At first glance, it may seem that assembling a homemade ATV is not an easy task. In fact, everything is much simpler than it seems, if there is necessary spare parts and tools. An off-road vehicle of this type is usually constructed from parts found on any unused motorcycle that is in decent working order.
Required set of tools
To assemble the device with your own hands, you may need the following tools:
Welding machine.
Bulgarian.
A good set of box and socket wrenches.
Other small tools like pliers and screwdrivers.
To assemble an ATV, you need a small room with good lighting and heating. If you assemble in the summer, you can sit under a canopy.
Engine and transmission
Engines from motorcycles are suitable as a power unit for a homemade all-terrain vehicle. Soviet production such as "Ural" or "Dnepr". For lighter and more maneuverable vehicles, you can use units from motorcycles like "Java" or "IZH", which were equipped with single-cylinder two-stroke engines.
To simplify the design of the future ATV, together with the engine, it is better to use the same transmission and drive with which they were originally equipped. To construct a machine with four-wheel drive you will need to install an additional gearbox. This is extremely rarely used in home-made devices, since it will be difficult to implement an additional unit without a sharp addition in weight at home.
Frame and suspension
The frame for a homemade apparatus is usually made by yourself from scratch. You can use blanks from an old motorcycle as material for the frame. The pipes from which they are made are lightweight and have the necessary strength and flexibility. As a last resort, you can choose the material yourself. Here the main parameter will be weight. Excessively thick tubes or profiles will make the ATV very heavy and overwhelming for fast and agile riding.
As a suspension, you can use shock absorbers with springs from the same motorcycles. The suspension itself is made in the form of the letter "A", and is movably fixed to the frame. Shock absorbers and springs should be selected in such a way that they can withstand the weight of the future machine and provide smooth ride with good handling on bumps and holes.
Steering and wheels
The steering can be partially used by motorcycle, with the addition of two-wheel drives. The drive is carried out by adding levers and ball joints to the design, which can be borrowed from the car. The main task of the steering is precise and comfortable steering.
The wheels for an all-terrain vehicle are best used from a car, as they are wider and will increase the vehicle's cross-country ability. The diameter of the wheels must be calculated in such a way that a homemade ATV can develop sufficient speed and also have a harmonious appearance.
Body and electronics
For installation attachments, gas tank and controls, you can use a motorcycle frame, which is structurally connected to the ATV frame. In this case, special attention should be paid to the stability of the all-terrain vehicle, its appearance and the convenience of the driver's landing.
Do not forget about installing all the necessary lighting and outdoor alarms on a homemade ATV. Headlights, taillights and the direction indicators are perfectly usable from the same bike that everything else was taken from.
See what a homemade ATV is in use!
Currently, the ATV is a popular vehicle. It is quite easy to operate, has good cross-country ability and a high degree of maneuverability. However, such an all-terrain vehicle is quite expensive and not everyone can buy it. Do not be discouraged, but you can try to make it yourself. How to make an ATV with your own hands? To help our recommendations.
If you are the owner of an old motorcycle and it is gathering dust in the garage, then do not rush to dispose of it. The Ural model is excellent for converting into an ATV.
The assembly of the all-terrain vehicle will consist of the following stages:
- alteration of the frame;
- installation of the instrument frame;
- engine installation;
- suspension installation.
What you need to work:
- bridge;
- shock absorbers;
- welding machine;
- Bulgarian;
- brake system;
- Tie Rod;
- metal profile sheet;
- motorbike.
Before starting the assembly, you should decide on the type of control of your homemade ATV. It can be motorcycle and steering.
The next step is to upgrade the frame by moving the vertical seatpost tubes 40mm back. Next, we weld the bridge to the Ural pendulum, slightly cut the lower fork and seat posts. Next to the pendulum suspension bushings, we weld struts made of pipes.
We shorten the bridge to make the vehicle more compact and more maneuverable. Now we do cardan shaft, which can be built from the Oka semiaxes.
We need square tubes 25 * 25 * 2 mm for the manufacture of the front suspension. You can borrow from a Zhiguli car steering knuckles... Close attention must be paid to the braking system. It is better to purchase it separately to ensure maximum security.
