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All-terrain vehicle on pneumatics. Personal transport

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The author of the article and the creator of the all-terrain vehicle, which will be discussed, is Boris Nikolaevich Ryzhov, a longtime acquaintance of the readers of our magazine. Photos of the machines he made (caterpillar and six-wheeled all-terrain vehicles) were published in the magazine back in 1990 (No. 7). But the desire to create and make a more perfect off-road vehicle has not cooled down since then. A professional aircraft mechanic and restless amateur designer, having retired, he continued to build all-terrain vehicles. Why exactly them? Yes, for now (and, apparently, for a long time) to get to most places in the Siberian outback, where Boris Nikolayevich lives, is possible only by such machines.

Well, if you are still a fisherman or a hunter, then such a machine is simply necessary.

And in recent years, he has made three more all-terrain vehicles (materials on the previous two were published in No. 1'2000 and No. 12'2003).

All machines are united by the fact that they have the same pneumatic propellers (the author believes that these are the most versatile propellers for any season). Otherwise, each machine has its own characteristics, but the last one is perhaps the most powerful and perfect of them.

The conversation about my next all-terrain vehicle on pneumatics was started back in No. 12 for 2003. At the very end of that publication, I gave a brief technical description of the new design conceived to be created. Now that the machine has been assembled, debugged and tested, it is time to tell readers about it in the pages of the magazine.

As well as according to preliminary estimates, the car was made with all four driving wheels - in general, a full-fledged SUV.

General view of the all-terrain vehicle (click to enlarge): a) on self-made pneumatics (all-weather version); b) on wheels from a UAZ-469 car (summer version)

All-terrain vehicle transmission scheme: 1 - engine (from the Zaporozhets car, 40 hp); 2- adapter-casing with clutch from the car "Zhiguli"; 3- gearbox (from the Zhiguli car); 4- short cardan shaft; 5 - transfer box; 6 - cardan shaft of the rear axle; 7 - rear wheel drive gearbox; 8 - rear wheel drive mechanism (2 pcs.); 9-wheel reducer of the rear wheel (2 pcs.); 10 - front wheel drive mechanism (2 pcs.); 11 - wheel reducer of the front wheel (2 pcs.); 12-wheel drive gear

All-season operation of the all-terrain vehicle is provided by pneumatics - they have long proven themselves as reliable movers for any off-road. Grip with slippery ice occurs due to the bolts installed in the bandage belts

To do this, it was necessary to perform a transmission similar at the same time to the power transmissions of the Niva and LuAZ. The similarity with the first is expressed in the presence of a lockable two-speed transfer case, two main gears (to the front and rear wheels), transmission of torque from the main gear to the wheels by shafts with CV joints. The similarity with LuAZ is manifested in the presence in the same transmission of cardan shafts and wheel gears with a gear ratio of i = 2 - for an all-terrain vehicle on large diameter pneumatics, the latter mechanisms are also necessary. Cylindrical gears with a module of 3,75 (z1 = 15, z2 = 30) were ordered by specialists, the remaining parts of the gearboxes, including the crankcases, were homemade.

The body was made two-volume (engine compartment and cabin combined with the luggage compartment) - this arrangement, in my opinion, is the most rational. For the engine compartment and cab, he adapted the front half of the body of the car "Zaporozhets" (ZAZ-968). The luggage compartment was made combined: the lower part of the sides is metal (welded from the doors of various old cars); the upper part of the sides and the ceiling (or rather, the roof, but since the beginning of the reforms I have ceased to like this word) are plywood, sheathed outside and inside with leatherette. The cavities in the lower part of the cabin and the sides of the body were filled with construction foam - to ensure buoyancy and thermal insulation. The latter circumstance is also of no small importance: there is no autonomous heater in the cabin yet and the flow of warm air is carried out only from the engine compartment through the hatch in the front wall. The back wall is completely metal. It has a metal door with a height of 990 and a width of 655 mm - only one for the entire all-terrain vehicle. Maybe such a body structure will seem unusual and even strange to someone (after all, some cars - even small cars - have up to five doors), but I think that it is justified for an all-terrain vehicle. The increased rigidity of the body during constant movement over rough terrain is by no means superfluous, however, as well as tightness - you have to travel quite often to ice-covered rivers and reservoirs during winter fishing.

