An ATV from the store is a pleasure not available to everyone. Therefore, many craftsmen make quadrics with their own hands. And in this article we will talk about the most interesting of them.
In the matter of manufacturing an ATV, everything that can be found in the garage and nearby can come in handy. Each vehicle handmade is unique and individual, so it is difficult to talk about drawings and diagrams.
Few people describe in detail the process of building their offspring, which makes it extremely difficult to find specific information. But there are exceptions.
How to make an ATV with your own hands
in 2012, the talented designer S. Pletnev shared the drawings and nuances of building his brainchild.
What was used in the design of the vehicle:
- Front and rear wheels from Niva Chevrolet 15 inches
- Engine a-m Oka
- Gearbox Oka
- Interwheel gearboxes from the rear axles of the VAZ "classics"
- SHRUS from the car VAZ-2108, 12 pcs
- Fuel tank from a 20l canister
- Passenger support from Oka's headrest
- Clutch from Oka
- Steering wheel from a motorcycle Ural»
- Instrument panel from Oka car
The main technical characteristics of the ATV:
ATV drawings:
The transmission is made from AvtoVAZ units with some modifications. For example, to reduce speed and increase torque, a chain drive was used instead of the main pair.
The interwheel gearboxes are borrowed from the classics, the axle shafts are removed and replaced with CV joints from front wheel drive vase. Equal velocity joints are also used in other transmission units.
Suspension independent on triangular cross-links. Shock absorbers from Oka.
Silencer homemade of 2 sections, insulated with asbestos.
The body kit is made of fiberglass. The creation of such plastic took 10 kg of epoxy resin, 1 kg of plasticizer and the same amount of hardener. 15 meters of fiberglass and 5 meters of glass mat.
ATV body kit - fiberglass. I pasted it for the first time, and therefore first studied the recommendations for the implementation of the relevant work. But as it turned out - this process is painstaking, although the result is worth it.
Bumpers and bumpers are welded from 20mm round tubes.
Photo of the finished ATV:
Material based on the article: http://modelist-konstruktor.com/razrabotki/853
ATV from a motorcycle
This quadric is made on the basis of the Ural motorcycle.
All details in the video.
ATV with motor IZH Jupiter. Razdatka from the motorcycle Ant.
ATV Cobra MIX
Generator, forced cooling, lowering, electric starter from dozens, engine from a Ural motorcycle.
Video of a homemade ATV in action:
Homemade buggy "Raptor"
Homemade ATV with an engine from Oka
It was assembled purely for entertainment purposes, so the author focused on industrial ATVs and assembling his car. However, there are a number of design differences that positively affected the cross-country ability of the all-terrain vehicle and significantly distinguish it from the background of standard ATVs.
The machine has excellent cross-country ability and reliability, largely due to its low weight.
During the construction of this model of a homemade ATV, the following parts and materials were used:
1) 32mm water pipe
2) 27mm pipe
3) Engine internal combustion from car Oka 11113
4) Gearbox from the same oka
5) Front and rear gears from the classic VAZ
6) hubs and grenades from VAZ 2109
7) fiberglass
Let us consider in more detail the stages of construction of this all-terrain vehicle:
Rover Suspension homemade design, organized using A-shaped levers, which are made of a pipe with a diameter of 27 mm.
Was installed engine and gearbox from the car eye, was brewed differential.
Gear ratio front and rear gears equal to 43 to 11, they were converted to internal grenades from the nine fret.
Hubs and disc brakes from the VAZ 2109 were installed, and the wheels were set to 15 radius through spacers.
Initially, it was planned to make the clutch on the steering wheel like on motorcycles, but then it was nevertheless decided to make it under the left leg, despite the unusual solution for an ATV, it turned out to be quite convenient according to the author. That is, there are no problems with gear shifting on the go. Moreover, the all-terrain vehicle is able to move off in any gear, even with a passenger on board, the engine power is enough. Therefore, the gears are not changed so often, when traveling on the roadway, only third and fourth gears are used, and off the road, respectively, the first and second gears are used as downshifts.