When all the main elements are assembled, then you can start installing headlights, turn signals and brake lights. We trim the ATV with a profile and prepare it for painting.
ATV from the motorcycle "Izh"
Assembling an ATV from "Izh" does not differ much from assembling an ATV from "Ural".
If you don't even have such a motorcycle, then you can buy it for a very nominal fee. Which will be much cheaper than buying an expensive vehicle.
The fundamental difference between the assembly of an ATV from "Izh" does not differ much from the assembly of an ATV from "Ural".
ATV from scooter
A great homemade ATV can be made from a scooter. We start the work process with drawing up drawings that you can do yourself and slightly redo the frame. Next, we install the engine. We connect the engine shaft to the gear of the rear axle of the ATV using an ordinary chain drive. We bring the controls to the frame and fix the pedals and control levers.
It is better to use components from the same scooter, but it is better to borrow a fuel tank from a motorcycle. Control can be set to steering or motorcycle, whichever suits you best, the brake lever must be fastened to the transmission brake on the rear axle sprocket.
For the body kit, we use material from old automotive technology or fiberglass.
ATV from the car "Oka"
You can breathe new life into an old car by trying to build an excellent homemade ATV out of it. Your whole family will love it.
We start by studying professional drawings. We modernize the body, remove the doors and the ceiling. We use comfortable seats for comfort. Next, we install the engine and muffler.
We attach the wheels to the frame, using shock absorbers and native suspensions. It is worth thinking about which one you will need and taking care of it in advance. The most important is the braking system. You shouldn't try to save money on this element. We will use the brakes from the motorcycle. The steering wheel can be installed motorcycle or left native. It is important to securely fasten the tie rods. The body is sheathed with metal and painted.
Children's homemade ATV
The presence of an all-terrain vehicle in families with children is even more important. There is no better gift for a child than a wonderful car made by dad. We pay special attention to safety in the manufacture of a children's all-terrain vehicle. After all, we are talking about the health and life of children.
What is needed for a children's ATV
We decide on the dimensions and appearance. The possibilities are unlimited, everything will depend only on your skills and efforts.
There is no better gift for a child than a wonderful car made by dad.
We draw up a drawing, it is easy to deal with it yourself. The main stage is the manufacture of the frame. For it, you can use a ready-made model or weld it from a square profile (25x25mm). If you make a frame with your own hands, then you need to pay due attention to the quality of the welds. We will buy new wheels, we choose them depending on the age of the child and on the quality of the road surface.
The choice of engine is wide enough. An electric motor from the Volga or a scooter will do. We will install the battery in such a way that it is not necessary to disassemble the entire structure for recharging.
After assembling all the major components, the most enjoyable part of the job begins. You can use a body kit from some old and unusable model of a children's ATV, or you can use your imagination and come up with a new original author's idea.
Do-it-yourself children's ATV 4x4 will significantly save your budget, bring joy to your child, and teamwork will bring the whole family together.
P.S. Homemade ATVs are not easy to do with your own hands. If something didn't work out right away, think about what and where you made a mistake. Thomas Edison made 10,000 unsuccessful attempts! before he invented the light bulb. And you will definitely succeed.
The ATV is a four-wheeled hybrid of a motorcycle and a tractor, a vehicle that is equally successfully used in both agriculture and recreation. A few years ago, a Russian person considered the ATV to be a foreign curiosity. And today he is able to independently design and manufacture it. In addition, today home-made ATVs are much more common in Russia, and not factory ones. Next, we will try to understand why it happens this way and not otherwise.
A self-assembled ATV is a common occurrence
Every day there are more and more daredevils who decided to create an ATV from improvised means and parts of old Soviet motorcycles. Naturally, self-made vehicles are significantly different from the factory ones. And it is often more powerful, but economical. The mass of a homemade ATV usually does not exceed 300 kilograms, which also greatly facilitates its operation.
Names and essence of the main stages of creating an ATV
Final stage and finishing works
The final stage creating a homemade ATV is by installing seats and headlights. In this case, anti-theft lights are the ideal choice, because the ATV should be suitable for use in any weather. Particular attention should be paid to the number of seats on the ATV and decide if the seat will be for the driver only or for the driver and passenger.
