel
Mock Suspension
Mock Axles
Mock Glass
Test drive checking for issues
Form HDPE/UHDPE pieces
Install HDPE/UHDPE pieces
Check fit
Finalize fit(making/installing any things that are needed)
Remove Power train,steering,electrical,recovery,cooling,safety,fuel, HDPE/UHDPE pieces, axles.
Soda blast primer off
Wipe down frame/body with cleaning agent
Paint Body/frame
Install Axles
Install Drive train
Install Steering
Install Cooling
Install Electrical
Install Recovery
Install Safety
Install Fuel
Install Suspension
Install HDPE Pieces
Install Glass

Drive it.:thumb:


I will jump around as needed to get this built.

This is The shopping list that I have been chipping away at over the last year. It will be updated as I progress.

Tools:
Have Pro Bender Pro 32 Bender
Have 240° 1.75" Die
Have Baileigh TN-250 Notcher
Have Miller 211 Welder
Need Oxygen,Argon Gas/tanks
Need Argon recirculating pump for back shielding
Have Welding/grinding Hood
Have 50' welder extension cord
Have Craftsman Grinder
Have Craftsman Saw Saw
Have Milwaukee porta-saw
Have Swag Porta-saw Vertical Table
Have SodaBlast Systems Soda Blaster/Hose
Need Industrial Air compressor
Need Plasma cutter
Have Central Hydraulics 2 ton Hoist
Have 3 ton floor jack
Need 4 3 ton jack stands for engine mockup(before cage is built)
Need 4 3 ton jack stands for cage mockup(before suspension is installed)
Need Primer(To prevent rust while building)
Have Magnets
Need Clamps
Have angel tool
Need 6'x6'x1' Hot Box for Molding HDPE
Need 6'x6' Vacuum form table/flipping arm
Have Dedicated Laptop
Need Autodesk Inventor
Need Break line bender
Need Extra blades, wire etc as used
Need Various


Drive train:

Have Low mileage Chevy 2 bolt 350 Long block
Need Engine mounts
Need Transmission mounts
Need Transfer case mounts
Need Block huger 90° down headers
Need Cross over pipe(in front of engine)
Need Heat shields
Need Muffler
Need Exhaust coating
Need Exhaust pipe
Need Tensioner pulley(GM stock style medal)
Need Tensioner pulley bracket
Need Serpentine belt
Need 3/8 Power steering pump/alternator mounting brackets(over intake no adjustment)
Need Idler pulley
Need Idler pulley bracket
Need 3/8" UHDPE oil pan cover/skid plate(formed)
Have Cast SM-465 Bell housing
Need 3/8" UHDPE lower Bell housing cover(formed)
Have SM-465 6.55 ratio with dana18 adapter Rebuilt by Herm the overdrive Guy
Have Rebuilt 3.15 Tera-Low D-18 t/f case, twin stick, with OD Built by Herm
Need Center force dual clutch
Need Flywheel
Need Drive shafts
Need ARP bolts
Need Aluminum Rocker covers

Axles:
Have 89 Toyota FJ 62 axles with 4.11(will freshen)
Need Long fields
Need Lockers
Need 16"x8.5" rims
Need 35" tires

Breaks/clutch/steering
Need Kugel Komponents Under dash 90° Power With 1" Bore Aluminum M/C, Clutch M/C & 8" Dual Booster
Need steering shaft from Chevy truck non airbag(with turn,haz,light switches)
Need Steering shaft to gear box linkage
Need Steering wheel
Need Through firewall Vacuum line
Need Rear disk Upgrade
Need Clutch Slave
Need Portioning valve
Need ******* Ram stage 3 (everything) steering assist
Need Ruff stuff 1.25 Heims
Need 2" rods for linkage
Need Hi-steer Toyota brackets
Need Various

Fuel:
Need Got Propane kit for 3 10 gallon tanks/lines
Need 3 10 gallon tanks
Need Wet line kit for 500 gallon propane tank(road taxed propane only)


Heating/Cooling:

Need Low rpm high flow water pump short shaft
Need 2 12"x36" radiators
Need Radiator mounts(rubber)
Need 6 12" fans
Need 16' 1.5 id hydraulic hose
Need Oil cooler with 2 speed fan(heater)
Need Heater hose

Electrical:
Need 160 amp alternator(stock style)
Need Starter(stock style)
Need 2 red top optima Batteries
Need Oil Gauge
Need Engine temp Gauge
Need Battery 1 voltage Gauge(for driving)
Need Battery 2 voltage Gauge(for winch/radio)
Need Air pressure Gauge (for seats)
Need 12volt air Pump (for seats)
Need Propane Heat box (air temp) Gauge
Need 3 in line under dash propane gauge/shutoff valves
Need Tach
Need GPS speedometer
Need Headlights(30's style)
Need Rock lights Switch
Need Back up lights Switch
Need Power lock door Switch
Need Power windows Switch
Need Heater hi/lo/off Switch
Need Propane on/off switch
Need Parking break Buzzer
Need Relays
Need Retractable fenders Switch
Need Front winch controls(in dash)
Need Rear winch controls(in dash)
Need Front winch controls(remote)
Need Read winch controls(remote)
Need Divert-er valve switch(for sending fluid to front or rear winch)
Need 12volt motor Switch(for powering pump/winches)
Need 4 power on/off for extra accessories Switch
Need Trail lights switch
Need Taillights
Need Marker lights
Need Rock lights
Need Trail lights
Need Painless wiring 16 kit
Need Painless 8 kit(high amp for accessories)
Need Painless wiring courtesy kit
Need Painless remote main shutoff kit
Need Power window kit
Need Power fender kit
Need Power lock kit/w poppers
Need Radio
Need Under dash Bass tube
Need 6 speaker competent system
Need Wiper motor/linkage
Need Various


