Chief buggy

[pennsylvaniaboy]

Well gents, it is time. I am starting a thread on a buggy build. This is a dream that I decided to chase. It has many factors. I got divorced last year, and this is cheaper than therapy. My son has shown a lot of interest in wheeling and when he is old enough I would like him to have a buggy that he can manage(auto, smaller, etc). I also find myself wheeling more and more just myself vs family of 4. Lastly, I find my current "buggy" to just be too big and heavy for some of what we want to hit. I want to keep trying harder stuff and this should open some of those doors.

This is a dream come true, I have built several rigs that have morphed from full body to framed buggies, but I wanted to build something that is all tube. I searched for tube buggies and kits. There are several out there that are top notch. TMR, PCR, IBEX, FAB801, Wende, Hulse, JHF, etc. All these kits have things that set them apart from others. Things that I liked and didnt like about each. Ultimately I chose the Hulse XL trail chassis. For me this was the most complete kit that offered the size, weight, and style I wanted. More importantly it all shipped to my zip code. There were other options I really considered, but I could line up shipping or a way to travel to get them.

Here are some pics of the chassis to show what it should look like

 

[Wisconsinite]

Killer. Can't wait to see it come alive.

 

[pennsylvaniaboy]

So in looking for a kit, I wanted something I could piece together, I didnt need a ton of tooling or jigs to complete. This is going to be built in a 2 car garage. Richard was great at answering questions. I took me a long time of asking question of multiple vendors to make a choice. He was patient all a long. ( I will also add, Wende chassis was my second choice. Adamwende was awesome to deal with, we tried hard to find transport and just could get the dots lined up)

Hulse has some options of the kits, from panels, to link mounts, fuel cell mounts, winch mounts, etc. I opted for the roof panel, link mounts, shock mounts, and winch mount. I may add the fuel cell mounts and cell later, but undecided on capacity and location at the moment. The picture above show most of those options minus the panels.

 

[white-rhino]

 

[YJ4Rox]

Richard is top notch to deal with. Great choice man!

which winch are you going to run?

 

[pennsylvaniaboy]

So the drivetrain to this is going to be the following-

GM 3.9LZ9- this is a 60* v6 that came in several Gm cars, This is from a pontiac g6, which will play into the name and the theme later on


Trans is a jeep 904 from a 4cyl XJ This gets you the 60* bellhousing, and 23spline output and pattern to run jeep cases

Doubler is a NWF eco box-i with some 231 guts

T case is a stock d300 that will get a girdle and back brace


Axles are a pass drop '05+ dana 60

and 2006 ford sterling with 2011+ e locker.

 

[pennsylvaniaboy]

Richard is top notch to deal with. Great choice man!

which winch are you going to run?

WInch is undecided. I bought the winch mount from HE, which is setup for the warn short 9.0 RC patten of 6"x4.5". I could mod most any traditional winch to that size, or make my own winch mount for the standard 10x4.5

 

[Bebop]

Cool ! I'll follow.

 

[chaplinfj60]

Awesome

so do you have to build a jig or something or is there super good instruction on assembly

cant wait to see it morph...

 

[pennsylvaniaboy]

Awesome

so do you have to build a jig or something or is there super good instruction on assembly

cant wait to see it morph...

assembly is a nice color coated instruction manual. The tubes are labeled with PN# and the tubes are etched with where the tube should land. I wll get some pics. But no jigs needed according to H.E.

 

[YJ4Rox]

I fitted mine on a simple weld table. Took about 6 hours with no jig, just some squares, clamps and normal fab stuff.
Everything is labelled clearly and the laser notches fit great.

 

[JR4X]

Awesome! Following

 

[posford]

In!

 

[Sterlingfire]

That's a nice looking pile o tubes!

 

[Wuz-A-zuk]

😎 sub'd


I'll assume your in PA? Can I ask what the shipping charge was? Also, where is it shipping from, I couldn't find their location.

 

[pennsylvaniaboy]

😎 sub'd


I'll assume your in PA? Can I ask what the shipping charge was? Also, where is it shipping from, I couldn't find their location.

Yes, in central PA. For me shipping was $450, I'm sure that is a fluid number as shipper change and costs change on location, etc.

As to H.E. location, I want to say Utah? I know his laser cut parts and tube parts come from a subcontractor.

 

[YJ4Rox]

Hulse is in Grand Junction. He drop ships the DIY kits from his laser/cnc guy which is a top notch vendor.
I am not sure he wants that info publicized but its a well respected vendor. ZERO worries or concerns.

 

[JohnnyJ]

Looking forward to the build. I feel like we are in a golden age where you can buy a knock down chassis kit for fair prices and come out with a very nice looking and good performing buggy.

 

[Penetrode Offroad]

Sweet deal man.

 

[pennsylvaniaboy]

Hulse is in Grand Junction. He drop ships the DIY kits from his laser/cnc guy which is a top notch vendor.
I am not sure he wants that info publicized but its a well respected vendor. ZERO worries or concerns.

Thanks, Couldnt have said it better.

 

[Tydes]

I would upgrade to a 6 gear 241 planetary over the weaker 3 gear 231 setup in the eco box-I. Easy upgrade and much stronger

 

[chaplinfj60]

I would upgrade to a 6 gear 241 planetary over the weaker 3 gear 231 setup in the eco box-I. Easy upgrade and much stronger

and you can find them tcases for under a 100 bucks all day long on market place. at least they were last year for me

 

[pennsylvaniaboy]

and you can find them tcases for under a 100 bucks all day long on market place. at least they were last year for me

Soo to this end, I got the correct input, can i just swap in the planet gears? I the Eco box will have to come apart eventually and could swap that in pretty easily..

 

[chaplinfj60]

if i recall thats all you have to do. if i remember the planetary gears do just swap around. because its either 231 / or 241. i do not know where i read this or if it was a phone call i had. dang it...

 

[pennsylvaniaboy]

if i recall thats all you have to do. if i remember the planetary gears do just swap around. because its either 231 / or 241. i do not know where i read this or if it was a phone call i had. dang it...

231 J Jeep Transfer Case 6 Pinion 94-up Planet Set Upgrade OEM | eBay

That should fit the bill right?

 

[Tydes]

Soo to this end, I got the correct input, can i just swap in the planet gears? I the Eco box will have to come apart eventually and could swap that in pretty easily..

The input shafts are interchangeable between the 231 and the 241.

231 J Jeep Transfer Case 6 Pinion 94-up Planet Set Upgrade OEM | eBay

That should fit the bill right?

As long as your 231 is 94+. The early years have a different cut and are little louder.

 

[pennsylvaniaboy]

Hmm i dont recall, Ill have to see if I have the case half, or other tell tale indicators. Does a 241 planet interchange or have the year cut off?

 

[rugburn]

Those Hulse Engineering chassis are so 🔥 this year

 

[Sterlingfire]

Hmm i dont recall, Ill have to see if I have the case half, or other tell tale indicators. Does a 241 planet interchange or have the year cut off?

Yes the 94 down 241 planet parts should not be interchanged with the 95 up planet parts. They will eat each other up if you do.

 

[SteerAndStuff]

Love a good buggy build thread, thanks for sharing. In for updates.