Finishing work when creating an ATV consists in sheathing the resulting structure with metal and painting.
ATVs, designed on the basis of "Oka"
For 20 years (from 1988 to 2008) in the vastness of our endless homeland, one of the most common cars was the domestic "Oka" (VAZ-1111, SeAZ-11116). Today "Oka" is one of the most popular options for vehicles, on the basis of which homemade ATVs are created. In the manufacture of ATVs, the engine, gearbox, wheels and other auxiliary parts are usually used. this car... Direct assembly and construction of an ATV based on the Oka car is carried out in accordance with the drawings created by experienced designers. The defining moment when creating an ATV is the formulation of the purpose of its use. Based on this, future owner ATV chooses one of the two existing variants of the Oka engine (35 HP and 53 HP).
ATVs designed on the basis of the Ural motorcycle
At the moment, a few decades ago, domestic "Urals" popular in Russia were replaced by much more nimble and economical foreign models. In this regard, many in the garages still have a recent best "friend" standing idle and rotting. But not a single Russian person is capable of allowing good to be wasted. Therefore, the "Urals" are increasingly used to create a relatively new type of transport for the Russian person. This motorcycle is unanimously recognized by folk craftsmen as the optimal basis for creating an ATV. Homemade ATVs from it turn out to be an order of magnitude more economical and have more pulling power than their factory counterparts.
The creation of an ATV based on the "Ural" consists of two stages: the design of the rear and the front. The use of the Ural gearbox when creating the rear part of the ATV will provide the structure not only with strength, lightness, but also with simplicity. In the end, the finished tool will not be equipped with a differential, which, in essence, can be sacrificed in the name of reducing the time spent on its creation. As for the design of the front of the future vehicle, it will take much more time and effort than the previous stage. Most of the work goes into fine-tuning the front levers of the ATV. This is due to the fact that they should be less rigid than that of a car, but more powerful than motorcycle ones.
ATVs built from scooters
Motor scooter (scooter) - a light motorcycle with an engine located under the seat - is ideal option, on the basis of which you can create a homemade ATV. A vehicle created by craftsmen on the basis of a scooter is an excellent alternative to the best factory copies.
It is extremely economical in terms of fuel consumption and at the same time possesses such qualities necessary for an ATV as mobility, light weight and a relatively large carrying capacity. The peculiarities of creating an ATV from a scooter are that the frame, engine, power supply and ignition system must be transferred from the same machine. But the fuel tank of the future vehicle should be a motorcycle tank, not a scooter one, since it has a significantly larger capacity. The rear and front axles are likely to be borrowed from a cargo scooter, the suspension - from the shock absorber of a large motorcycle, and the control - from the "Oka" or any domestic motorcycle.
ATVs, designed on the basis of the "Ant" motor scooter
For 36 years, the Soviet plant "Tulmash" organized the production of scooters "Muravei". In total, over the years, 8 models have been produced, differing in the volume of the gas tank and the power of the engine. Today the Ant motor scooter is an ideal base for making an ATV with your own hands. In order to convert the "Ant" into an ATV, you should perform some fairly simple steps: redesign the frame somewhat, work on reinstalling the seat posts, and so on. The installation of the steering wheel and brakes of the future ATV will require special attention, long-term efforts and time. When constructing homemade ATVs, it is strongly not recommended to use brake system previously used. It will be much safer to buy a new one. In the same time steering system can also be used from an old "Ant" scooter or an "Oka" car. The final stage in creating an ATV from a motor scooter "Ant" is the installation of turn signals, headlights and stops.
Instead of a conclusion. Why do many people prefer home-made ATVs rather than factory ones?
A home-made ATV, in comparison with a serial factory one, is much more economical, lightweight and comfortable to operate.
When assembling a vehicle with his own hands, the owner takes into account his taste preferences and requirements in the field of functionality.
Assembling the ATV on his own, the master has the opportunity to carry out finishing work (trimming, painting, tuning, the presence / absence of pleasant things), based on his wishes.
Today we will talk about how to make yourself out of a motorcycle, walk-behind tractor or moped real ATV do it yourself. We will also consider drawings, diagrams and methods for assembling a homemade ATV from scrap materials in the garage.
