Homemade Amphibious side by side (aatv)

[Positrac]

Something a bit different than your average thread on here I thought I’d share and update as I go along an amphibious all-terrain vehicle build I’ve been planning for the last few years. Planning is probably an understatement. I’ve spent hundreds of hours obsessively watching YouTube videos of those clever Russians and their big-tyred or tracked buggies going over all sorts of terrain and through swamps that would make your average Argo cringe. My wife thinks I have a real issue. Truth be told I probably have several issues, I’m just pretty good a hiding most of them from her better than I have this one...

So, why an aatv? The need came about from living in Fort McMurray. There’s a million miles of cut lines up here but very little in the way of roads. You can’t go more than a mile in any direction without hitting a Muskeg hole or Beaver pond. I’ve had a couple Argos over the years and while they can get you off the beaten path they are not the most comfortable mode of travel. Add to that fact they still get stuck pretty easy even with tracks and they are very high maintenance. I also went the jet boat way for the last 5 years and while I did enjoy getting on the water it didn’t get you away from people. Lots of disposable income up here and every second house seems to have a jet boat in the driveway. So, I needed something different that not everyone had where I could get out where the critters roam free with not much worry from man.

I originally thought of building a buggy similar to the skid steer Sherp but with slightly less tall tires. Less tall being 52” tall as opposed to the 63” tall tires on the Sherp. Then I had the pleasure of driving one. While they are a very capable machine the herky-jerky skid steering brought back unfavourable memories of all the hours I’ve spent in an Argo. Plus, the drivetrain is pretty complicated and once things start to get a few hours on them I can see the maintenance being very similar to an Argo but with the added bonus of being super expensive. I suppose though, if you can afford the $140,000 price tag of a Sherp the maintenance costs probably don’t matter much to you...

So, my plan is to build a conventional sxs style buggy with a front steering axle. It will be a complete custom with a front Dana60 Kingpin steer axle and another full floater D60 out back. 4:88 gears with Detroit lockers in both axles. Full hydro-steering. Mid mounted 4-cyl Ecotec with an automatic transaxle with a welded center differential turned 90 degrees from the way it sits stock in the 130,000 kilometer Cavalier it’s coming out of. Front driveshaft going to a Samurai divorced transfer case although I don’t think I’ll need the low gear all that often with the transaxle having a low first gear. No brakes on the axles but I’ll have one on each side of the transfer case up high and out of the slop. Steel square tube frame and all aluminum body. No suspension since the tires will soak up the bumps and I’m hoping to keep it under 2,500lbs all done so that it floats high in the water.

Below are the tires with 21” double beadlock wheels leaning up against my Powerwagon on 35’s. With 9 psi in them they measure out at 52” dia x 27” wide. They are rated for 1-11 psi max. While not being as tall as the ones on the Sherp they are actually 3 inches wider so they provide a huge footprint when aired down. I had them imported from Russia through Stone Tusk Off Road in Thorsby after being put on to Stone Tusk by a couple members on here in another thread I started when I was originally looking for tires.

Since buying the tires a couple months ago I’ve just been digging up parts and equipment for the build. I bought a 2003 Cavalier with low kilometers. It has the 2.2L Ecotec motor with auto transaxle. I also managed to find a couple Dana 60’s with the front Kingpin model being from an ‘89 Ford 1-ton and the rear from a ‘79 3/4 ton. Different widths but that will be rectified since I’m going to narrow the front by 12 inches and then make the rear to match. On top of that I’ve bought grinders, a cut-off saw, a porta-band saw, a new to me Millermatic 211 mig welder with spool gun, new Optel auto-darkening helmet, engine lift, etc, etc, etc...

The plan is to try and have it done by next summer so that the bugs will be worked out by hunting season. I purposely didn’t pull an early season moose draw this year so that I’ll have a tag for next year when the buggy is done. Like I mentioned above, I’ll update the thread as work is done. I’ve been a member on 4x4 Wire and Pirate 4x4 for years and these build threads have always been my favorite. Since I spend most my time on here these days I thought I’d document the build on here instead of a more conventional 4x4 site since I’m sure there will be a few of you that find it interesting.

Hope you all enjoy,

Positrac


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[MugEye]

Very cool keep us updated

[Big Grey Wolf]

Posi, sounds like a interesting project. I lived in Ft Mac for a few years and agree special designed ATV needed for all the swamp, especially east towards Namur lake area.

