Buggy Depot - Off Road Buggies 3.0

by **Travis @ BD-ORB** on Sun Jul 08, 2007 5:40 pm

I'm transforming my old 3202 frame into a 150cc Gy6 powered beast.

The original 6hp Tecumseh is trashed, the front end is mauled, and various other components are in disrepair, but when I'm finished it should be quite a capable buggy.

Buggy highlights:
- 150cc Gy6 swapped.
- GX150 steering & suspension swapped.
- I estimate the overall frame to be well over 100lbs lighter than the GX150.
- Will have 1x rear and eventually 2x front disc brakes.

Work done so far:
1. Cut off factory engine-subframe shackles. Cut down to size & relocated for GX150 subframe.
2. GX150 nose cone, A-Arms, & steering rack mounted.
3. ENGINETICS master cylinder is mounted and ready to start plumbing to my front and rear calipers.

I've began work as of yesterday and should have it in ridable condition pretty soon. The rear sub-frame is mounted and ready for a GY6.

Fabrication pics coming soon!

by **David @ BD-ORB** on Thu Jul 12, 2007 2:28 pm

I have seen the new mods to it.
It's looking good Travis!
That kart is going to fly when its done! :yikes:

by **Offroadkarter** on Sun Jul 15, 2007 9:41 pm

you love to beat the crap out of your stuff dont you :shock:

by **Travis @ BD-ORB** on Sun Jul 15, 2007 10:28 pm

Heh, yep no mercy. Repairs are easy to come by around here for anything/everything that breaks.

We quite literally beat the brakes off of that thing while it was still running.... as well as the entire steering system... and the engine for that matter..

Anyway, I've got the engine about ready to go in. Finally getting around to testing out one of my decked heads this go around. We cut this one as far as we could go before hitting the valve seats.

One of the things I noticed whilst putting the cylinder back on was that the piston comes up much farther relative to the top of the cylinder than the HOWHIT. The 57.4mm piston comes up nearly flush with the top of the cylinder.

Power modifications thus far:
- Decked Large Valve Head
- 57.4mm Cylinder 149.8cc [HOWHIT is 147.3cc]
- What seems to be a High-Comp Piston
- A12 Cam
- Rollers, 1500 spring, 115mm variator, high stall clutch.

Oh yes, it is going to fly when we're done. :thumbsup:

by **Travis @ BD-ORB** on Mon Aug 20, 2007 11:10 pm

More pictures... it's getting nearer. It's been confirmed, this project yerf is a full 110lbs lighter than a standard GX150. So, I've decided to call this the "GX150 Lightweight".

Engine, suspension, steering is all finished. Tackling the brakes and wiring is next. After that comes removing & fixing up all of the stock weak points -- ball joints, spindles, etc.. you all know the deal.

Such a great way to use company scrap!

by **jtramsey4** on Tue Aug 21, 2007 12:38 am

Don't forget to put some nuts on the a-arm bolts.James

by **Travis @ BD-ORB** on Wed Aug 22, 2007 3:53 pm

No worries, it's all coming back off soon for the front end upgrades.

by **Travis @ BD-ORB** on Tue Nov 13, 2007 2:56 pm

As it stands...

A lot of polishing up is coming soon, but it runs... and boy does it run well!!! Killer acceleration. The modifications are working perfectly with one another. The little 150cc GY6 engine is pushing 13.3:1 compression ratio, and seems to thoroughly enjoy it being fed 93 octane pump gas.

More info coming soon.

by **crazy yerf rat** on Wed Nov 14, 2007 12:50 am

Thats awesome :shock:

by **pghruby** on Wed Nov 14, 2007 4:07 pm

Nice tie rod stand-offs. You should include them with your ball joint kits and sell them stand alone for people who already have BD joints.

The extra BD spindle length is nice. As you can see by Travis' pictures, you can space the wheels further from the frame and mount wider tires or put a few more teeth in your steering rack and not rub.

by **Offroadkarter** on Tue Dec 04, 2007 10:57 pm

Bump

Bring this to one of our NE meets please :thumbsup:

by **ninja_monkey16** on Sat Feb 16, 2008 5:33 am

i am doing something similar to this with my 3202 frame.pretty much the only differences are that instead of using a 150gy6 i am using a 250 lifan engine and bigger tires up front.and it is going to be 5 speed manual w/reverse.

by **ckau** on Mon Feb 18, 2008 3:34 am

some more info on those tie rod stand-offs would be appreciated

by **Travis @ BD-ORB** on Tue Sep 16, 2008 5:55 am

Honestly, I'm not sure why I haven't added the standoffs to the store yet. We have boxes full of them. Officially added:
http://www.buggydepot.com/store/index.p ... cts_id=354

Stats on the performance of this buggy can be seen in this thread:
viewtopic.php?t=1302

I'll attach some pictures of how this thing stands now.

by **NFA TOYS** on Mon Sep 28, 2009 3:11 am

Very nice

Travis @ BD-ORB wrote:More pictures... it's getting nearer. It's been confirmed, this project yerf is a full 110lbs lighter than a standard GX150. So, I've decided to call this the "GX150 Lightweight".

Engine, suspension, steering is all finished. Tackling the brakes and wiring is next. After that comes removing & fixing up all of the stock weak points -- ball joints, spindles, etc.. you all know the deal.

Such a great way to use company scrap!

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