From a motorcycle like "Ural" - this big, bulky, heavy and "gluttonous" animal has a wonderful four-stroke engine with reverse gear and costs "a penny". For this reason, it is much cheaper and more fun for enthusiasts to create their own designs for these SUVs.
Before starting the assembly, it is necessary to draw up a detailed list of units and parts that will be needed to create your own brainchild, develop a work plan and a design drawing.
It is logical that first of all it is necessary to find the "heart" of the future ATV - power unit... Absolutely anything will do, from a conventional walk-behind tractor to a six-liter V12 - there are such precedents. In most cases, motorcycle engines are used - they are economical and small-sized.
To use high gear ratios under normal operating conditions, a Minsk or Ural engine will suffice.
In summer, the issue of overheating arises, so you should choose models with air cooled... Another good option is boxer engines Soviet-made, an indisputable plus of which is a powerful traction and completely unpretentious cardan transmission.
There are two most common solutions rear suspension for ATV.
Gear-cardan system. The design turns out to be as lightweight and simple as possible, but there is no differential, which, in principle, can be sacrificed for the sake of the previously mentioned advantages.
Using a road bridge. The construction turns out to be extremely heavy, and if there is no desire to have an ATV with a car base, it is necessary to shorten the bridge, which is a very non-trivial task. Of the advantages, it is worth highlighting only the presence of a differential, which is useful when driving on highways.
The possibilities for front suspension and steering are tremendous. The suspension arms of an ATV carry a significantly lower load than automobile ones, respectively, they can be made independently, using available tools for this. The best option- creation of a suspension based on the existing Ural motorcycle.
Ideal - remove the frame from the donor motorcycle and weld necessary elements- this eliminates a number of problems, but the design may turn out to be unnecessarily complex.
Having prepared necessary tools, vehicles-Donors and freeing up time, you can start creating your own ATV:
We collect the frame (frame). We connect the prepared metal beams, according to the drawing, to each other using spot welding. We check the structure and carry out solid welding. Alternatively, you can simply remake the frame from the donor motorcycle - it will be no worse.
Installing the engine. It can be installed both from the back and from the front - the main thing is to firmly fix it with bolts on the bottom of the frame.
We mount the drive and transmission on rear wheels... The drive does not need to be created independently - it goes with the engine from the donor transport and is installed on the frame. Again, the drive and transmission must be properly secured to the frame to prevent backlash.
The steering is also installed from the motorcycle. Together with the steering wheel, the fuel tank "migrates" to the ATV. In general, if you imagine the structure, it will look like this: 3/4 of the ATV is the same "Ural" or another motorcycle, 1/4 is homemade frame and suspension. ...
We install wheels from a small-sized vehicle ("Oka" or "ZAZ-968"). The rear wheels can go to the ATV together with the rear axle of the car, or they are attached as follows: we take the ready-made axles with disks, and then we attach the gearbox to the rear for the drive. and install wheels on the disks
With a gearbox on the rear axle and an engine, we assemble a single drive (again, it will be easier if it is completely rearranged from the donor tool). We do it as follows: from the engine we pull the chain onto the gearbox and fix it, after which we carry out a performance check. Finally, we fix the entire structure on the frame.
The front suspension is independent - it is more profitable in terms of time and money, since an all-wheel drive ATV requires significant revision of this unit by a professional turner, welder and electrician, which will take a very long time. Alternatively, we purchase ready-made factory units for ATVs.
Thanks to its reliable, time-tested design, excellent power and traction, it is the Ural motorcycle that is the most popular donor for homemade ATVs.
Frame.
ATV Frame Specification:
Material: 2.5 x 2.5 square profile
Total length: 130cm
Overall height: 74 cm (landing level)
Overall height: 84 cm (handlebar level)
Wheel base: 105 cm
Distance between axles: 70.5 cm
Axis tilt: 14 degrees
Track (distance from the outer edge of the tire to the outer edge of the other): front: 105 cm; back: 112 cm
Ground clearance: 7 inches (with 16-inch rear wheels)
Materials:
Square profile:
2.5x2.5 square profile - 9.75 meters
Pipes:
1.22 meters - 1 x .065 (inches)
1.22 meters - 3/4 x .065
0.3048 meters - 3/4 x .125
0.915 meters - 5/8 x .125
0.61 meters - 1/2 x .083 T6 aluminum tube
Rental:
0.61 meters - 1 x 3/16 (inches)
0.915 meters - 1 1/4 x 1/4
0.61 meters - 5 x 1/8 (engine and suspension plate)
You will also need spring dampers for the rear and front suspensions.