Was organized transfer case own design of the author, thanks to which it became possible to turn off front axle. Below is a photograph of the entire front axle disengagement mechanism, where you can see the main elements of the parts:
Work was carried out on the rear suspension of the all-terrain vehicle:
The car frame is being prepared for fiberglass gluing:
The process of fixing fiberglass on the machine:
Then the author proceeded to paint work on the all-terrain vehicle:
The weak point of the structure, as you can see from the photos, are the anthers on the grenades. The author has not yet decided how exactly to protect them from possible breaks.
In the next photo, the gear selection mechanism is clearly visible, as you can see in the photo, the lever was slightly distant from the engine, since before that it was installed closer and the author was often burned on the muffler, there was especially a high probability of such an injury when turned on reversing. At the moment, the problem is completely fixed by moving the lever:
There are no photos on the radiator yet, but what exactly are you interested in?
The all-terrain vehicle's radiator is hidden under plastic right in front of the instrument panel, despite the fact that the hole that exists there is very small, it is quite enough to cool the car. Although there may be problems when driving in heavy mud, as the hole is easily clogged, and cooling from the incoming air is not obtained. But the fan copes with such a load, although the all-terrain vehicle is not operated in heavy mud. In addition, the fan turns on only under really heavy loads, which is extremely rare.
The reason for this is that the device itself turned out to be quite light and the engine from the Oki copes well with the loads.
Below is a photo of the radiator placement:
The all-terrain vehicle has an approximate mass of about 450 kilograms.
Video of testing the all-terrain vehicle when driving on snow:
If you watched the video, you probably noticed the slippage rear wheel as much as several meters, which should be said about the operation of the rear differential. In this way, this all-terrain vehicle is very different from industrial ones, since they do not have a rear differential and the rear axle always rows, which does not interfere with the controllability of the ATV, since the width of the machine is small.
The author also wanted to initially brew the rear differential, but thought that he would always have time to do this, and decided to try to ride with the differential for now. But since the cross-country ability of the all-terrain vehicle suited and there were no problems with the rear axle, the author did not have any desire to disassemble the structure and weld the rear differential.
That is why the all-terrain vehicle remained with the rear differential.
The only author plans to install more serious wheels on the all-terrain vehicle. Or remove the stands for disks 15 by installing disks with a 4 by 100 bolt pattern from Logan or Opel, which are great for VAZ hubs.
Quite a few hunters, fishermen, and just outdoor enthusiasts dream of their ATV. But the prices of even used equipment are beyond the reach of most people, not to mention new equipment. Do not despair, because today we will learn how to make an ATV with our own hands! This is excellent transport for household needs, for the transportation of trailers, which has a high cross-country ability due to a short wheelbase, as well as easy to drive. But just want to say to do homemade quad bike it will take a lot of time. As practice shows, a project can take from 6 to 12 months on average.
Preparatory stage
So let's get started. First, prepare your tools and equipment. It will take a lot of welding work, for which manual arc welding is quite suitable. Choose electrodes for welding critical and vibration-loaded structures, which will be the ATV frame. By the way, this very frame can be cooked with your own hands from ordinary water pipes. These are easy to find at the nearest scrap metal reception, or metal depot. Choose a pipe diameter from 25 to 32mm, and the wall thickness should be around 3mm. For bending such pipes, it is desirable to have a pipe bender, but if it is not there, then you can also bend the pipes for the frame frame manually using a lever, heating the place of the desired bend with a gas burner, and preferably with an oxy-fuel cutter.
Choice of main parts
The next step will be the selection of the necessary parts in the first place, namely:
- engine
- wheels
- shock absorbers
- rear axle
If you want to assemble a simple lightweight quad with a drive only to the rear axle, then it is preferable to choose an engine from a motorcycle of average cubic capacity, from 250 cubic meters and above. Depending on the construction budget, it can be almost any motor from a Soviet motorcycle, preferably with a chain drive, due to which it will be quite easy to make a drive rear axle. The axle can be made from a tube made of structural steel. In the center, weld the flanges for fastening the driven star and the disc brake, and install the wheel bearings from the car on the sides, having previously pressed them into the housings made in advance.
