My DIY farm buggy

[Ricoffy]

Hi Gents,

First and foremost, as this is my first post (and thread) on this forum, let me begin to say that its a pleasure to be part of this forum. I came across this site while browsing on the internet for general questions and answers on VW air-cooled motors - the knowledge on this site is awesome - so thank you for that.

Started to post this build on another forum: 4x4ag.co.za so if you want to have an in-depth look at it, here's the link:

https://www.4x4ag.co.za/forum/viewtopic.php?f=36&t=601

Anyway, getting to the thread, you need some background to this build:

My Father in law is a farmer in the North of Nambia and due to the rough terrain, the farm bakkies just does not last as long as they need to. As a cheap solution, I got a beach buggy for free and decided to build the old man a sort of farm buggy - which I hope to be done with by Christmas this year. The buggy is fitted with a duel port 1600 air cooled motor.

Before I started with the build, I have absolutely no knowledge of these engines. It was quite a learning curve (and one which still subsists to date) but after a bit of research, I think I got the hang of the motor - and I fell in love with it instantly. The simplicity thereof is amazing.

The engine initially ran rough and sounded like a 70 year old smoker climbing a set of stairs. Rebuilt the carb, replaced the ignition coil, condenser and points and set the valves correctly. I then did the timing and it now purrs like a kitten - although a fat loud kitten due to the straight pipes.

So here goes the story of the build so far:

This was the fibre glass body removed - a very ugly blue



The chassis was still in relatively good nick:



Started with the frame for the fuel tank. Initially wanted to fit it on top of the motor (like the yanks do), but it seemed like an obvious fire hazard. Also made the frame on which the seats mounted. I redid this later on in the build as my initial idea was kak - the seats were too close together and as a result I could not reach the handbrake. Don't mind the little helper in the pic - he eats me out of the house and gets to sleep next to my wife - the luckiest employee alive:







Dolla the Dane - always there to lend a helping hand:



Started with the nose and side support beams:








Steering wheel mounted:




Dash frame (aluminium plate to be fitted) and fuel pump bracket made. The previous owner used a similar external pump (max 3 bar pressure) and I opted for the same:








Basic cabin frame and spotlight mounts. I liked the idea of a slanting roofline - gave a more aggressive look:












Fuel tank funnel (loosely) fitted. Had a small hole due to rust - fixed that with steel putty and still needs to be sanded down. Don't mind the crayons in the pics - it was a joke between friends:




Got some of the dials for the dash:




More to follow soon...

[Ricoffy]

Started with the load bin:




Back frame - load bin:








Fitting the first drop side:




Front end of load bin:








Fitting the load bin on the bracket:












Secured the bracket to the cabin (to stop it from tilting under load) and gave it 45 degree braces x 3:





Drop side hinges and latches welded:




Removed the frame to re-weld the kak welds and to smooth it off with me trusty angle grinder. The old adage does ring true: Grinding and paint makes me the welder I ain't...

[Ricoffy]

All assembled, this is how Janneman looks at present. Yes, I named it Janneman:




By redoing the seat brackets, I got a lot more space and height and can now grab hold of the handbrake comfortably. I got the seats from a local scrapyard out of an old ford focus for R350 a pop. It slides forwards and backwards and the driver seat can tilt towards the steering wheel which I thought was quite nifty.

Side view:

[Ricoffy]

Disclaimer: I am a complete knob and noob with this - my first attempt so please keep that in mind.

[John Alves]

well done, I suppose you won't be doing registration and licensing?

[Ricoffy]

well done, I suppose you won't be doing registration and licensing?

Thank you.

I won't register it - don't think it is necessary as it will spend the rest of its life on the farm.

[Tony Z]

Welcome to the forum. Thats some pretty good work that you've done so far.
I'd consider adding a few gussets to the main hoop, both forward and aft, as well as left to right. Doesnt need to be box section, even 3mm flat will work.

I too am more of a grinder than a welder. There are a few of us like that on the forum. But I think you've done more welding on that bug than I have in the past 10 years.
Keep up the progress

[John Alves]

Seeing that you are an experience welder now, I would cut bend and weld the clutch and brake pedal slightly to the left to accommodate plaas bootse

[Ricoffy]

Welcome to the forum. Thats some pretty good work that you've done so far.
I'd consider adding a few gussets to the main hoop, both forward and aft, as well as left to right. Doesnt need to be box section, even 3mm flat will work.

I too am more of a grinder than a welder. There are a few of us like that on the forum. But I think you've done more welding on that bug than I have in the past 10 years.
Keep up the progress

Thank you.

TBH, I first had to google what gussets are before I understood your post

Its a good idea. I think I have 3mm steel plate lying around somewhere - may just be enough for a few gussets.

Cheers

[Ricoffy]

Seeing that you are an experience welder now, I would cut bend and weld the clutch and brake pedal slightly to the left to accommodate plaas bootse

Thank you for the idea!

[Terry Phillips]

Great job this is how you learn by doing it your self.

[retrovan]

Well done, looks excellent, and it is yours, build by you to your taste.

Can not get better then that

Enjoy it , you deserved it, now just have fun...

Herman

[73type2]

Enjoy it , you deserved it, now just have fun...

Herman

What? Is it done? I thought there was more to come.

[Ricoffy]

Enjoy it , you deserved it, now just have fun...

Herman

What? Is it done? I thought there was more to come.

Not done yet. Still need to cut and attach the aluminum skins, paint the floor and frame, do the wiring, adjust the brakes, paint and service the engine.

For now I only have Saturdays to work on it - work and family consumes the rest of my time.

[73type2]

For now I only have Saturdays to work on it - work and family consumes the rest of my time.

I know the feeling. Too many projects... I'm thinking about getting up earlier and do a small task every day before going to work in order to make some headway on my projects. Or maybe I'll start doing it when it gets a bit warmer and easier to get up.