Frame (click to enlarge): 1 - front bypass (pipe d16); 2 - spacer (pipe d16, 2 pcs.), 3 - jumper (pipe 50x25); 4 - stalk spar (pipe 50x25, 2 pcs.); 5 - front traverse (pipe 50x25); 6-front longitudinal beam (pipe 25x25,2 pieces); 7 - arch of the front wheel arch (corner 25x25, 2 pcs.); 8 - spring support cup (2 pcs.); 9 - crossbar (pipe d16); 10 - strut of the front wheel arch (corner 25x25, 4 pcs.); 11 - transverse front beam (pipe 25x25, 2 pcs.); 12 middle longitudinal beam (pipe 25x25, 2 pcs.); 13 - box spar (corner 35x35,4 pieces); 14 - threshold (corner 25x25, 2 pcs.); 15- transverse rear beam (pipe 50x25, 2 pcs.); 16 - longitudinal rear beam (pipe 25x25, 2 pcs.); 17 - arch of the rear wheel arch (corner 25x25, 2 pcs.); 18 - details of the frame of the rear overhang (pipe 25x25, 2 pcs.); 19 - rear traverse (pipe d35); 20 - brace of the rear overhang frame (pipe 25x25, 2 pcs.); 21 - transverse beam of the box (corner 35x35,4 pieces); 22- console of the spring support cup (pipe 25x25,4 pcs.); 23 - thrust post of the spring cup (pipe 25x25, 2 pcs.); 24 jumper racks (pipe 25x25); 25 - panel for mounting engine brackets (St3, sheet s3, 2 pcs.); 26 - box stand (corner 35x35,4 pieces); 27 - metal lining of the box (St3, sheet s3); 28 - fiberglass lining of the box (fiberglass, epoxy glue, 3 layers)

The door, like on most station wagon or hatchback cars, rises up and is held by two springs (from the front fork of the Minsk motorcycle). The door has a small window, and the doorway is edged with an airtight seal. The cabin has only two seats in front: driver and passenger. Behind the seats is a free space measuring 1700x1350 mm. Here two people can comfortably sit even lying down.

Windshield - from the car "Zaporozhets". The side windows have sliding windows. Over time, I'm thinking of making a hatch in the roof - for better ventilation in the summer and in case it is used as an emergency exit.

The frame of the all-terrain vehicle is rather peculiar: its base is a simple rectangular box with ribs made of steel corners 35x35 mm. The upper ribs of the box are welded to the bottom of the body. The box protects the transmission units from dirt and accidental damage when driving off-road and provides additional displacement to make the car unsinkable - sometimes you have to move on it on soft ice. Almost all units and transmission units are located in the box: gearbox, transfer case, cardan shafts, crankcases of the main gears of both axles. In the area of ​​the front and rear axles, the walls of the box and the bottom are made of 3 mm steel sheet, and between them - of fiberglass (several layers of fiberglass impregnated with epoxy resin). Access to them is through hatches in the bottom. Brackets made of a steel angle with shelves 45x45 mm are screwed to the vertical side walls of the box at the points of attachment to the frame of the suspension arms. The crankcases of the main gears are attached to the end walls of the box (front and rear) through corner brackets welded to them.

Ahead, above the frame in the engine compartment, an engine from a Zaporozhets with a power of 40 hp is fixed. The engine, in relation to how it is installed in the base vehicle, is now rotated by 180°. The box with the clutch is docked to it Zhiguli. To do this, the clutch housing had to be replaced with a home-made adapter casing, one side suitable for the engine mounting holes, and the other for the gearbox. The transfer box is homemade. Its body is welded from steel sheets with a thickness of 4 to 6 mm. The oil is filled through one of the upper holes for the cover bolt to the body, and the oil is drained through the same hole in the bottom of the box.

Front wheel drive (click to enlarge): 1 - bottom of the body (from the car ZAZ-968); 2 - main gear housing (details of the rear axle gearbox are not shown, from a VAZ-2101 car); 3 - axle shaft (from the VAZ-2101 car); 4- cuff; 5 - slotted sleeve; 6 - brake disc; 7 - locking pin with washer and cotter pin; 8 - box-frame (steel, sheet s3); 9 - M10 bolt for fastening the arm of the levers (2 sets); 10- M8 bolt with a square washer for fastening the bearing housing (4 pcs.); 11 - bearing housing; 12 - cuff; 13 - bearing 205; 14 - M10 bolt with washers and spring washers; 15 - spring (3 sheets, from "Moskvich-412"); 16- bracket for mounting levers (steel angle 45x45); 17 - M16 bolt with nut, silent block and two washers (2 sets); 18 - M8 bolt for connecting flanges with a spring washer (4 sets); 19 - cuff body with boot; 20- slotted flange (from agricultural machinery); 21 - flange with cardan fork (from agricultural machinery); 22- cross (from agricultural machinery); 23 - cardan fork with a slotted sleeve (from agricultural machinery); 24- upper lever (steel pipe 032); 25 - spring cup; 26 - splined shaft of the CV joint; 27 - rubber cover; 28 - restrictive nut; 29 - shock absorber (rubber washer); 30 - rubber cover of the CV joint (from the car "Niva"); 31 - upper ball joint (from a VAZ-2101 car); 32 - wheel gear; 33-lower ball joint (from the VAZ-2101 car); 34 - lower arm (steel pipe d32)

A design feature of the transfer case is that it uses an assembled rear axle differential from a Zhiguli car. He only turned the outer surface of the case. A special glass-gear is mounted on the body (selected from agricultural machinery), on the circular ledge of which teeth with a module of 3,5 are cut. Under this module, all other gears and gears of the transfer case were ordered. The end of the glass (it has a shoulder) adjoins the crown of the gear wheel mounted on the differential case. All the mentioned parts are connected into one unit with M10 screws (longer than standard ones).