Engine for ATV:
Now you need to securely attach the engine to the frame. The engine is best used from a moped. After screwing it to the frame, connect the motor shaft to the gear on the rear axle with a simple chain drive. After that, bring all engine controls to the steering wheel and secure the pedals and levers to your frame.
The best and easiest way to make parts of the body kit or bodywork of an ATV is fiberglass. After manufacturing on wooden or plasticine blanks, the elements of the aerodynamic body kit are adjusted relative to each other, polished and then painted in the desired color, after which they are already attached to the ATV frame. Ideas, as well as some ready-made elements, for example from a broken car (of course, if you have them available), options for an external body kit can be taken from any serial models.
Important:
Remember that in order to operate the ATV on public roads, you will need to register it with the traffic police, where it is necessary to register any vehicles with an engine over 50 cc and a maximum design speed of over 50 km / h. Therefore, we recommend not to use engines larger than fifty cubic centimeters.
The frame for the ATV is welded using round pipes, corners and square profiles. At the same time, it is advisable to use elements of various mopeds and motorcycles, because it is there that pipes with high strength are used. Never use water pipes. They do not have the required strength and can crack at any time. Then we weld on the mounting brackets and fix the engine to the frame. Make your first ATV out of a moped engine
Even your children will like it, who will simply be delighted with it. The fact is that petrol-powered ATVs for kids are a great toy for every child. After all, he does not develop huge speeds, but the guys will have more than enough emotions from overcoming rough terrain. Next, we connect the engine shaft to the rear axle gear using a chain.
We install the ATV control mechanisms on the steering column, and attach the pedals and levers to the frame. The power supply and ignition system is taken from the same moped model from which we took the engine. Over time, they can be improved and refined within reasonable limits, of course. You can choose a fuel tank of the appropriate size. Do not forget also the point that in the question of how to make an ATV, each stage must be carefully worked out. Therefore, installing a battery on such a car is simply necessary.
You also need parts for assembling an ATV:
1 - disks from a scooter tourist or ant
2 - rubber for motoblock 10 inches and wider 4.5 or 5.0
3 - profile pipe 15 * 15. 17 * 17. 20 * 20. 25 * 25.
4 - bearing 306 - 12 pieces
5 - CV joint outdoor vase 2109-08 16 pieces, 4 of them are new 4 used, but workers, and 8 can be killed (for any hundred in scrap metal) and 8 anthers.
6 - engine with a moped at least 150 cc. for example, a viper storm in a place with a wiring with an ignition switch with a wheel and a glushak
7 - reducer from a motor scooter ant reinforced (all shafts on bearings)
8 - four leading sprockets from 21 tooth Izh and two new chains
9 - ball joints with Renault 21 for any disassembly with a shaft and a penny
10 - jet thrust rear axle (short.) from 2101 - 6 pcs.
11 - a bunch of different bolts of cutting wheels and electrodes, well, that's all along the way
12 - shock absorbers of the Yamaha ario smoped -4 pcs from Honda Lead 2 pcs and 8 more killed shock absorbers from any yap mopeds (we will cut off the ears from them)
.
In winter, the ATV can be easily converted by replacing the rear wheels with pneumatics and installing a steering ski in front; the car thus turns into a snowmobile, and the transformation takes less than an hour. The use of available materials in the manufacture of the all-terrain vehicle, the simplicity of the design may well ensure the repeatability of the machine even in a home workshop.
The frame of the MTS is made of round tubes, square profiles and corners. It features detachable connections that allow you to remove the steering column assembly when installing the engine, as well as the front axle beam. Each of the connectors consists of a conventional "water pipe" sleeve, squeegee and locknut.
To tension the chain connecting the engine with the gearbox, the motor frame (part of the frame of the Minsk motorcycle) is moved; the axle of the rear wheels with bearings also has the ability to move in the longitudinal direction, which allows you to adjust the tension of the second chain connecting the gearbox to the rear axle. Front and rear fenders are removable (they are not available in the version of the snowmobile). The frame elements were joined by electric welding.
