This is a variant of an all-terrain vehicle in which the objectives of patency were primarily pursued. The author immediately identified priorities for himself. It must be a reliable machine, which is not afraid of any obstacles. Due to these circumstances, I had to save a lot on the mass of the all-terrain vehicle, and therefore on convenience, because the biggest load on all-terrain vehicle this is his weight. What came out of such an idea, you will learn from this article.
Materials and assemblies used in the construction of the machine:
1) The engine is taken from the VAZ 2106
2) Gearbox from vaz 2108
3) Cylinders to turn, this is the clutch from the VAZ 2106
4) Hydraulics was also taken from the VAZ-2106
5) Calipers and wheels were borrowed from the Volga 2110
6) The wheels of the vi-203 are stripped.
Now consider the steps of assembling an all-terrain vehicle.
To begin with, the author welded a frame from the profile and engaged in fitting and estimating future improvements to the main components.
And also the frame is immediately welded:
The author failed to eliminate the runout of the shaft with the differential on his own, so he turned to professionals who made the same shaft as a whole, without seams. After that, the unit was installed on the frame design and the transmission worked:
Swap Host:
The leading star assembly has been finalized:
Regarding used stars:
lead-11 tooth
on the tooth-25 tooth
twin-12 tooth
wheeled-45 tooth
This is how swap cranes look before assembly:
Crane assembly:
In the pipe:
Installed on an all-terrain vehicle:
Then the author took up wheels for an all-terrain vehicle. Since the author did not even consider the option with cameras (reliability is needed), it was decided to strip the wheels off the VI-203 to reduce their weight and load on the chassis.
Started from the sidewall, where the tread ends, 5 layers of cord. On the running author left another layer.
The main problem was preparing the disks for such tires, it is rather difficult to make such in garage conditions, especially in terms of quality.
Checkers were left on the treadmill, since with them it would be easier to turn from a place on solid ground. In addition, it can always be removed from, if desired.
Circles for wheel disks were cut with plasma:
Here the disk is almost ready:
After welding, the author found that the metal behaved well both circles and the hub, the fourth bearing is now only under the hammer, the photo shows a black strip at the end of the groove:
Landing 630, circles cut 670, when trying to stick a circle inside, problems arose.
In a hurry, a machine was assembled for bending the profile, in the photo he and what was done on it:
Here are the blanks installed on the disk:
Two pulleys for the desired profile with bearings that the author had, the third one and the drive one (with handle) are made on two bearings, again from what it was, all the pulleys of different diameters were obtained. The middle one goes along the groove in the plates, the plates are 2 mm, the tension bolt abuts against the thrust plate 4 mm, the thread on it is a metric step 1.5 diameter 16.
Breather in the front part, out between the thrust bearings diameter 8.
Drive Assembly:
Unfortunately, the disc did not fit, or rather its seat, after the collar, it turned out that it would not be possible to pull it. After that, the disk was flanged, the seats were cut and sanded and welded again, but 1 cm less in diameter. The wheel is machined by Rossvik and re-flanged.
Finished Wheel:
Five hours after pumping, the pressure has not changed. Actual size considering protector 1485 * 600, disk 450.
Since this all-terrain vehicle is the first for the author, during the assembly there were many omissions and shortcomings, which the author tried to cope with.
For example: after installing the wheel on an all-terrain vehicle, it rested against twin stars. The author decided to make another disk on the right wheel, and then move the shaft with the differential closer to the front axle in order to solve this problem.
Since the wheels turned out to be large and massive, the author wanted to supply a Nissan Almera 2.2 engine with an electronically controlled fuel pump.
The start and operation of the engine is controlled by the on-board computer. The electronic sensors are connected to the on-board computer: 1 - vehicle speed, 2 - TDC of the crankshaft, 3 - engine temperature, 4 - air temperature, 5 - amount of incoming air, 6 - gas pedal position, etc. An anti-theft system is installed in the on-board computer. The high pressure pump is controlled by the BC. Of course there are some differences from model to manufacturer model, but basically it is. In general, the use of this unit is not easy, and the author is new to the construction of all-terrain vehicles.
And yet he confidently walked towards his goal:
In the photo in the wheel 0 atmospheres:
The wheels weigh 81 kg.
After design improvements, another wheel was made:
This time the author succeeded, and the wheels stood under the weight of the all-terrain vehicle for 4 days, and they didn’t lower the wheels, which means that the remaining two are a matter of technology.
It remains to install long chains, put tensioners, a battery, and a driver's seat:
The maximum clearance is 62 cm.
The metal on the skin is 0.5 thick, the rest is replaced by polycarbonate.
The all-terrain vehicle was tested in garage conditions on two chains. The main task was to find out if the diameter of the brake discs was enough. When you try to turn at low speeds, the car stalls, when the gas is supplied, the non-braked wheel breaks into the axle box and turns the car around, this is taking into account the concrete coating.
The pressure at the time of testing was 0.1 atm. Hydraulics without a vacuum, and the effort is not large, which is very good.
Only the clutch junk.
For subsequent tests, all the necessary transmission chains were purchased.
Test Video:
Purchased paired stars from some machines were used, but the distance between them was large, and the author sharpened one of them, reduced the distance to the desired one and welded a new one, the shaft under them was not spline, but the key with key 14 was not a cone.
The clicks during reverse are eliminated with a conveyor belt.
The spring loaded tensioner with a rigid stop was softened by tape.
After eliminating problems with the tensioners, the etching wheel was removed and laid on the sidewall that poisons.
The etching ceased (clogged all the holes with fine fibers).
Then the wheels were put in place. After 30 minutes, the pressure decreased by two. Unfortunately, the poison has become stronger upon arrival in garage the result is as follows: from 0.2 to 0 atm lowers in 10 minutes.
It was decided to get into the wheel and this is what was discovered there:
Here is what the author flared it with:
Then 9 patches were glued, the disk was washed and painted, the wheel began to hold the atmosphere. During the next race, the all-terrain vehicle on a steep slope carried sideways down to the first obstacle that fell on this most vulnerable wheel, the author thought the tire would be ripped off the disk, but it just started to lower again.
A wide base kept the car from a coup. In general, except for the wheel, which will be subsequently replaced, everything works perfectly and without complaints. The all-terrain vehicle is ready, perhaps in the future windows and doors will be added, although this will increase the mass of the all-terrain vehicle.
As a result, the width in the cabin is 123 cm, the height from longitudinal profiles to the top point inside 145 cm, length 280 cm.
Video with the off-road vehicle ready: