Buggy Double Aarm Front

8/2/2019 Buggy Double Aarm Front

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Piranha Double A Arm FrontModification

IntroductionThe following set of drawings is designed to be used in conjunction with the 'Piranha Series II' plansavailable from 'The Edge Products LTD'. The design incorporates components manufacturedexclusively by 'The Edge '. Other manufacturer's similar products may be substituted at the builder'sdiscression but this is not recommended as the design is based around those parts readily availablefrom the above manufacturer and any changes may affect the steering characteristics or handling.

Suspension Mount PlatesBegin by cutting out and drilling all components constructed out of flat bar. All these componentsare drawn full size and should be traced or punch marked directly onto the flat bar material. Note:The following drawings are required to be joined accurately together to form the larger componentsalong a centre dividing line. Join A to A, B to B, etc.Front upper shock mount,Rear upper shock mount,Rear inner plate,Rear outer plate.After all components have been cut out, like parts should be clamped or tack welded together anddrilled through at the same time. Drill together the following:Left and right front outer plates,Left and right front inner plates,Front and rear upper shock mount (W ' holes only),Rear inner and rear outer plates,Front left and front right spacers,Steering arms (x4),Lower shock mounts(x4).Once drilled, separate and clean up all edges. If you intend using countersunk bolts for the upper Aarm pivots, countersink the inner plates to suit the bolt heads now.

Modifications to the Piranha nose frameIf you are modifying an existing completed frame, remove the following: Bonnet bars, upper shockmount, lower steering column mount, pedal box mount rail and all other 2Ox20x1.6m RHSin thenose section, all 30x30x2.0mm RHSand suspension arm mounts and steering rack mount. Clean upall remaining steel with angle grinder Note: the upper steering column mount is NOT removed.If you are adding this modification to a frame under construction, complete the entire buggy frameless the above components.Begin by tack welding in place the 30x30x2.0mm RHSfront suspension frames (page 7) as shown onpage 8. Note: due to the common practice of extending these buggy frames to suit the engine ordriver, the builder will need to check the length of these components against their own machine, asany extensions will affect the length of these bars. The folded end of these bars MUST be made asshown, otherwise it will be difficult to install or extract the lower A arm pivot pin.


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Next, install the 20x20x1.6mm RHSlower frame components as shown on page 8 and fully weldboth these and the 30x30x2.0mm RHSpreviously tacked in place.It is now necessary to notch the 40x40x2.0mm top frame for 'Edge' shock clearance, as detailed onpage 9. Note: although it would be easier to do this without the 30x30x2.0mm and 20x20x1.6mmRHScomponents in place, these will support the nose section whilst this operation is being done andhelp minimise any distortion. After cutting notch to shape, cap the cavity using 2.0mm sheet andfully weld.

Suspension ArmMountsTack weld the suspension arm mount components onto the 30x30x2.0mm frames as detailed onpage 10. Hint: use scrap tubular material cut to the correct length as temporary spacers to hold thefront and rear, inner and outer components together and in line by passing a 16mm bolt (fabricatefour of the bolts shown on page 64 of the Piranha series" plans for this) through the pivot pointholes and the tubes. install a nut on the end of the bolts and tighten. The top of the front plates mayneed to be trimmed to fit properly into the 40x40x2.0 RH$ top frame. Check every component issquare and aligned correctly and tack weld in place.

Steering Rack set upCut out and drill the steering rack mount shown on page 11 and fabricate the steering column onpage 12. Remove the rubber boots on the XRV rack and bolt the rack to the completed rack mount.Note the 'Edge' fogo on the rack body will be upside down when the rack is installed correctly in theframe.To set up the rack mount positlon, install the steering column onto the rack by passing a suitablysized bolt through the drive pin hole in the rack adaptor and rack shaft. Next, make the two set upcradles for the rack shafts to sit in and position as shown on page 13. Install the rack and columnassembly so the rack shafts sit in the cradles and the steering column is located in the top steeringbush. Bolt the bush in place on the top column mount plate. A small adjustment may need to bemade to the top column mount plate to align it correctly with the steering column. The lowercolumn mount plate position is found by installing the lower bush onto the steering column, boltingthe mount plate to the bush and tack welding the plate to the front of the 40x4Ox2.0mm crossmember as shown on page 79 and 80 of the Piranha series II plans. Alternatively the lower columnmount plate can be installed first. Mount this flush with the top face of the 40x40x2.0mm crossmember and tack weld in place at an angle of approximately 16 deg, down off the horizontal andthen set up the rack mount position as described above. Once everything is square and positionedcorrectly, tack weld the rack mount and column mount plates, and then remove the XRV rack, rackcradles, column bushes and steering column. Fully weld all suspension plates, rack mount andcolumn mounts. Remove 16mm bolts and tubular spacers after welding.

Suspension ArmsPages 14-20 show the details for constructing the suspension arms. These are all drawn full size andsome pages are required to be joined together as before. Lay these out on a flat surface and use as atemplate. Two are required of each. The upper A arms can be made from the same template, oncefabricated, one is simply flipped over to become the left arm.Notes on constructing the top arms: Fully weld the entire arm before cutting the excess material offthe 25NB pipe. It will be necessary to re-adjust these arms by manually bending them after thismaterial is removed due to welding stresses. Caution: do not attempt to cut all the way through the


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25NB pipe with a power tool as the material is likely to grab the blade. leave the last 3mm to be cutmanually.Hint: It is not necessary to fish mouth the 15NB pipe braces that form the cross on the upper arms.Just straight cut them and weld up the small gap.

Upper Shock Mount InstallationDetailed on page 21.Install the acetal bushes into the lower A arms and bolt them into the suspension arm mounts usingthe bolts fabricated from the Piranha series II plans on page 68. Next construct the upper shockmount set up bars shown on page 7. Bolt one end into the lower shock mount through the holemarked 'x' on the drawings. Use washers or shims to make up the gap ON ONE SIDEOFTHE BARONLY so when the bolt is tightened up the bar is firmly gripped, but still able to be rotated. Next,weld on the pedal box mount pin supports to the rear face of the Rear upper shock mount platewhere shown on page 6A and 6B, then tack weld the spacer between the two Upper Shock Mountplates (page 21). Ensure the W' bolt holes are aligned between the two plates. Position the Uppershock mount assembly onto the 40x40x2.0mm Top frame so the upper end of both shock mount setup bars can be bolted into the W' holes marked 'x' on the front upper shock mount. Again usewashers or shims ON THE SAME SIDEASTHE LOWER END ONLY and tighten. This will now give youthe correct angle to mount the top shock mount plates. Ensure these plates are square to the centreline of the buggy, level in relation to the top frame and that the set up bar is .parallel to the innerplates on the suspension arm mounts. Once this is done tack weld the base of the upper shockmount plates in position. Note: It may be necessary to trim the base of the shock mounts for anexact fit.Install the bonnet bars as shown on pages 8 and 9 of the Piranha series II plans and tack weld inposition. Fabricate the pedal box mount pin and mount rail as shown on page 22 and positioncorrectly by using two pedal boxes bolted to the outside mount tags and installing the pin throughthe front of the boxes and pin supports. The top face of the pedal box mount rail should be flushwith the top face of the bonnet bars and the rear vertical face of the pedal box (where the mastercylinder is bolted to) should be at, or very close to 90 deg. to the floor pan if installed correctly.Remove the lower A arms and set up bars.now fully weld all components.

Modifications to Barracuda UprightsCut off the original steering arms on the Barracuda uprights, tack weld together the new steeringarm assembly shown on page 23 and install on the uprights as detailed on page 24.Unlike theuprights on the Barracuda, these new uprights will be installed with the steering arms facingforward, as per the original Piranha steering arm direction, so right Barracuda upright becomes leftPiranha upright etc.


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Tie RodsFabricate the tie rods as shown on page 12 and install 5/8" rod end with locknut into each one.Install this assembly onto the steering rack ensuring the 14mm locknut supplied with the XRV rack isused.

Final AssemblyInstall the X R V rack and tie rods, steering column, upper and lower column bushes.Install the acetal bushes into the upper A arms (they will need to be cut down in length),Cut the four M16xl00mm countersunk or standard bolts to a length of 70mm (measured from theunderside of the head to the end of the thread) and clean up the threaded end.Install the upper A arms using the cut down bolts as the pivot bolts. Note:These A arms sweepforward as shown on page 20B.Install the lower A arm using the standard Piranha pivot bolt.Install the shock absorbers into the bolt holes marked 's',Install the W' rod ends, rod end spacers and jamb nuts into the ends of the A arms.Install the uprights onto the rod ends ensuring they are the correct way up as shown on page 24.Install the rod end spacers onto the tie rod 5/8" rod ends and bolt onto the uprights.The settings below will give you a good starting point for fine tuning the suspension to your ownpreference/ driving style.Adjust toe in to zero.Adjust the camber to 1 deg. negative.'Edge' Shock setting to 80-85mm from end of sleeve to underside of locknut.


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Steel Material ListNote: extra has been added for cutting and bending allowances.Material Quantity Total Used for25NB 3.2mm Pipe20NB 2.3mm Pipe

15NB 2.6mm Pipe

800mm1900mm

Suspension armsLower suspension armsTie rodsSuspension armsSteering columnXRV Rack mountFront suspension frameUpper shock mount set up barsPedal box mount raillower side framePedal box mount pinPedal box mount tags and pin supportsUpper shock mount spacerFront inner platesFront spacersRear centre and rear outer spacersSteering arms

Lower shock mountsFront outer platesRear inner plateFront and rear upper shock mountRear outer plate

5.8M

100xl00x3.0mm RHS 120mm30x30x2.0mm RHS 1850mm

20x20x1.6mm RHS

12.0mm BMS Bar25X5.0mm Flat bar32x5.0mm Flat bar40xS.Omm Flat bar

50x6.0mm Flat bar

75xS.Omm Flat bar

100xS.Omm Flat bar125xS.Omm Flat bar

1000mm

380mm350mm100mm1200mm

600mm

900mm

350mm1400mm


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Part No. Qty Part description Use

Parts and tv1aterials ListThe foilowing is a list of parts required from 'The Edge' products andtheir catalogue numbers, i f any.

RACK 1 XRV rack Steering rackSteering rack to shaft adaptor

3/4R004

3/4SPACBC4

1 XRV rack adaptorset 4 3/4" Male rod endset 8 3/4" Rod end spacer

Suspension armsRAKADP

Suspension arms/tie rodset 6 machined inserts22

14mm machined insertsTie rods/8" rod endsTie rods

4 5/811 rod end spacersSuspension armsSH16-8

BCBRAKE kit Braked hubsAcetal pivot bushes

Complete wheel hub12

Extra Bolts/nuts etc required over those listed in the 'Piranha' plansDiscription QtyW' UNF x 3W' bolt 6

Use

% " UNF x nvloc nut 6Y z " Flat washers 12

2244

M12 x 65 boltM12 nvloc nutM12 fiat washersM16 x 100 bolt orM16 x 100 countersunk boltM16 nyloe nut 4S/8"UNF nut 2

Upright pivots and steering armsTo suit above boltsTo suit above boltslower front shock mountTo suit above boltsTo suit above boltsUpper suspension arm pivot bolts

To suit above boltsTie rod Jam nut;


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Buggy Double Aarm Front

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