Chevy, Dana 60, Dana 44, Ford, Dodge, Jeep lets go 4wheeling in Arizona

Photos & Videos => Builds => Topic started by: ROCKZILLA on August 27, 2018, 09:25:15 PM

Title: Big Little Buggy Build
Post by: ROCKZILLA on August 27, 2018, 09:25:15 PM
I started gathering parts to build a buggy and itís getting better by the day. I started out with just a Zuk buggy I got from Michael, a 4.8, 4L80E. Now it looks like itís getting 4 linked front and rear and 14 inch Fox shocks. D60 up front, 14 bolt rear, full hydro steering and I think Iím going to run a doubler. Rickie and I started pulling the engine and trans from the donor vehicle today. Zuk chassis is going to be delivered Saturday. Stand by for a pretty fun build and for sure the best rig Iíve built yet!
Title: Re: Big Little Buggy Build
Post by: JYD on August 28, 2018, 05:01:08 AM
Better hurry FF is close!
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on August 28, 2018, 11:30:21 AM
 I will have the engine and transmission out tonight. Looks like Iíll be running 14 inch fox shocks in the front and 16 and the rear. Things are coming together fairly quickly .
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on August 30, 2018, 11:19:50 AM
I got the engine and transmission out yesterday. I'm going to hold off on pulling the rest of the harness out until I'm ready for it. Someone also found seats!
Title: Re: Big Little Buggy Build
Post by: RCinLaveen on August 31, 2018, 10:24:14 AM
Nice.  Look forward to following the build.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on August 31, 2018, 10:18:00 PM
I went and picked up the material for the cage modification and upper and lower links today. If everything goes as planed I will be finished up the cage but next weekend. While Iím searching for a t-case Iím going to get the engine ang transmission set in place for mock up.
Title: Re: Big Little Buggy Build
Post by: elmh on September 01, 2018, 06:14:41 PM
Cool glad to see you building another one
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 01, 2018, 09:29:03 PM
Chassis has been delivered today and I have started stripping it down to build back up for a 4 seater. I have a lot of work to do to make this engine and transmission fit!
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 03, 2018, 02:54:41 PM
I cut more off the rig and just about have it ready to test fit the engine and transmission.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 08, 2018, 06:14:35 PM
We got the engine and transmission dropped in place and engine mounts fabbed up and put into place. Things are a little on the tight side, Iím going to have to find some block hugger headers or something as the factory manifolds dump in the center of my frame rails.Hope to get some tube work done tomorrow.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 09, 2018, 08:42:15 PM
We didnít get too much done today, as it took awhile to get the tubing bender set up. We did get one piece bent and tacked into place. Iím gonna try a couple different manifolds and see if they will fit also. Slow but steady progress.
Title: Re: Big Little Buggy Build
Post by: JYD on September 10, 2018, 04:24:16 AM
Going to be nice when you are done
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 12, 2018, 09:38:20 PM
I got a little more tube work done today. Iím starting to see something other than a pile of parts and a crappy chassis.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 14, 2018, 01:23:19 PM
Plenty of head room and feet room for the rear seat.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 17, 2018, 07:05:36 AM
So I spent most of this weekend cleaning up crappy tube work and rebuilding the front loop for more radiator/fan room. I relocated the seat mounts to fit the new seats. I pushed the hood forward about 7 inches and will extend the cowl to meet the new hood location.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 23, 2018, 09:10:22 PM
I got both front and rear axles cleaned up. Found that my rear diff already has a grizzly locker so I welded the truss on it and just need to put the brakes together. The front axle got new rotors, bearings repacked and new seals then Lincoln locker installed. Iím waiting on the front truss to get it welded into place. I need to pick up the steering parts so I can get the mounts made for the ram. The rear axle is sitting in its approximate spot. Still have a lot of parts to get and a lot of work to get done before FF.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on September 26, 2018, 01:12:24 PM
Since I'm cheap I made the factory manifolds work, I cut the bottom part off that was hitting the frame and welded in a piece of 2 inch exhaust tubing to get it behind the firewall and away from the frame. Once the transfer case is in I will figure out what to do with the rest of the exhaust.
Title: Re: Big Little Buggy Build
Post by: JYD on September 26, 2018, 05:52:39 PM
Just got to keep plugging away!
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 08, 2018, 09:57:36 AM
I took a few days off work to get some stuff done, even though it pored for two days I still got quite a bit done. I got the rear four link done and the front 3 link done except I still need to build the trac bar. I picked up a doubler, but have to custom make an adapter to my 4L80E as nobody sells one. Picked up brakes, radiator and steering parts. PSC ram is mounted, going to push to get the brakes, steering and shocks completed this week.
Title: Re: Big Little Buggy Build
Post by: JYD on October 08, 2018, 01:21:09 PM
Really starting to look like a buggy now!