Cage/Body:

Need 1.75" x250 tube
Need Hood shocks
Need 180° Spare shocks
Need 3 10 gallon Propane tank mounting hardware
Need Flat glass windshield/windows
Need 3/8" thick flat Lexan rear window(rear firewall/derbies protection)
Need HDPE roof(removable)(formed)
Need HDPE outer door panels(removable)(formed)
Need HDPE Outer cage cover sections (removable)(formed)
Need HDPE Wheel Housings(retractable/removable)(formed)
Need HDPE Hood(formed)
Need HDPE Floor(formed with drains)
Need HDPE Center section(removable) (formed)
Need HDPE Vertical Hood sides(removable)
Need HDPE Inner body Air Dam/front area behind wheel(formed)
Need HDPE Heat box(vented box to keep propane tanks warm)
Need HDPE tire cover
Need Drivers Dash(formed lexan)
Need HDPE Passenger dash
Need UHDPE 3/4" transmission/Transfer case skid plate(formed)
Need UHDPE 3/8" drive shaft skid plate
Need UHDPE 1/8" Front and rear Axle skid plate(formed 2 piece)
Need HDPE air tank(for seats)

Suspension:
Need Ruff Stuff 1.25" 4 link kit F/R
Need 8 6' 1.75" Thick rod
Need Fox coil overs
Need Ebiach Springs
Need 2 2"thick rod with Ruff stuff heims for pan hand bars
Need Drop stop straps
Need Sway bars(removable)
Need Nitrogen

Recovery:
Need 12v 1500rpm electric motor
Need Hi output Power steering pump
Need MM H9000 winch front/rear
Need Extended tubing
Need Extended wiring(controls)
Need Diverter valve(with electrical solenoid)
Need 90° bends
Need Straps
Need Tree saver
Need Tackle

Safety:
Need Fire suppression system
Need 5 point harness(mounted to seat)
Need Side windows defrost
Need Auto darkening rear view mirror
Need Power mirrors with defrost
Need Air ride seats
Need DOT air ride seat restraint straps
Need Oil accumulator
Need Propane high discharge shutoff
Need Engine master kill(with electric horn alert after engaged)
Need Air Horn
Need Parking Break
 
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#186 ·
I overthink everything and frustrate myself regularly. Thanks for making me feel normal with your insane ramblings.
 
#188 ·
This is by far the worst thing I have read all year. To say that I am disappointed is an understatement!!!

Cerial, how dare you!?!?!??

We didn't quit when the Germans bombed Pear Harbor and neither should you.

How much would you sell the cage that you started building for?
 
#189 ·
And what's with getting trying to get it legal in every state you're going to drive through.

Just build it and drive the m'fer.

A very devout Catholic once told me "Its easier to beg for forgiveness than to ask for permission" :sonicjay:
 
#194 ·
They must be Internet laws...home built shit doesn't go through a 50 state inspection, and michigan doesn't do anything with "defined frame". You can build a frame or you can build a unibody...either one will work. And getting your home built inspected doesn't including measuring your "defined frame"
 
#203 ·
I've been following this build thread since the beginning and there seems to have been a lot of design work (which I am willing to pay for) and planning (which I am willing to pay for) and at least some axles, I was hoping that the part collecting got farther than that.
@cerial I am however dead serious, let me know what you've collected and whatever drawings/plans you can include. I am very interested in this project.
 
#210 ·
I am


Drive train:

Have Low mileage Chevy 2 bolt 350 Long block
Need Engine mounts
Need Transmission mounts
Need Transfer case mounts
Need Block huger 90° down headers
Need Cross over pipe(in front of engine)
Need Heat shields
Need Muffler
Need Exhaust coating
Need Exhaust pipe
Need Tensioner pulley(GM stock style medal)
Need Tensioner pulley bracket
Need Serpentine belt
Need 3/8 Power steering pump/alternator mounting brackets(over intake no adjustment)
Need Idler pulley
Need Idler pulley bracket
Need 3/8" UHDPE oil pan cover/skid plate(formed)
Have Cast SM-465 Bell housing
Need 3/8" UHDPE lower Bell housing cover(formed)
Have SM-465 6.55 ratio with dana18 adapter Rebuilt by Herm the overdrive Guy
Have Rebuilt 3.15 Tera-Low D-18 t/f case, twin stick, with OD Built by Herm

Need Center force dual clutch
Need Flywheel
Need Drive shafts
Need ARP bolts
Need Aluminum Rocker covers