The placement of the engine and all transmission units is symmetrical with respect to the longitudinal axis of the machine. Even the front axle gearbox is located in the middle between the wheels, under the engine.

A gas tank with a capacity of 35 liters is mounted behind the box under the bottom of the body.

Drives of all wheels are the same. Suspensions are also of the same type - spring-loaded with shock absorbers, only the front one is on transverse levers, and the rear one is on longitudinal ones. The front suspension is also reinforced with a transverse spring of three sheets from the Moskvich car, and the wheels are made swivel.

All-terrain vehicle wheels are replaceable. For the summer, I put UAZ ones, and in the rest of the year - home-made pneumatics - they are the same as the front ones on the previous all-terrain vehicle model. The description and drawings of pneumatics are published in No. 1 '2000 of the magazine "Modeler-constructor". In the UAZ wheels, in order for them to fit the Muscovite flanges, I cut out the middle part of the disk along with the holes, and in its place I welded another home-made one with suitable holes.

Two-speed transfer case with differential lock (modules of all gears and gear wheels m = 3,5) (click to enlarge): 1-nut M16x1,5 with spring washer (4 pcs.); 2 - flange for connecting a short cardan shaft; 3 - input shaft; 4 - anther (3 pcs.); 5 - cuff (4 pcs.); 6 - screw M6 (24 pcs.); 7 - bearing housing (2 pcs.); 8 - bearing 205 (4 pcs.); 9 - small gear of the input shaft (z = 26); 10 - gear shift clutch; 11 - gear shift mechanism; 12 - gear wheel of the input shaft (z = 36); 13 - hand brake drive; 14 - hand brake; 15 - differential lock mechanism; 16 - end clutch of differential lock; 17-front distributing shaft; 18 - bearing housing; 19 - bearing 208; 20 - cup-gear (z = 33); 21 - transfer case (steel sheet, s4...6); 22 - M8 screw for fastening the cover to the body (6 pcs.); 23 - ring gear (z = 43); 24 - differential (from a VAZ-2101 car, complete); 25 - bearing housing; 26 - bearing 207; 27 - bearing housing cover (2 pcs.); 28 - crankcase cover (steel sheet s6); 29 - rear distributing shaft

Wheel reduction gears (a - front right; b - front left, c - rear right) (click to enlarge) (click to enlarge): 1 - front suspension lower arm bracket (St3, sheet s3); 2 - bearing housing; 3 - bearing housing cover; 4 - nut M16x1,5 with washer; 5 - bearing 205; 6 - remote thrust washer; 7 - bracket for the upper arm of the front suspension (St3, sheet s3); 8- anther (St3); 9 - bearing housing with labyrinth grooves; 10 - bearing 207 (3 pcs.); 11 - splined shaft (from the CV joint VAZ-2108, modified); 12 - drive gear (m = 3,75, z = 15); 13 - screw M6 (15 pcs.); 14- bearing housing; 15 - cover; 16 - special nut; 17 - wheel mounting flange; 18 - threaded pin; 19 - bearing housing cover; 20 - cuff; 21- anther; 22 - wheel gear housing (St3); 23 - driven gear (wheel, m = 3,75; z = 30); 24 - gearbox housing cover (St3, sheet s3); 25 - screw M4 (8 pcs.); 26 - breather (from agricultural machinery); 27 - trailing arm of the rear wheel suspension (pipe d60x3); 28 - scarf for mounting the lever (St3, sheet s3, 2 pcs.)

Fastening of the crankcase of the main gear to the frame box: 1 - crankcase; 2 - bottom of the body; 3 - corner bracket; 4 - transverse beam of the box (corner 35x35); 5 - M10 bolt with nut and spring washer (4 pcs.); 6 - casing of the box (St3, sheet s3)

Steering scheme: 1 - front steering wheel (2 pcs.); 2 - steering gear (steering wheel, shaft, worm gear, bipod); 3 - the first intermediate thrust; 4 - two-arm pendulum lever; 5 - the second intermediate thrust; 6 - wheel reducer with a lever (2 pcs.); 7 - right thrust; 8 - right hinge; 9 - medium thrust; 10 - left hinge; 11 - left traction

I made the wings above the wheel niches removable: when replacing wheels with pneumatics, I also remove the wings.

When changing propellers, some overall dimensions also change slightly: for example, the height of the all-terrain vehicle on wheels is 1770 mm, on pneumatics it is 1900 mm, and the width, respectively, is 1920 and 2100 mm. Similarly, the ground clearance changes from 370 mm to 500.

All mechanisms, components and parts of the steering - from the car "Lada" and only the steering wheel - from the "Zaporozhets".

The speeds of the all-terrain vehicle, and with them the speedometer readings with different propellers at the same engine speed in the same gear, are different. The speedometer is set to the speed of the UAZ wheels, and when driving on pneumatics, these readings have to be corrected - multiplied by a factor of 1,5.

The maximum speed on wheels from the UAZ with a low gear of a transfer case is 40 km / h, with an increased one - 60 km / h. On pneumatics, I do not turn on the higher gear - even with a lower gear, the speed reaches 60 km / h.

Author: B.Ryzhov

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