The engine of the motor vehicle is from the Minsk motorcycle, I have no comments on its operation. It is, of course, possible to install more powerful engines - from the Voskhod motorcycle or the Tula scooter; it is only necessary to adjust the dimensions of the frame for them. The choice of the "Minsk" engine was due to its efficiency and low weight. Its power turned out to be quite sufficient for trips on a snowmobile with a passenger, it is also possible to tow a skier or sled. The starting properties of the motor in summer and winter are quite satisfactory.
The directional control of the summer version of the motor vehicle is provided by turning the front wheels using two rods; for the winter version, there is a lever and a rod connecting it to the ski fork. The latter is borrowed from a moped. Front axle- from the SZD motorized carriage, however, somewhat reduced: sections are cut out of its beams and the central parts (with the torsion bolt) are welded to the peripheral ones (with the suspension arm bushings). In the winter version, the levers, steering knuckles, rods and torsion bars are dismantled.
The steering wheel is from the "Tourist" scooter, it fits perfectly with the steering shaft with an M10 bolt. The controls are standard, motorcycle. The brake lever is connected by a cable to the brake pads mounted on the gearbox.
Reducer. Its basis is the hub of the rear wheel of the Tula-200 scooter, to which an asterisk is welded from the side of the brake drum. The rear axle is driven by a chain with a 19 mm pitch. The transmission brake makes the rear axle much simpler. The sprocket on the axle is fixed with an M14 bolt, the hubs of the travel wheels are similarly attached, as shown in the drawings. As the basis of the gearbox, you can use not only the hub of the "Tourist" wheel, but also other motor vehicles.
The axle of the driving wheels is a rod with a diameter of 30 mm; its ends are turned to Ø25 mm, turned hubs are put on these places. Wheels are used from a motorized carriage with a size of 5.00X10.0. Winter wheels conventional for pneumatic tires on tires low pressure designs: with plywood discs, aluminum cradles and camera straps. The axle bearings are double-row, they have tapered inserts with nuts, which fix the axle well and do not require high machining accuracy.
More information about ATVs can be found at this link:
Optional equipment. This includes front and rear racks, headlights, turn signals and brake lights; their attachment points are shown in the figures.
The design of the all-terrain vehicle is simple, it can be made in just a few days in a fairly primitive workshop - of course, if all the components are available. And the possibilities of using such a machine are the widest: as a winch when plowing a vegetable garden, to drive a circular saw, as a simple garden tractor (excellent cross-country ability, therefore cultivation, hilling, etc. is possible). In addition, you can increase cross-country ability by installing twin rear wheels. You can also mount a reverse gear from the SZA motorized carriage, in which the differential is replaced by a shaft, and then the all-terrain vehicle will receive reverse gear... Rubber wear due to the lack of a differential is not observed, and this does not affect handling.
Quite a lot of hunters, fishermen, and just lovers of outdoor activities dream of their ATV. But the prices even for used equipment are too expensive for most, not to mention new equipment. Do not despair, because today we will learn how to make an ATV with our own hands! This is an excellent transport for household needs, for transporting trailers, with high cross-country ability due to a short wheelbase, as well as easy to operate. But right away we want to say that it will take a lot of time to make a homemade ATV. As practice shows, a project can take from 6 to 12 months on average.
Preparatory stage
So let's get started. Prepare your tools and equipment first. 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 warehouse. Choose a pipe diameter from 25 to 32mm, and the wall thickness should be around 3mm. To bend such pipes, it is desirable to have a pipe bender, but if it is not there, then you can also manually bend the pipes for the frame frame using a lever, heating the desired bend with a gas burner, or better with a gas-oxygen cutter.
Selection 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 build a simple lightweight quadric with a drive only to the rear axle, then it is preferable to choose an engine from a motorcycle of an average cubic capacity, from 250 cubic meters and above. Depending on the construction budget, this 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 rear axle drive. The axle can be made from a structural steel tube. In the center, weld the flanges for attaching the driven star and disc brake, and on the sides, install wheel bearings from the car, having previously pressed them into pre-made housings.