The housings are used to attach the axle assembly to the pendulum. The pendulum can be left standard, additionally strengthening it and making a new mount for the disc brake caliper. Also, don't forget to make brake hose mounts along the swingarm.
Our next task is the choice of wheels. And ideal option not only in terms of accessibility, but also in terms of size, there will be wheels from Oka. main feature The fact is that such stamped discs are very light, ideally fit into the proportions of a home-made ATV, and most importantly, rubber from factory quadrics fits perfectly on them, which will significantly improve patency. How it looks can be seen below:
Selection of a donor for a new frame
How to make an ATV even easier to manufacture? You can simply use a donor frame, for example, from a Ural motorcycle by welding the rear axle to the standard swingarm and only slightly change the front suspension! The thick frame of the Urals is made of good steel, has an excellent margin of safety. And a motor with a lot of torque is perfect for such a purpose. As for the gearbox, it is better to use it from the Dnepr motorcycle. It is designed for good loads, it is distinguished by the clarity of gear shifting, and the most important thing is the presence of reverse gear, which is a mandatory feature of a full-fledged ATV. A photo example of a homemade ATV from the Urals is below:
Steering
Assembling an ATV with your own hands is not an easy task. And perhaps the hardest thing to do steering. To do this, first weld the frame of the front of the ATV, then you will need steering knuckles from a car, for example from a Niva, but any others will do. Then you need to build suspension arms. Pay special attention to the design of the attachment of the levers, since large loads occur in their interface with the frame, so additional stiffening ribs will not be superfluous. Levers, as a rule, are bolted through silent blocks. This is a rubber-metal hinge which is an indispensable link in the suspension. It dampens vibrations of the wheels, preventing vibrations from being transmitted to the frame. The levers can be made according to the drawings.
Move on. What front suspension without shock absorbers? Here you can use 4 motorcycle shock absorbers, one for each arm in the front, and two for the swingarm to dampen the rear axle. fit rear shock absorbers from Izh, but if you are ready to fork out for gas oil with pumping, then this will give you the opportunity to adjust the suspension under road conditions, which is very useful for such equipment as an ATV!
Four-wheel drive and car engine
And how to create an ATV with all-wheel drive yourself, you ask? Above, we considered the simplest option. But a variant is possible not only with a motorcycle engine, but also with a car engine! And then we will tell you how to make an ATV with an engine from Oka. In case of four-wheel drive ATV with a car engine, things are much more serious. Here it is no longer possible to use a motorcycle frame as a basis, it will have to be welded completely from scratch under car engine. By the way, it can be not only from Oka, but also from any other, depending on your desires and capabilities. Immediately do not forget about the liquid cooling system. Consider designing the frame in such a way as to place the radiator with the fan in a protected place from forest branches. The engine with the gearbox should be mounted along the frame so that the drive shaft from the gearbox is immediately directed to the rear axle. To distribute the rotation of the wheels to each wheel, you will need 2 identical bridges, for example from Zhiguli. But you will have to shorten them to install. To increase the cross-country ability, if desired, you can make a reduction chain reducer, compatible with a standard gearbox. In this case, the drive gear should be slightly smaller than the driven gear. By simple calculations of the ratio of the diameters of these gears, you can find out how much it will decrease maximum speed and traction will increase. If the ATV is not going to be used for driving on public roads, then this will be a very significant technical decision.
Increased functionality
Now that the frame and chassis the ATV will be assembled, the engine installed, you need to think about secondary structures, thanks to which it will be practical to use the equipment. The fuel tank is well suited from a Ural motorcycle. Its impressive capacity will be enough even for a car engine. An important modification will be the installation of a "snorkel". Since the engine in the frame is located quite low, then air filter respectively draws air from below. To prevent water from getting into it when overcoming fords, it is highly recommended to do this. Completely needs to be redone exhaust system, with the output of exhaust gases at a fairly high level, so that water also does not get inside. Also for an ATV you need a large wide seat by moving the weight of the body, it will be possible to achieve better control when moving. Aluminum sheet metal can be made into underbody protection to protect the front suspension arms and engine. Not superfluous in the forest will be a winch installed in front. Fog lights can be used to illuminate the road.
