Somthing

Yay!Gurrr

Yay!Gurrr

Better Faster Stronger
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Joined
Mar 17, 2005
Location
N. N. Raleigh, NC
No idea what to call it yet, not even sure at what its gonna look like at this point..

But I picked up a 2000 cavalier for the engine and am planning to do a low budget transaxle type buggy. Plans are to gut the car for usable items, rad, brakes, pedals, and sell off the rest.

Plans, 2.2 Engine, 5 speed, 35-36" tires, light weight <3000#
toyota axles, hydro steering, linked, byond that no real plan.

Timeline = NONE so don't ask for daily/weekly updates, maybe monthly progress at best..

20090430-Sunfire 165.jpg

20090430-Sunfire 169.jpg
 
Take it to the FARM this weekend and wheel that ThanG...:huggy:
Test drive it...Dont Be Scared of It...:alien:
 
motor is out... (though it needs a little work) along with radiator, mounts and many other items I will reuse to keep the costs down on the project.

20090512-Engine 041.jpg
 
How are you planning the transfer case set up?
 
no tcase will be using 5speed transaxle. It has ~4.1 spur gear type r/p in there. Plan to find/make a spool or last resort weld it. Carrier is around 7.5-8" best guess so I should be able to make something fit.
 
That's the same drivetrain that's in my GF's DD. Finally something a Sunfire is good for.
 
no that's just the engine its sitting in a stand I whipped up and thats sitting on a small dolly thing, engine is roughly 20" wide x 24" tall x 22" deep
 
its really not a high HP engine, 120hp/140# but I like it. This one needs a little work :) Granted its a cast iron block but there really isn't much block there, and the head is alum. The intake is plastic and all the accessories are about as small as they could make them.

Based on my past experience wheeling my 60hp zuke with 4:1 tcase on 35s. I'm guessing 120Hp with similar size/weight rig should do ok...

I'm still looking for the 5 speed I want to use. Needs to be from a 2000-2002 w/ 2.2 (not ecotec) I've seen some really cheep on ebay. The transaxle weighs ~107# so its just light enough to be shipped... I may go that route vs spending time/$ at junk yard...
 
... I thought you sold this thing already??
 
I'm planning to use a F23 transaxle. It is short 3 axis/shaft 5 speed, and has good weight to torque capacity and considering it will be used as a t-case and not the final drive as in a FWD car it should be pretty solid... and compact which is why I want to use it.

ok.... some better pics....
5T45MI-1.jpg

400-03583-01-04.jpg

400-03583-01-03.jpg
 
Transmission shifted by cables? If so, thats good, you don't want to fool w/ solid shifter linkages... My new transmission is cable shifted and I've about got the cables shortened and modified enough to fit, wasn't bad to do at all.

Whats the gear ratio? Hope you don't plan for it to hve a great top speed, OR a really low crawl gear. I've figured on mine w/ the 6 speed manual it will top out @ 5 mph in SL (super low), and 30 mph in 5th gear (around 5K rpm's). 5mph seems fast to me for a crawl gear, and I doubt the chevy transmission would be geared very low. Just guessing I would bet you might be able to hit 10-15 MPH in 1st gear.

Good luck w/ the build, I'll definetly keep watch on it, maybe we will finish at the same time :)
 
yes cable shifted. ill reuse a factory shifter setup. no plans for top speed.. (I figured out how to multiply the numbers together :) )

Gear Ratios
1st 3.58,
2nd 2.02
3rd 1.35
4th 0.98
5th 0.81
Final Drive/Axle ratios = 3.63,3.84,3.95,4.41

with the 3.95 ratio (most common in cavaliers/sunfires) @5k = 9mph
and hit 40mph in 5th gear @5k

who knows, again based on previous zuke driving with similar low range #s it seemed fine, 5mph Well see...
 
Easiest calculator I have found:
http://wahiduddin.net/calc/calc_speed_rpm.htm

Don't you think 9mph in 1st gear is too fast? I know the automatic guys can geat away with it cause of the torque converters, but us guys brave enough to try and make a manual work have more to worry about :) If you don't plan on getting into huge rocks you would probably be OK though.
 
your calc there is missing the 'tcase' option...

using this one http://4lo.com/calc/gearratio.htm
36" tire diameter (smaller aired down)
4.1 diff ratio
3.58 trans ratio
3.95 final drive ratio (ring gear in transaxle)

I get 1.5mph at 800rpm ... ? unless I'm missing something??
 
yager said:
your calc there is missing the 'tcase' option...

using this one http://4lo.com/calc/gearratio.htm
36" tire diameter (smaller aired down)
4.1 diff ratio
3.58 trans ratio
3.95 final drive ratio (ring gear in transaxle)

I get 1.5mph at 800rpm ... ? unless I'm missing something??
Click to expand...

I did it using my calculator, and your math checks out to me. I got 1.48mph at 800rpm with true 36" dia tire. I think it will crawl like crazy and you will find yourself starting in 2nd and 3rd gear most of the time and probably launching obstacles that require wheel speed in those gears too.
 
I've seen this type buggy in the Honda and the Toyota versions. Really cool set up for light weight buggy. With the axle gearing you can go about as low as you want, the only draw back is on the high end if you want it road friendly.
 
yager said:
considering it will be used as a t-case and not the final drive as in a FWD car it should be pretty solid
Click to expand...

Quick question about this, Tacoma747 might have gone over this in his build, but looking at the pics of the transaxle and going over your quoted comment ^. You're saying a transmission will go between the motor and that transaxle? Just curious and a little confused about it
 
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