Please help me build a Honda powered gokart/sandrail/dune buggy

[MatobaImportRacing]

I’ve decided that I want to build a Honda powered go-kart/sandrail type vehicle. Basically I want to use street tires to drive both on and off road. To achieve this I would like to use a Honda/Acura front-engine and transaxle to power the rear tires, this idea being provided by Lotus’ use of the Toyota 2ZZ in the Elise. I have a good idea of what I want to do, but very little actual idea of how to go about it. I have never built anything like this before and have a lot to learn, but I believe it will be fun. Basically I would like the rearend to be the same width as a small Honda, a newer Civic of Integra probably. I would like to keep it as short as possible too, but considering the length of the motor/transaxle setup, a seat and driver, pedals, steering rack, and front axles I don’t see this being much shorter than eight feet. It is going to be a one-seater and I would like to use an aluminum floorpan. In addition I would like to modify the front axle to be about four feet long. I have come up with a series of questions that I need answers too prior to building this badboy.

(Most Importantly) What kind of acceleration/speed can I expect? If my reasoning is correct if the whole shebang weighs 600 pounds with me (165 pounds) in the drivers seat and I use a non-vtec B18 (which I have lined up now) that produces about 100 HP and 85 Ft. Lbs. of torque (is this reasonable? I don’t have many much experience with older, non-Vtec Hondas) it should have a power to weight ratio of 1/6 or a 450HP Civic. Does this make sense?

How much would this whole thing weigh, chassis and all?

What is the best way to relocate the shift-linkage, clutch cable, throttle cable, and break lines?

What is the best suspension setup for this type of off-road buggy?

What is the best motor-mount setup? I can imagine that bouncing and jumping a buggy with no real unibody would shear motor mounts really quickly.

What are the heat considerations involved with putting a shifter-kart seat (layback style body is at about a 45 degree angle) a few inches in front the engine?

Where should the radiator be located? Is it possible to run it air-cooled?

Would it be possible to modify the Honda rear-axle to use it as the front axle in the gokart?

How should the steering rack be set up? I assume that turning the front axles would be much easier than the rear, is this correct?

Would a buggy of this size need power steering? Along that line, would the front breaks (in the rear of the buggy) off a Honda be sufficient without front break?

Where should the battery and the fuel cell be located?

What kind of weight bias should I shoot for?

Thanks for all your help in advance. Even if you don't know it would be great if you could point me in the right direction as far as website and/or people.

Also please note that this project doesn't have to be legal for any governing classes of any of that stuff, and it doesn't need to be street legal, so go wild!

[goinbig]

Well, I don't have too much time right now, so I'll just answer a few things for now!

First of all, this sounds just like a SandRail, not so much a Go-cart.

For the Front axle, the easiest way would be to mount the spindles and that stuff right to the frame. Having a full front axle would be extremely heavy.

The best suspension would be to use Coil springs, and some shocks. This would be the best (and simplest/cheapest) for both the front and rear.

You probably will want a radiator (small one would work fine) and an electric fan, otherwise it will most likely keep over heating when you slow down at all. It can be placed wherever you have the room---Same for the battery and fuel cell.

For motor mounts, Use some with some higher quality polyurethane bushings. Then you might want to build additional supports in various spots. A good way to do it is take short pieces of chain and weld on end to the side of the block and the other to the frame (use a couple on each side). This keeps the engine movement very minimal, and will hold it there if you brake an engine mount.

You will not need powersteering. You don't really need to have front brakes either. Rear discs will have enough stopping power.

For the frame, I would build a tubular frame, just like on a sandrail. A lot of these things you just have to make-up as you go.