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 10, 2018, 10:19:52 PM
Built shock hoops for the front tonight and had to loose the hood, I built a nice tube front end and got the front shocks put on and holding itself up. I will need to set them later but they are good for now. Took the next two days off to get more done.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 11, 2018, 08:46:00 PM
Finished my full hydro mounts and tie rods, installed the front calipers and brake pads. Got the new Wiillwood brake pedal installed and started working on the orbital valve and steering shaft mounting.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 14, 2018, 09:19:32 PM
I put the rear brake calipers and pads on. The orbital valve and steering shaft are all completed. I was able to modify and mount the gas pedal from the van I pull the engine and transmission from. Made a simple dash for gauges and what not. TJ finished my adapter for the doubler, I need to pick up some bolts and put it together.  I didnít get to work on it at all Saturday considering there was 7 1/2 inches of water running through my shop after all the rain.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 16, 2018, 08:09:29 PM
I got the custom adapter in place shortened the transmission tail shaft and got the doubler bolted up after reworking the frame. Currently building the cross members.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 18, 2018, 09:44:01 PM
For the first time since I started this build I donít have any ratchet straps holding anything in place! I finished the doubler mounts. I took tomorrow off work to get three days on this thing. The fuel cell, pump and shifter all got ordered today.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 21, 2018, 09:27:13 PM
Brake system is done and the lines just needs to be tied to the frame and links. Radiator, transmission cooler and winch are all mounted. I got the rear shocks mounted and charged and the front pan hard bag built so itís holding itself up. The rear seat mounts are done as is the rear floorboard. I added a few more tubes for strength and got the triple sticks mounted and new linkage made and they work great.
Title: Re: Big Little Buggy Build
Post by: JYD on October 22, 2018, 03:19:07 AM
You might be ready before me
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 29, 2018, 07:46:34 AM
I was able to complete the floorboards, seatbelt mounts. I got the front lights put on, battery mount done, brake lines all secured. I set all my links and locked them down, put the switch panel and gauges in the dash. I pulled the wiring harness apart and removed the stuff I won't need and now need to wrap it all back up and start wiring in all the relays and fuses. Still waiting  on the fuel cell and fuel pump, hope to have it running  this weekend.
Title: Re: Big Little Buggy Build
Post by: kkattfish on October 30, 2018, 11:17:38 AM
Really nice build Chuck.  You are definitely fast and get a lot done in a short period of time.
Looking forward to seeing this done.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on October 31, 2018, 08:17:06 PM
Thanks we have been busting our asses on this thing trying to get it ready for FF. Iím excited to see what it will do!
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on November 01, 2018, 07:11:30 PM
I have been sick all damn week, but have tried to keep going as I could. We got the fuel cell and pump mounted. I have the wiring about half done, gonna pick up the rest of the AN fittings I need for the fuel system tomorrow and hopefully get it fired up Saturday.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on November 13, 2018, 10:46:44 PM
Well with all the work I have been doing I hadnít updated much. Itís just about ready for FF it wonít have side panels or hood this time but it soon will have. I hade to relocate two tubes on the rear that I thought would clear the tires but didnít, and adjust the track bar to keep the front drive shaft from hitting the frame. Hope this last 74 days of busting a** on building this rig will all be worth it when this thing works great this weekend. It will be great to be out wheeling with yíall again!
Title: Re: Big Little Buggy Build
Post by: JYD on November 14, 2018, 03:30:49 AM
Buggy looks bad a** canít wait to see it and you on the trail this weekend
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on November 26, 2018, 10:47:38 AM
The buggy did good in Florence until I broke both stock 30 spline outers. Replace them with chromo 35 splines and CTM's. We hit Table Mesa and had no  issues at all it worked really great. I built some side panels out of plastic and it looks a lot better. I still need to make a hood but it's slowly getting there.
Title: Re: Big Little Buggy Build
Post by: RCinLaveen on November 27, 2018, 10:54:33 AM
The buggy turned out very nice.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on November 27, 2018, 04:20:42 PM
Thanks. I still have some more things I need to do along the way while wheeling to better it but for as quick as it was built Iím very pleased
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on February 19, 2019, 06:12:37 PM
So I have been pushing this rig harder and harder and itís been really surprising me that it continues to tackle whatever I throw at it. The only issue I had was a rear output yoke coming apart, but I caused that by taking too much material off when clearancing it. I got the hood made and installed. Next is to build some bump stops so I can drop it a couple inches to help the COG.
Title: Re: Big Little Buggy Build
Post by: ROCKZILLA on March 07, 2019, 08:50:04 AM
I found a large bolder that knocked a hole in my oil pan while in Mammoth. I have never liked how far the pan stuck down, but now I had to change it. I bought a Speedway LS swap shallow pan and got it installed and it is almost three inches shallower than the stock van pan I had. Now I need to quit being lazy and build the belly pan I have the material to do anyway. I also swapped out the 2"x16" rear shocks for 2.5"x16" and it sits much better and handles the weight of my kids better also.
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