Custom Steel Chassis Hustler

[shawngray66]

Anybody out there currently working on a custom chassis and suspension setup. I have one designed in 3D and now working on construction drawings and pricing. My Hustler body is in not so good shape - top half has cracking. Drive train is in good shape with Kohler 16. Since I am going to 14ga steel chassis going to instal 34hp Kohler.

Cadman

[shawngray66]

Custom Steel Chassis Hustler

I am looking for feedback from anyone who has built an aluminum or steel chassis for a Hustler. I have currently designed one in 14ga steel and expect to run a diesel or large Kohler to push it. I also designed a simple springer system that would likely work for a plastic tub as well.

My main concern is weight as a steel chassis puts it up there in the Polaris weight category. I did not design this to be a floater but a utilitarian rig. With the extra weight what type of performance hit in the field would I see?

Will post pics of springer setup if anyone is interested. I also have construction drawings as well.

Cadman

[Mike]

There are several builds on this site that are completely custom and some that are springers (mainly from whipper-ag). Look around the forums some and you will see them. These are the first few that popped into my mind and there are more:

http://www.6x6world.com/forums/other-aatvs/15306-custom-made-volkswagon-powered-8x8-sea-doo-pump.html

http://www.6x6world.com/forums/max-atvs/24192-max-ii-gila-monster-springer.html

http://www.6x6world.com/forums/other-aatvs/16242-amphibious-kettenkrad.html

Bushwacker II BWII Custom 6x6 - Amphibious ATV Pictures

[shawngray66]

With the 980 I think the additional height would give me room for my no cv springer design. About how tall is it from the center-line of the axle to the bottom of the fender?

I could finish a modified 3D design for a springer and the 980 tub if someone could give me a cross section drawing of the tub and fender area. Approx dims would be ok as my design is flexible, low cost, and simple. I will post some pics if there is interest.

[Stonewall]

With the 980 I think the additional height would give me room for my no cv springer design.

Approx dims would be ok as my design is flexible, low cost, and simple. I will post some pics if there is interest.

I'm going to take a guess and say your idea is a torsional trailing arm suspension? I always thought that would be a better springer design for an amphib, but I don't have the means to design one right now...

Could you please post up some pictures of the design as you have it right now?

[shawngray66]

Stonewall,

Not torsional although not a bad idea. That might have advantages but the disadvantage would likely be the adjust ability unless you used a hybrid shock system.

This design uses one similar to that of the bugs without the cv. The bearing assembly is very simple holding block and uses an LM76 BullDog bearing that is designed for tough service (Minuteman glass epoxy). This eliminates a second a-arm set and the shock becomes the upper support. In addition, the bearing accommodates for the linear and rotational forces.

This is not a long stroke system and designed to improve the ride.

cadman

[shawngray66]

Stoneman,

I will put some thought into the torsion idea. Off the top of my head I can think of a few ideas that would allow for use on any body.

[Stonewall]

Ahhh, so your going for the "like a Macpherson but not exactly" suspension system. lol

Basically the same principle that the old school custom springers used:



I still think a trailing arm system would be the way to go, it would keep the vehicle much narrower and more maneuverable in tight spaces (woods in particular). With trailing arms you could even put the shocks inside the tub if you wanted...

[Stonewall]

Stoneman,

I will put some thought into the torsion idea. Off the top of my head I can think of a few ideas that would allow for use on any body.

A simple way to do it would be to use bearing and chain boxes off the main axles, using the axles as the drive and pivot. I don't know how well that would hold up though...

[thebuggyman1]

A trailing arm/chain box system would work well, especially since the chain box could be an oil bath.
Trailing arms also give a better ride because they swing back slightly as you hit a bump, instead of just up.

[IMG][/IMG]

[IMG][/IMG]

[shawngray66]

Stonewall,

Correct. My design does add width but less than a CV setup. However a trailing arm using a similar bearing design could be done cheaply I think. I found some torsion stubs for #500 pounds per set which is a little stout. Moving to a shock or airbag setup might not be too difficult.

[shawngray66]

bottom tub.jpgStonewall,

Sorry for hijacking this thread. I may need moved.

I looked at the offset and it seems with my design the additional width is half a tire on each side. Less than that of a CV.

[shawngray66]

Stonewall,

In looking at the design I believe I can tighten it even further by reducing the a-arm dim. I will try it as send an offset measurement. I went a little wider for stability.

[Stonewall]

A trailing arm/chain box system would work well, especially since the chain box could be an oil bath.
Trailing arms also give a better ride because they swing back slightly as you hit a bump, instead of just up.

That's exactly what I was thinking. Oil bath chain box, with coilovers on the inside of the tub. You could even run tracks over that kind of setup, since all the movement is up and back instead of up and out.

Shawngray,

You could also reduce some width simply by using a different wheel offset. A 5+2 offset would put the track a bit closer to the tub, but still not as close as a trailing arm system. Remember that the more you shorten the A-arm the less travel your suspension will have.

[shawngray66]

Right.

I have built a quick model to show the plastic mount with the current design. I would need about 10" of head space from the cl of the axle to the top of the bracket. I dont have that on my 950 so the question is does the 980 have the headroom?