Work on appearance
In conclusion, to bring the ATV into proper appearance similar to the real you need a case. To do this, you need epoxy resin ED-20 and fiberglass. These components can be purchased at a hardware or hardware store.
To give this shape, first you need to cut a blank from dense foam, which is also sold in large hardware stores in the form of 1 m2 plates, which is very convenient for creating such projects. Then fiberglass is applied in several layers, while each layer is smeared with resin. The more layers, the stronger the case. Do not forget about the metal fasteners that must be inserted between the layers, in the future, for which the body will be attached to the frame of the ATV. After drying, it can be primed, sanded and painted. This fiberglass body is light weight and very durable.
With a serious approach to business, such an ATV will not be much inferior to the factory one, and in terms of assembly costs, it turns out to be many times cheaper. Despite the fact that you can collect such a thing for yourself and get a lot of driving pleasure.
Unfortunately, not every person has the opportunity to purchase an ATV in a store. Everything more or less interesting models now they are quite expensive, and buying a used ATV is always a certain risk. In this regard, many motorists are advised to make a four-wheeled all-terrain vehicle with their own hands, using an engine and spare parts from some old Soviet motorcycle. Earlier, we already told you about how to make an ATV from a Ural motorcycle. In today's article, we will talk about other donors that you can use if you decide to assemble an ATV with your own hands.
Why is it worth assembling an ATV with your own hands?
Putting together a four-wheeled all-terrain vehicle with your own hands definitely helps to solve several problems. The first reason why people decide to make a homemade quad bike is, of course, a small budget. If we analyze the market prices for ATVs, we can understand that such vehicles can be considered almost a luxury. Prices for the simplest and low-power models start at 150 thousand rubles, for example, the Yamaha Blaster YFS200. In principle, such a single "quadric" is enough, but the power will always be lacking.
But models of ATVs with engines with a volume of 500-800 cm 3 will cost much more, about 500 thousand rubles. You can also consider Chinese models, such as the Russian manufacturer Stels, but they will have to be well monitored. New all-terrain vehicles of this brand will cost approximately 300-400 thousand rubles, but the engines are already much more interesting - 45-70 hp.
Nuances in the operation of a homemade "quadric"
If you definitely decided to make an ATV with your own hands, then you should know about the intricacies of its operation. In principle, if you need an all-terrain vehicle to ride in impassable places where patrol cars have never been, then there is probably nothing to worry about. You will have to face problems if you plan to drive even on small settlements, which are sometimes visited by patrol cars. Having caught you without documents for this vehicle, then with a probability of 99% it will be taken away from you. The whole difficulty lies in registering a home-made ATV, because the traffic police will most likely refuse you. In a good way, you can register a homemade product, but this is extremely difficult to do. Therefore, assembling a homemade ATV makes sense only if you operate it in some wilderness.
Making a choice
So, how to make an ATV with your own hands? When creating a homemade ATV, we need to decide on a donor, that is, a motorcycle that will underlie our project. Old Soviet motorcycles are perfect for a four-wheeled all-terrain vehicle. From them we can borrow an engine with a gearbox, a frame, a steering wheel and, if desired, such details as a tank, a seat and other elements. Since we already had an article about a homemade ATV from a Ural motorcycle, in this review we will talk about how to make an ATV based on an IZH motorcycle.
For our purpose, almost all models of motorcycles from the Izhevsk plant are suitable for us. The only thing that is important to understand is the power of the engine. Still, the end result will be a rather heavy structure, so best solution will use latest models- IZH Jupiter 5 or IZH Planet 5. There is no point in considering more interesting models, like IZH Planet Sport, because it is not easy to find them, and if possible, it is better to restore them, because the motorcycle is quite rare and interesting. We turn to the main thing, how to make an ATV and what is needed for this.
Rear suspension
Once you have decided on a donor, in our case it is IZH Jupiter 5, you need to completely disassemble the motorcycle. After disassembly, we need a frame on which everything was held, including the engine. It is quite logical that in order to increase the reliability of the structure, the frame must be strengthened in several places.
