It was finally time to start finishing
off the rear tubing. the chassis still needed a cross brace
for the passenger cabin and I needed a way to extend the roof
further back to provide shade for the rear seat. I decided to tackle
the roof extension first so I could make the cross bracing blend
with it. The inspiration for the roof extension came from a
backwards ballcap on my sons head of all things. The other
option was to extend the D pillar back further but that starts to
make the chassis look big where as this solution keeps the
look of the smaller cab intact.
ran out of tubing for the cross braces so I moved on to mocking up
some templates to complete the rear upper link mounts.
This finished tab puts the link mount
bolt in double shear and also ties the diagonal brace in the rear
floor into the upper chassis frame rails.
The radiator tie down is made from
a water jet cut plate that I bent up on my brake before adding the
mounting tabs. You may notice the skull and cross bones,
one of the requirements from my son was the buggy had to have a
skull on it somewhere so here it is. The hold down plate will
tie into the chassis via three posts made from some .75" DOM and
some cut down 1/2-13 bolts. I will be using some high temp foam to
cushion the radiator so the posts have clamping adjustment via the
While I had the plasma cutter out I went
ahead and cut some oval plates to cap off the rear shock clearance
Moving to the front I came up with a
simple bracket to mount the steering reservoir. The cooler
still needs a home, I have been eyeballing the space above and in
front of the oil cooler.
The front axle still needs a lot of
work, namely finishing off the bracing and closing up some of the
gaps around the cylinder mounting plate. I added a brace for the
lower link mount on the passenger side due to the inner tab being
attached to the cast portion of the housing
I also started final welding all the
plats to the axle housing. Pretty much started laying beads until I
ran out of CO2.
After picking up some more tubing early
in the week I set about finalizing the chassis bracing for the
passenger compartment. This is essentially a giant cab compared to a
typical 2 seater so when in doubt I error'd on the side of overkill
when it came to the bracing.
The little tab next to the radiator is a
mount for the overflow container.
A few shots showing the roof bracing.