[Trochu]

I'm pretty sure you should just cut the fenders on your truck, use an extender, and put them on the 1500.

[Sooner]

Cool, I seen the earlier post where you showed this pic. I remember hunting Fox Creek in the 80's with the dads, I was 13 ish. Where all the 4x4's stopped on this old logging road and basically had to wait for freeze up to cross this spot, this lifted, monster tire homemade jeep thing just drove up and rolled through the worst swampy muskeg beaver dam crossing without breaking a sweat. We all knew he had prime big bull areas all to themselves. This was before trikes.

Sounds like your making a sherpa type craft. I look forward to this thread.

[NCC]

Great thread and interesting project. How much does each wheel weigh? I think you will struggle to stay under 2500 lbs.

[TreeGuy]

Dang! This right here has the potential of being one of those very few legendary AO threads...for a GOOD reason!

Tree


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[Reeves1]

My wife thinks I have a real issue. Truth be told I probably have several issues, I’m just pretty good a hiding most of them from her better than I have this one...

You too , eh ! LOL


Cool build & I'll be watching

[1899b]

Cool thread. I know the muskeg well up there. Spent 36 years up there and for a few seasons we got away from the old atc trikes as Dad bought an Argo. It’s soft country up there. When I left and moved to Edson in 2003 I was elated how I could drive my Jeep down most cutlines and powerlines unlike the McMurray country I grew up in. Good luck with your build...

[Wrong way]

Yes that’s me
I have Brent’s original set of tires.

We had planned to go skeggin together
So far I’m a year late
Lol

One day it will happen
hopefully we can all get out when your build is complete.

The body on mine was a rusted out mess, it has swallowed a lot of my time patching.
Would have been further along with a scratch build.

Thinking on purchasing a tubing bender to build an exo cage for it but they sure are pricey. Any suggestions?

[Positrac]

I’m not sure about the tubing bender Wrong Way. I thought about one of those cheap benders based on a bottle jack and some dies, but I’ve heard they crush the tube a bit so that wouldn’t look all that great. For 300 bucks or so they may be worth a try though.

Some torrential rain here today with lightning and thunder like I haven’t seen/heard in a while. I did manage to heat the inner C up and install it on the front D60. Even managed to get it in the same plane as the drivers side inner C. The original fit was .0025 interference. After cleaning the tube up and bore of the inner C I’m about a thou less. Plenty as I’m planning on welding both sides of the C’s.

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[does it ALL outdoors]

Originally Posted by TreeGuy

Dang! This right here has the potential of being one of those very few legendary AO threads...for a GOOD reason!

Tree


Sent from my iPhone using Tapatalk

X2! VERY cool.

Are you sure those Dana 60's are gonna hold up? Those are some BIG tires to turn. A good set of Rockwells would be bulletproof but looks like your well on your way with the 60's. Good luck & keep us posted.

[Positrac]

As for registering, there are avenues for getting a new vin and registering home-built vehicles. As for insuring, I can’t speak for all carriers but ours will ensure the vehicle. The only sticking point is I may need to get an appraisal before they will ensure it. I don’t know what it will be worth once done but stuff adds up fast.

Originally Posted by does it ALL outdoors

X2! VERY cool.

Are you sure those Dana 60's are gonna hold up? Those are some BIG tires to turn. A good set of Rockwells would be bulletproof but looks like your well on your way with the 60's. Good luck & keep us posted.

The 60’s should be fine. They are strong for their weight. I’ve narrowed them to 54-1/2” wheel surface to wheel surface from the original 69”. I’m also now shooting for a 3500lb total weight so the buggy will be on the light side.

The rear 60 has a Detroit automatic locker and Yukon 5.29 gears. The original 30 spline 1-1/4” full floater axle shafts have been replaced with custom length Dutchman 35 spline 1-1/2” 300M shafts.

The front 60 has a selectable cable-actuated OX locker and Yukon 5.29 gears. The original 30 spline 1-1/4” inner and outer shafts have been replaced with 35 spline 1-1/2” 300M shafts. It has Yukon drive flanges at the wheels and Reid Racing knuckles. The high-steer arms are custom made and utilize the 5th (extra) mounting hole that the Reid knuckles have over the stock Ford Kingpin knuckle. The arms mount to the top of the knuckle and face rearwards. When the wheels are straight the arms are pointed at the middle of the rear differential, providing the perfect Ackerman steering angle.

