AWD Buggy Plan

The Goal
Looking to build a High speed AWD buggy. LIGHT AS POSSIBLE! If using automotive Motors,
transmissions, transfer cases, differentials, axles, etc.. The buggy will be too heavy. You might as well
build a Suzuki Samurai or a Rhino Buggy from Subaru parts. Would have great traction for Forest Roads
and Desert Roads.

Brief List of Components

Motorcycle/Briggs and Stratton motor based.
IFS front and rear. (With VW Type II CVs on all four corners)
Differentials from an IFS 4x4 ATV.
Lawn mower Transaxle to direct power from motor to front and rear Diff(s).

THE PLAN
Suspension
IFS front and rear with VW Type II CV's

PRO(s)
Lighter than solid axles
10-12 inches of Travel
Can run drive shafts to thirds low and horizontal along the frame.

CON(s)
Little more work than Swing Arms.

The Scoop
IFS would allow the buggy have great ground clearance and since it will be AWD it should provide great
traction for tall skinny tires.

Differentials
IFS 4x4 ATV Diffs

PRO(s)
Lightweight
Limited slip available

CON(s)
Not sure how to hook up VW Type II CV shafts to the diffs?

The Scoop
I think Diffs from an IFS 4x4 ATV would be the best (Light Weight)
Use a differential from a ATVs with at least a 400cc or larger motor for greater Diff strength.
 Not sure what a IFS Diff looks like but the below pictures are from TIMBERWOLF YFB 250 REAR
DIFFERENTIAL

Tires
Motorcycle Tires

PRO(s)
Increases ground clearance
Lightweight

CON(s)
Fitting Motorcycle rim to ATV Drive Wheel or Hub.

The Scoop
Has anybody ever ponder the idea of mounting Motorcycle Tires on ATV Wheels and Hubs? I figure
use rear motorcycle tire in the rear and front motorcycle tires for the front maybe rears up front for mud
bogging only. The closest thing I’ve seen is the The Edge Buggies out of Australia, but their supplier
does not make the rims anymore.

I figure the toughest part is making the front hubs with steering and room for an Axle shaft or CV. I keep
thinking of using 4x4 ATV front Hubs for this. But I wonder if the ATV front hubs can be modified to fit
the VW Type II CV's?

Transfer Case
Lawn Mower Transaxle

PRO(s)
Variable gears
Reverse
Lightweight

CON(s)
Not sure how to connect the Transaxle to Front and Rear Diffs?
 The Scoop
Use the Transaxle from a lawnmower as a transfer case. (Can get 1-8 speed transaxles with reverse)
This would double as a transfer case with low and high shifting gears. Plus you would have the 5sp or
6sp Engine/Trans from a Motorcycle or ATV Engine. (Could get really creative with gearing for this.)

Connecting the Engine to the Transaxle.

Motorcycle Engine
This would be done with sprockets and chain with little fab work. (Again this would allow you to play with
the gearing)

Briggs and Stratton

Connect the Motor and clutch drive belt to the Transaxle pulley.

With the above gearing options you could build a buggy that will go fast and have grunt for climbing.

Some examples:

Wheel Horse B/C Series 8-speed Transaxle

Gears shift for gears and reverse

MTD 7 Speed *TRANSAXLE. Model number is 618-0073.

The serial number is A655952. (That number is on the label
on the Transaxle) The number in the casting on the bottom
is MTD-719-0313

Big Problem
Connecting the Transaxle to the Differentials

PRO(s)
Can’t think of anything? Oh, Almost Forgot! It will achieve AWD.

CONS
Where do I start?
Lets talk about the axle shaft
Is it one piece or two piece? Does it really matter?

For the drive shaft I would have to machine custom axle shafts for the Transaxle. One Long for the front
diff and one short for the rear diff, or it might be one piece running through the Transaxle? This will
depend on the type of transaxle being used for this project.

The drive shafts ends would have to be machined to fit the differential from an ATV.
Other Stuff
Brakes
I think incorporating a brake on one of the drive shafts coming from the Transaxle would automatically
give you for wheel brakes since the both drive shafts will not be independent of each other.

Otherwise I would have to come up with disc brakes for the rear wheels connected to the wheel hubs.
This may also work on the front wheel hubs. (Kind of like what The Edge Buggies out of Australia is
doing to their go-karts)
Have the option to put brakes on all four corners.

4 wheel steering
This could also be a possibility depending how the motorcycle wheels mount to ATV Hubs and wheels?
But it would have to be Hydro driven. Subaru cars have an electric power steering pump that could be
used with two small rams to achieve this.

Please email me (Ryan) at kozaz@yahoo.com for any input or advice for my plans I’m trying to do as
much research before I go buying a bunch of parts.

This will me posted in several forums for a greater audience.