The housings are used to fasten the axle assembly to the pendulum. The swingarm can be left as standard by further strengthening it and making a new mount for the disc brake caliper. Also, do not forget to make the brake hose mounts along the swingarm.
Our next task is the choice of wheels. And the ideal option not only in terms of accessibility, but also in size will be the wheels from the Oka. The main feature is that such stamped discs are very light, they will perfectly fit into the proportions of a home-made ATV, and most importantly, rubber from factory ATVs is perfect for them, which will significantly improve cross-country ability. How it looks can be seen below:
Donor selection for a new frame
How to make an ATV even easier to manufacture? You can simply use a donor frame, for example, from the Ural motorcycle by welding the rear axle to the standard swingarm and just slightly change the front suspension! The thick frame of the Urals is made of good steel and has an excellent margin of safety. And an engine with a high torque is very suitable 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 clear gear changes, and the most important thing is the presence of a reverse speed, which is an indispensable function of a full-fledged ATV. Photo example of a homemade ATV from the Urals below:
Steering
Do-it-yourself ATV assembly is not an easy task. And, perhaps, the most difficult thing is to do it steering... To do this, first weld the frame of the front of the ATV, then you will need steering knuckles from the car, for example, from the Niva, but any others will do. Then you need to build the suspension arms. Pay special attention to the design of the attachment of the levers, since in their conjunction with the frame there are heavy loads, so additional stiffeners will not be superfluous. Levers are usually bolted through silent blocks. This is a rubber-to-metal hinge that is an indispensable link in the suspension. It dampens wheel vibrations, preventing vibration from being transmitted to the frame. Levers can be made according to these drawings.
Move on. What is the front suspension without shock absorbers? Here you can apply 4 motorcycle shock absorbers, one for each arm at the front, and two for the swingarm to shock 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 handy for such equipment as an ATV!
Four-wheel drive and car engine
How do you create a 4-wheel drive ATV yourself? Above, we have considered the simplest option. But an option 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 Oka engine. 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 any other, depending on your desires and capabilities. Don't forget about the liquid cooling system right away. Calculate the frame design so that the radiator and fan are located in a protected area from forest branches. The engine with the gearbox should be mounted along the frame so that the drive shaft from the gearbox is directly directed to rear axle... To distribute the rotation of the wheels to each wheel, you will need 2 identical axles, for example, from the Zhiguli. But for installation you have to shorten them. To increase the cross-country ability, if desired, a lowering chain reducer can be made, combining with a standard gearbox. In this case, the driving gear should be slightly smaller than the driven one. By simple calculations of the ratio of the diameters of these gears, you can find out how much will decrease maximum speed and the thrust will increase. If the ATV is not planned to be used for driving on public roads, then this will be a very significant technical solution.
Increased functionality
Now that the frame and chassis the ATV will be assembled, the engine installed, you need to think about the secondary structures, thanks to which it will be practical to use the technique. Fuel tank fits well from the Ural motorcycle. Its impressive capacity will be enough even for a car engine. An important modification will be the snorkel installation. Since the engine is located quite low in the frame, then air filter accordingly draws in air from below. To prevent water from getting into it when overcoming the fords, it is highly recommended to do this. Completely need to be redone and exhaust system, with the exhaust gas outlet at a fairly high level so that water does not get inside either. Also for the ATV you need a large wide seat, moving the body weight, it will be possible to achieve better control while driving. Aluminum sheet metal can be used for underbody protection to protect the front suspension arms and engine. A winch installed in the front will not be superfluous in the forest. Fog lights can be used to illuminate the road.
Work on the appearance
In conclusion, you need a body to get a proper ATV look and feel. To do this, you will need ED-20 epoxy and fiberglass. These components can be purchased at a hardware store or hardware store.
To give this shape, first you need to cut out 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 coated with resin. The more layers, the stronger the case. Do not forget about the metal fasteners, which must be inserted between the layers, in the future for which the body will be attached to the ATV frame. After drying, it can be primed, sanded and painted. This fiberglass body is lightweight and very durable.
With a serious approach to business, such an ATV will be little 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 assemble such a thing for yourself and get a lot of driving pleasure.