As for steering, I just receiver the complete package from PSC. High-flow pump that mounts on the front of the Ecotec and uses the motors serpentine belt, steering (orbital) control valve, remote reservoir, aluminum cooler, and a massive 8” long x 2-3/4” dia double-ended hydraulic Ram. It also came with an upgraded 1-1/2” tie-rod kit with 3/4” heim joints. I also ordered from another company that specializes in Ecotec swaps the aluminum bracket to mount the PSC pump and they also had the billet pump pulley that matches the 5 rib design on the rest of the Ecotec pulleys.

[does it ALL outdoors]

Originally Posted by Positrac

As for registering, there are avenues for getting a new vin and registering home-built vehicles. As for insuring, I can’t speak for all carriers but ours will ensure the vehicle. The only sticking point is I may need to get an appraisal before they will ensure it. I don’t know what it will be worth once done but stuff adds up fast.



The 60’s should be fine. They are strong for their weight. I’ve narrowed them to 54-1/2” wheel surface to wheel surface from the original 69”. I’m also now shooting for a 3500lb total weight so the buggy will be on the light side.

The rear 60 has a Detroit automatic locker and Yukon 5.29 gears. The original 30 spline 1-1/4” full floater axle shafts have been replaced with custom length Dutchman 35 spline 1-1/2” 300M shafts.

The front 60 has a selectable cable-actuated OX locker and Yukon 5.29 gears. The original 30 spline 1-1/4” inner and outer shafts have been replaced with 35 spline 1-1/2” 300M shafts. It has Yukon drive flanges at the wheels and Reid Racing knuckles. The high-steer arms are custom made and utilize the 5th (extra) mounting hole that the Reid knuckles have over the stock Ford Kingpin knuckle. The arms mount to the top of the knuckle and face rearwards. When the wheels are straight the arms are pointed at the middle of the rear differential, providing the perfect Ackerman steering angle.

As for steering, I just receiver the complete package from PSC. High-flow pump that mounts on the front of the Ecotec and uses the motors serpentine belt, steering (orbital) control valve, remote reservoir, aluminum cooler, and a massive 8” long x 2-3/4” dia double-ended hydraulic Ram. It also came with an upgraded 1-1/2” tie-rod kit with 3/4” heim joints. I also ordered from another company that specializes in Ecotec swaps the aluminum bracket to mount the PSC pump and they also had the billet pump pulley that matches the 5 rib design on the rest of the Ecotec pulleys.

Roger that, I just read it's going to be a light buggy, those 60's (built) will be more than strong enough. I was assuming it would be a hardcore bush buggy.

Again, very cool project!

Looks like your making KILLER progress. Also looks like you have some serious fab skills.

[Positrac]

Originally Posted by does it ALL outdoors

Looks like your making KILLER progress. Also looks like you have some serious fab skills.

Thanks. I played with Lego lots as a kid.

I’ve got a long ways to go before I can pat myself on the back. Maybe next fall when I’ve got a bull loaded up on it heading out of the bush...

[buckbrush]

Originally Posted by does it ALL outdoors

Are you sure those Dana 60's are gonna hold up? Those are some BIG tires to turn. A good set of Rockwells would be bulletproof but looks like your well on your way with the 60's. Good luck & keep us posted.

Unless he ends up adding TONS of weight, the 60's will be more than enough.
He'll also be saving over a couple hundred pounds not going with Rockwells.

It's looking great Posi. Thanks for the updates.

[Positrac]

I think what most people need to remember is that this is a purpose built vehicle. It’s going to spend most of its time going 5km/hr through boggy ground with water coming up through it. There’s hard ground up here too but you seldom go in any direction for long before hitting some Muskeg. If I was building a rock crawler it would look a lot different.

[Big Grey Wolf]

Posi, I like your design, most guys do not know the Ft Mc muskeg, only way to cross some is with a pair of chest waders or wait until January when you have a foot of ice.

[Iron Brew]

Originally Posted by TreeGuy

Dang! This right here has the potential of being one of those very few legendary AO threads...for a GOOD reason!

Tree


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Right up there with the kidnapping baby birds thread! 😇

[TrollGRG]

If you put those on the back and regular tires on the front you would be going downhill all the time. Save on gas ;o)