Fibreglass Kite Buggy (No.1)


My first attempt at building a kite buggy out of fibreglass. The reason I went down this route was that at the time I didn't have a welder available to me. And I was keen to see what a fibreglass buggy would be like. I put a speedo on the buggy at some point and got a max speed of 31 mph, and on a good day at Hoylake I would cover about 18 miles.

NEGATIVE: I hadn't tried other buggies when I built this so I made some mistakes. The worst mistake being the height of the seating position, but saying that some of the smaller metal buggies you can buy have the same problem.

POSITIVE: The thing that supprised me most was the strength of this buggy, nothing on it ever broke with the exception of the 10mm back axles bolts, which once they had been replaced with 12mm where fine.

I created the core of the buggy out of expanding polyurethane foam, using a mold made of cardboard and wood, lined with black refuse bags.
I sanded the core to the shape I wanted and covered it with fibreglass mat. I made the back axle separately and bonded it to the main body once it was complete.
Being my first buggy I thought 10mm bolts would work on the rear wheels, so I got a thick rod of auminium (25mm diameter) and drilled and tapped 10mm threades into it. It was then bonded into the end of the axle using resin and fibreglass (you can see the dark resin in the ends of the back axle in the pictures)
The front forks where taken off a childs BMX and worked perfectly. I cut the tube that the forks are housed in off the rest of the frame and bonded it into the buggy using fibreglass.
The foot pegs are pieces of wood bonded to the BMX forks.
The Mud guard was formed using two thin pieces of fibreglass which were molded on a wheel shape mold and then split down the middle to get the width of the front wheel. The side of the mud guard was supported on a piece of cardboard coated in floor wax.
The finished product (upside down) and given a lick of yellow paint, which I took a lot of flack for.