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Coolster 250cc single seater
I bought this buggy a couple years ago and have slowly been transforming it to accommodate an adult.
Here's some pictures from the seller when I bought it: https://imagizer.imageshack.com/v2/xq90/922/4CiCWs.png https://imagizer.imageshack.com/v2/xq90/923/6bUlVy.png https://imagizer.imageshack.com/v2/xq90/923/QFsid3.png |
The electrical was a nightmare so I cleaned it up a bit and made brackets for the solenoid, CDI and rectifier.
https://imagizer.imageshack.com/v2/6...922/OrVsKs.jpg https://imagizer.imageshack.com/v2/6...923/2PP2Xk.jpg |
Next I removed the craptastic exhaust and started mocking up a new one.
https://imagizer.imageshack.com/v2/6...923/fRUVel.jpg https://imagizer.imageshack.com/v2/6...922/dLJVFl.jpg https://imagizer.imageshack.com/v2/6...922/f1SZIW.jpg |
Next I flipped the rear wheels around for maximum width and added aluminum wheel spacers
https://imagizer.imageshack.com/v2/6...923/4a2mQ6.jpg I wanted to add a temp gauge and fuel gauge https://imagizer.imageshack.com/v2/6...924/stdvdY.jpg cardboard dash: https://imagizer.imageshack.com/v2/6...922/NqZlte.jpg https://imagizer.imageshack.com/v2/6...922/NqZlte.jpg https://imagizer.imageshack.com/v2/6...923/GgDUBy.jpg |
Nice. I haven't worked on my buggies much this year, but if I ever get the time and good weather I will.
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Aluminum dash:
https://imagizer.imageshack.com/v2/6...923/zV1HNu.jpg https://imagizer.imageshack.com/v2/6...922/KRlbFF.jpg https://imagizer.imageshack.com/v2/6...924/GAVsLp.jpg decided to ditch the temp gauge in favor of a tachometer https://imagizer.imageshack.com/v2/6...923/EJhi20.jpg |
Realized I wouldn't have enough head room so I made it a convertable
https://imagizer.imageshack.com/v2/6...922/YIaBiy.jpg https://imagizer.imageshack.com/v2/6...924/dAJaM5.jpg Cut off the roll cage from another kart and got it mocked up https://imagizer.imageshack.com/v2/6...923/pyr231.jpg |
Added some tube
https://imagizer.imageshack.com/v2/6...922/KC917u.jpg Thought I'd mount the engine to the chassis and cut the engine in half in order to get the gear box on the same axis as the swingarm pivot https://imagizer.imageshack.com/v2/6...924/pFOYMA.jpg https://imagizer.imageshack.com/v2/6...923/xKxOzJ.jpg https://imagizer.imageshack.com/v2/6...922/fLxztF.jpg |
Took some measurements off the old swingarm and temporarily mocked up the new rear shocks
https://imagizer.imageshack.com/v2/6...924/bkU4ge.jpg https://imagizer.imageshack.com/v2/6...924/q6XJEJ.jpg I had some rusted box tubing I wanted to use to make a new swingarm https://imagizer.imageshack.com/v2/6...924/fDbIeA.jpg https://imagizer.imageshack.com/v2/6...922/KC0tmX.jpg Decided to try to remove the rust with electrolysis. I used a little battery charger and mixed up a solution of sodium carbonate and water to remove the rust. https://imagizer.imageshack.com/v2/6...923/utgOCy.jpg |
made some temporary aluminum spacers and pieces of steel tubing for swingarm bushings and shock mounts
https://imagizer.imageshack.com/v2/6...923/kLzvux.jpg https://imagizer.imageshack.com/v2/6...922/m0N6iX.jpg Then started laying out the parts for the new swingarm https://imagizer.imageshack.com/v2/6...923/bEgmQy.jpg https://imagizer.imageshack.com/v2/6...924/dzIJ0j.jpg https://imagizer.imageshack.com/v2/6...924/chLGO9.jpg https://imagizer.imageshack.com/v2/6...924/tEa8Fs.jpg https://imagizer.imageshack.com/v2/6...924/Myi7sP.jpg |
Holesaw through the swingarm for multiple swingarm mounts