Axles:
Have 89 Toyota FJ 62 axles with 4.11(will freshen)
Need Long fields
Need Lockers
Need 16"x8.5" rims
Need 35" tires

Breaks/clutch/steering
Need Kugel Komponents Under dash 90° Power With 1" Bore Aluminum M/C, Clutch M/C & 8" Dual Booster
Need steering shaft from Chevy truck non airbag(with turn,haz,light switches)
Need Steering shaft to gear box linkage
Need Steering wheel
Need Through firewall Vacuum line
Need Rear disk Upgrade
Need Clutch Slave
Need Portioning valve
Need ******* Ram stage 3 (everything) steering assist
Need Ruff stuff 1.25 Heims
Need 2" rods for linkage
Need Hi-steer Toyota brackets
Need Various

Fuel:
Need Got Propane kit for 3 10 gallon tanks/lines
Need 3 10 gallon tanks
Need Wet line kit for 500 gallon propane tank(road taxed propane only)


Heating/Cooling:

Need Low rpm high flow water pump short shaft
Need 2 12"x36" radiators
Need Radiator mounts(rubber)
Need 6 12" fans
Need 16' 1.5 id hydraulic hose
Need Oil cooler with 2 speed fan(heater)
Need Heater hose

Electrical:
Need 160 amp alternator(stock style)
Need Starter(stock style)
Need 2 red top optima Batteries
Need Oil Gauge
Need Engine temp Gauge
Need Battery 1 voltage Gauge(for driving)
Need Battery 2 voltage Gauge(for winch/radio)
Need Air pressure Gauge (for seats)
Need 12volt air Pump (for seats)
Need Propane Heat box (air temp) Gauge
Need 3 in line under dash propane gauge/shutoff valves
Need Tach
Need GPS speedometer
Need Headlights(30's style)
Need Rock lights Switch
Need Back up lights Switch
Need Power lock door Switch
Need Power windows Switch
Need Heater hi/lo/off Switch
Need Propane on/off switch
Need Parking break Buzzer
Need Relays
Need Retractable fenders Switch
Need Front winch controls(in dash)
Need Rear winch controls(in dash)
Need Front winch controls(remote)
Need Read winch controls(remote)
Need Divert-er valve switch(for sending fluid to front or rear winch)
Need 12volt motor Switch(for powering pump/winches)
Need 4 power on/off for extra accessories Switch
Need Trail lights switch
Need Taillights
Need Marker lights
Need Rock lights
Need Trail lights
Need Painless wiring 16 kit
Need Painless 8 kit(high amp for accessories)
Need Painless wiring courtesy kit
Need Painless remote main shutoff kit
Need Power window kit
Need Power fender kit
Need Power lock kit/w poppers
Need Radio
Need Under dash Bass tube
Need 6 speaker competent system
Need Wiper motor/linkage
Need Various


Cage/Body:

Need 1.75" x250 tube
Need Hood shocks
Need 180° Spare shocks
Need 3 10 gallon Propane tank mounting hardware
Need Flat glass windshield/windows
Need 3/8" thick flat Lexan rear window(rear firewall/derbies protection)
Need HDPE roof(removable)(formed)
Need HDPE outer door panels(removable)(formed)
Need HDPE Outer cage cover sections (removable)(formed)
Need HDPE Wheel Housings(retractable/removable)(formed)
Need HDPE Hood(formed)
Need HDPE Floor(formed with drains)
Need HDPE Center section(removable) (formed)
Need HDPE Vertical Hood sides(removable)
Need HDPE Inner body Air Dam/front area behind wheel(formed)
Need HDPE Heat box(vented box to keep propane tanks warm)
Need HDPE tire cover
Need Drivers Dash(formed lexan)
Need HDPE Passenger dash
Need UHDPE 3/4" transmission/Transfer case skid plate(formed)
Need UHDPE 3/8" drive shaft skid plate
Need UHDPE 1/8" Front and rear Axle skid plate(formed 2 piece)
Need HDPE air tank(for seats)

Suspension:
Need Ruff Stuff 1.25" 4 link kit F/R
Need 8 6' 1.75" Thick rod
Need Fox coil overs
Need Ebiach Springs
Need 2 2"thick rod with Ruff stuff heims for pan hand bars
Need Drop stop straps
Need Sway bars(removable)
Need Nitrogen

Recovery:
Need 12v 1500rpm electric motor
Need Hi output Power steering pump
Need MM H9000 winch front/rear
Need Extended tubing
Need Extended wiring(controls)
Need Diverter valve(with electrical solenoid)
Need 90° bends
Need Straps
Need Tree saver
Need Tackle

Safety:
Need Fire suppression system
Need 5 point harness(mounted to seat)
Need Side windows defrost
Need Auto darkening rear view mirror
Need Power mirrors with defrost
Need Air ride seats
Need DOT air ride seat restraint straps
Need Oil accumulator
Need Propane high discharge shutoff
Need Engine master kill(with electric horn alert after engaged)
Need Air Horn
Need Parking Break
According to this post I'm going to need a lot of items to finish this build.
 
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