Now it is necessary to weld the rear axle so that instead of a wheel, a block of bearings with a chain drive can stand on the axle. An example, you can see in the photo. As a suspension, you can use ordinary shock absorbers from a motorcycle, and parts from an old Zhiguli car are suitable for the rear axle. You can go a more complicated way and install a monoshock absorber, but then again you will have to look for spare parts from the car, for example, from the same Zhiguli or Oka.
Front suspension
Once the rear suspension is finished and installed, it's time to move on to the front of the bike, which is a bit trickier. In the case where we were dealing with rear suspension, we had the opportunity to choose how much shock absorber will be installed. When creating the front suspension, we have only one option - to use two shock absorbers.
Oka's car is perfect for the role of a donor for the front of the ATV. From it we need shock absorbers, rotary nodes and steering trapezoid. However, be prepared for the fact that the spare parts will still have to be changed - something to be welded, sawed off, filed. Also good and more simple option, there will be a monoblock installation with fixed wheel planes. Then you do not have to look for a steering linkage, couplings, hinges and other spare parts.
A monoblock is a really simple option, because it takes literally an hour to install. The only disadvantage of this design of the front suspension is a heavier mechanism. Turning the steering wheel will be somewhat more difficult than with a suspension with shock absorbers.
Engine
Many wondering how to make an ATV with their own hands, they understand that it is worth starting with the engine. And indeed, main detail in the future ATV is the engine. The end result, and indeed the whole structure, depends on how powerful it will be. Of course, you can leave the engine from the donor motorcycle, but in the end the “quad” will turn out to be not so powerful. If, however, a little more seriously approach the creation of an all-terrain vehicle, then the installation is more powerful engine would be a great solution. We hope that we have answered your question about how to make an ATV yourself.
ATVs can be equipped with two types of engines: electric and gasoline. Electric motors have less power and low energy storage. If you take the average ATV with an electric motor, the range will be about an hour of time, and then a long battery charge is required. In this regard, children's models of ATVs are equipped with this type of motor.
The most common ATV engines
Gasoline engines are the most widely used in ATVs. They produce high power, which, together with the transmission, is converted into high torque. Thanks to this, ATVs feel so great on any off-road. Also an important indicator is specific power (power per unit mass). Low weight of the motodevice paired with good engine allows you to show amazing cross-country ability to four-wheelers. For ATVs, motors with a displacement of about 49 - 900 cubes are used. Of course, there are smaller volumes that are designed for children's versions of devices.
The difference between gasoline engines for ATVs
Gasoline engines for ATVs can be divided into two large groups: two-stroke and four-stroke. The difference between these two types is that in a two-stroke engine, the piston completes one work cycle in one movement. In a four-stroke engine, injection, compression, detonation and exhaust are performed in two piston strokes. Based on this, we can say that a two-stroke engine produces more power with the same volume of cylinders. For example, one of the most common Stels ATV 300 ATVs is equipped with a four-stroke engine. Many people believe that fuel two-stroke engine oil needs to be added. However, this is not a completely correct judgment, since there are many engines that do not require this, for example, Catarpillar engines do not require the presence of oil in gasoline. Of course, the talk that two-stroke engines produce more harmful substances is true, but it should be understood that this is due to the higher frequency of fuel combustion in the cylinder. It can be noted that today mechanical engineering technologies are so developed that engine emissions different types differ little and are kept to a minimum.
ATV engine maintenance
performance power unit depends directly on the quality of service and frequency. Service maintenance two-stroke motors produced much more often compared to four-stroke. This is primarily due to the fact that more frequent combustion of the air-fuel mixture occurs in the cylinder. As a result, a higher engine operating temperature is achieved. Such factors lead to faster wear of the parts of the power unit operating on a two-stroke cycle.
So when buying a 2-stroke ATV, be prepared for more frequent maintenance and buying parts. The indisputable advantage of a two-stroke engine is its low weight and simplicity. But at the same time, there are many disadvantages: high oil and fuel consumption, high vibration and noise. A two-stroke engine is equipped, for example, with the Omaks Dragon ATV-024-15 ATV.
However, athletes and fans of quad bikes pay little attention to engine assembly, perhaps the most important point in choosing is the output power. In terms of power, it can be noted that the superiority of a two-stroke engine over a four-stroke engine with the same volume.