https://imagizer.imageshack.com/v2/6...924/hNZ8zt.jpg https://imagizer.imageshack.com/v2/6...922/zGJPmA.jpg https://imagizer.imageshack.com/v2/6...924/Fxu4YF.jpg https://imagizer.imageshack.com/v2/6...922/tSSYml.jpg https://imagizer.imageshack.com/v2/6...924/Iw24JN.jpg New swingarm bolted up, radiator and gas tank relocated https://imagizer.imageshack.com/v2/6...923/WZLrCy.jpg https://imagizer.imageshack.com/v2/6...922/pKYWwC.jpg https://imagizer.imageshack.com/v2/6...922/bOeVZG.jpg |
Cleaned up the reverse box and put some fresh grease in it
https://imagizer.imageshack.com/v2/6...922/as2GvO.jpg https://imagizer.imageshack.com/v2/6...923/cgKY8Z.jpg https://imagizer.imageshack.com/v2/6...924/6pEMqm.jpg |
started mocking up new motor mount and reverse box mount
https://imagizer.imageshack.com/v2/6...923/AOeqRJ.jpg https://imagizer.imageshack.com/v2/6...924/Wkw8qB.jpg https://imagizer.imageshack.com/v2/6...922/QC8b4R.jpg https://imagizer.imageshack.com/v2/6...924/PGYxxG.jpg https://imagizer.imageshack.com/v2/6...924/YDwxzd.jpg https://imagizer.imageshack.com/v2/6...924/OBwUCQ.jpg I got to this point and I didn't like where the project was headed so I let it sit for a year. |
After thinking about it for a year I concluded that i should go a different route with the engine. I had a new in the box Chinese 200cc 4 stroke 5 speed manual with electric start that I bought for another project and decided to use it on this buggy project.
I started by making an engine cradle mount with a jackshaft. This gave me tons of gearing options and gave me the clearance I needed for the shifter linkage. https://imagizer.imageshack.com/v2/6...923/JUao5q.jpg https://imagizer.imageshack.com/v2/6...923/8CESpc.jpg https://imagizer.imageshack.com/v2/6...923/W5bFYa.jpg https://imagizer.imageshack.com/v2/6...923/nVBD10.jpg https://imagizer.imageshack.com/v2/6...922/4Hk8xf.jpg https://imagizer.imageshack.com/v2/6...924/BiOV5E.jpg I couldn't find a shaft mount sprocket that matched the pitch of the countershaft sprocket on the engine so I made my own out of two sprockets. https://imagizer.imageshack.com/v2/6...922/5NUqmG.jpg I had to anneal the larger sprocket in order to bore out the id. https://imagizer.imageshack.com/v2/6...923/DDUnel.jpg https://imagizer.imageshack.com/v2/6...924/PrN10n.jpg https://imagizer.imageshack.com/v2/6...924/vOMsen.jpg https://imagizer.imageshack.com/v2/6...923/WOt99k.jpg https://imagizer.imageshack.com/v2/6...922/paJDXS.jpg |
made plates for the pillow block bearings to bolt to
https://imagizer.imageshack.com/v2/6...923/2yG1bH.jpg Then made a plate on the swingarm to mount the engine. https://imagizer.imageshack.com/v2/6...922/4TkxiD.jpg |
bracket for shifter cable and mounted the rectifier
https://imagizer.imageshack.com/v2/6...924/yZFHE5.jpg bracket for coil, cdi and solenoid https://imagizer.imageshack.com/v2/6...923/Exl4ui.jpg https://imagizer.imageshack.com/v2/6...924/biQ2nE.jpg https://imagizer.imageshack.com/v2/6...923/wDPBEt.jpg https://imagizer.imageshack.com/v2/6...923/rFMHJn.jpg https://imagizer.imageshack.com/v2/6...923/dkxB83.jpg https://imagizer.imageshack.com/v2/6...922/WDPbdq.jpg https://imagizer.imageshack.com/v2/6...924/ovy9rK.jpg https://imagizer.imageshack.com/v2/6...922/QhXZNo.jpg https://imagizer.imageshack.com/v2/6...924/b3cxjk.jpg https://imagizer.imageshack.com/v2/6...924/XBnuOn.jpg https://imagizer.imageshack.com/v2/6...922/j6ADzm.jpg https://imagizer.imageshack.com/v2/6...922/RrzHn3.jpg and all finished with the electrical components attached https://imagizer.imageshack.com/v2/6...924/UKyedn.jpg Next I moved on to some wiring https://imagizer.imageshack.com/v2/6...923/cguCxB.jpg https://imagizer.imageshack.com/v2/6...923/kcIaXw.jpg |
I wanted reverse on this buggy and was thinking about rigging up an electric reverse with an starter motor and small ring gear from a geo metro. I was just about to buy the parts when I found a 200cc like the one I had except with reverse for $300.
