Off-Road Vehicle Construction Plans, Quality Parts & Kitsets This booklet shows how to build this off-road vehicle FROM SCRATCH! Long Travel Suspension featuring Fox Racing Shocks qb hk, pc Racing Seat Kit Pre-Bent Tube Kits More Great Now Available! Now Available! Designs Available! Lwww badiliandbuggy-comCopyright 2005 By Bodland Buggy, Edmonton, Alberta, Caneda All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or tranemittes, in any form or by any means: photocopying, electronic, mechanical, recording or otherwise, without prior express written permission of the copyright holder. WARNING: The doing of an uncuthorized act in relation to a copyrighted work may result In both o civil ‘elaim for damages and criminal prosecution. First Edition, First Printing Jonuory 2008 ISBN 0-9733172-0-5 "Badiond Buggy", "ST2", ton", “ST2 Long Travel”, “Sabretooth II", “Sabretooth” and "Velociraptor" are all trademarks of Badland Buggy, Edmonton, Alberta, ‘Canada.TABLE OF CONTENTS Introduction . Getting Started . Engine Selection . Fuel System Considerations . .. Copyright Warranty Returns Policy (Plans) Errors Chassis Steel Selection Tools . How to Bend Round Tubes Section "A" — Building the Chassis Frame Material List Template Board for All Bent Chassis Tubes Bending Details Tubes “TA” & “TB” Bending Details Tubes "TC" & "TD' Bending Details Tubes "TE” & "TF". . Bending Details Tube “TG” & “TH”. . Pre-Assembly of Bent Tubes Notching of Tubes “TF” & "TG". Assembly of Upper Rollcage . Adding Reinforcing Tubes to Upper Rollcage. . Lower Square Tube Base Frome Details. Weldments to Square Bose Frame. Weldments to Square Base Frame - Details for Plates PLOO18, PLOO19 & PLOO20 Marrying the Upper & Lower Chassis Assemblies Installing the Vertical Chassis Bracing... . Installing the Bonnet Bars & Front End Tubes. Installing the Cross Bracing : Front Upper Shock Chassis Tube Adding o Cutout for the Foot Pedal Box Aluminum Floor Plate Details . , Kitsets available for Section "