https://imagizer.imageshack.com/v2/6...923/ZuCig6.jpg then found a cheap 250cc piston/cylinder kit https://imagizer.imageshack.com/v2/6...923/JgYsM4.jpg https://imagizer.imageshack.com/v2/6...922/BTAYjK.jpg https://imagizer.imageshack.com/v2/6...924/YiNu1C.jpg https://imagizer.imageshack.com/v2/6...923/UdGWVm.jpg https://imagizer.imageshack.com/v2/6...923/MoZzqL.jpg https://imagizer.imageshack.com/v2/6...924/KgH9E9.jpg https://imagizer.imageshack.com/v2/6...923/UbxFG8.jpg |
Made an intake manifold
https://imagizer.imageshack.com/v2/6...924/DwQTfJ.jpg https://imagizer.imageshack.com/v2/6...924/wv8kO9.jpg https://imagizer.imageshack.com/v2/6...924/jznWcG.jpg https://imagizer.imageshack.com/v2/6...924/aNIrPv.jpg https://imagizer.imageshack.com/v2/6...922/zbDIep.jpg https://imagizer.imageshack.com/v2/6...924/SnbEJb.jpg https://imagizer.imageshack.com/v2/6...922/QlJL5v.jpg https://imagizer.imageshack.com/v2/6...922/88ALTA.jpg |
Holy Smokes ! Awesome Build ! , Thanks a Lot , I Feel About As Useless As Tit's On A Bull Now ! Wait , I'm Old and Wore Out , Yea That's It .... :rofl:
Wear Your Helmet !!! :cheers: |
Glad to see this posted here. The other site doesn't seem to be working, and I want to see this project when it's done.
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I didn't like the front suspension and some of the frame cage I built had to be redone. https://imagizer.imageshack.com/v2/6...923/In8kyu.jpg https://imagizer.imageshack.com/v2/6...924/hyadcz.jpg https://imagizer.imageshack.com/v2/6...924/Hn2lIQ.jpg So I got a Honda TRX400 front end https://imagizer.imageshack.com/v2/6...922/pHIVtb.jpg And started making some brackets https://imagizer.imageshack.com/v2/6...923/8rgQqB.jpg https://imagizer.imageshack.com/v2/6...924/0UDwvY.jpg https://imagizer.imageshack.com/v2/6...922/eUKslt.jpg https://imagizer.imageshack.com/v2/6...924/NtUkVT.jpg https://imagizer.imageshack.com/v2/6...922/mag38E.jpg https://imagizer.imageshack.com/v2/6...923/5C9vTB.jpg https://imagizer.imageshack.com/v2/6...924/QISTDY.jpg |
Then got the front end tack welded
https://imagizer.imageshack.com/v2/6...923/he0rg7.jpg https://imagizer.imageshack.com/v2/6...923/ifjFBp.jpg https://imagizer.imageshack.com/v2/6...922/2nNKJ2.jpg https://imagizer.imageshack.com/v2/6...924/ILaIYQ.jpg https://imagizer.imageshack.com/v2/6...924/hxd1eC.jpg https://imagizer.imageshack.com/v2/6...922/R4rVK4.jpg https://imagizer.imageshack.com/v2/6...923/NQcTIp.jpg |
Pretty cool, been looking to do the same motor swap on my son's 150. I'm old school and just like a good manual gears over a CVT.
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