This DIY Electric Vehicle Buggy Conquered the Rubicon Trail, Achieving Victory Two Times.
Ian Lane-Lohse
Get The Drive’s daily newsletter
The latest automotive news, reviews, and features.
If you're not aware yet, the Rubicon Trail is quite the challenge. It tests even the toughest factory off-road trucks with large boulders, narrow paths, and occasional water crossings. You need to be either bold in your ambition to create a vehicle that can tackle the 22-mile trail or simply ready for an adventure. I’m uncertain which category Nick Dey falls into, but he designed and built this custom EV rock buggy in under seven weeks before attempting to navigate the Rubicon the hard way.
Over the past couple of weeks, my inbox was flooded with emails and DMs suggesting that I connect with Dey because he’s too modest to promote his achievement. In a brief phone conversation, I discovered not only did he create something remarkable, but he also did so on a reasonable budget and in virtually no time at all. This is a benefit of being an experienced online shopper and skilled fabricator, as Dey co-owns 80% Off-Road with his friend John Graham.
“We had a weekend trip wheeling in Cougar Buttes near Johnson Valley, and I noticed a buggy enthusiast having a lot more fun than I was,” Dey recounted. “I called my metal supplier for a quote on tubing, and it came in at about 400 dollars. I thought, ‘Alright, I guess we’re doing this.’”
Dey only worked on the build during evenings and weekends, yet within less than two months, he was driving it on the Rubicon.
Dey emphasized that he did not create any designs in CAD; he simply dove in. The buggy began with a seat on the floor, and he constructed everything around it. The end result is an approximately 1,400-pound buggy powered by three 48-volt batteries purchased from Amazon, an HPEVS AC-20 motor found on eBay, and interestingly, a T90 three-speed manual transmission sourced from a flatfender Jeep (more on that later).
The buggy employs Samurai axles and 35-inch UTV tires to demonstrate that you don’t need one-ton axles and 40-inch tires for off-roading. Inside those solid axles are 4.57 gears and lockers, which work in tandem with the previously mentioned transmission to achieve significant gear reduction. Dey shared that the electric motor produces only around 30 horsepower, but thanks to the three-speed gearbox and two-speed transfer case, he can extract every bit of torque. This is crucial for utilizing a smaller battery pack and compact electric motor.
“Before, it was just a two-speed, low and high. Then I added the three-speed manual transmission, making it essentially a six-speed now,” Dey remarked.
Furthermore, it is compact. Dey compared the motor to a fire extinguisher that weighs about 60 pounds. Its diameter is just under 7 inches and it measures 11.35 inches in length. He mounted it beneath the floor towards the front of the vehicle, highlighting the considerable packaging advantages of going electric. “You can truly manage your weight distribution,” he noted. “It made it much simpler not having to design around a small-block [V8] engine or something.”
Regarding suspension, the buggy features a three-link setup in the front and a four-link in the rear. Ian Lane-Lohse from Wheel Every Weekend valved the Fox 2.0×8.5-inch air shocks, which Dey chose for their affordability. Although none of it is particularly complicated, it is purpose-built and efficient. The same can be said for the entire vehicle.
Dey estimates he invested around $10,000 into the whole project, with about half of that allocated for the EV components. While he notes that electric powertrains aren't “super cheap,” this build is relatively inexpensive compared to the Jeeps he has owned in the past. Plus, it can handle the entire Rubicon without any concerns about fast charging: “I just plug it into the wall for eight to ten hours, and it’s good to go.”
From a drawing on a napkin to roller in two weeks and wheeling the Rubicon in seven, the buggy is “really close to its final form,” Dey shared with me. It doesn’t need to be more than it is because it already conquers trails as is. Dey resides in Southern California, allowing him to trailer it wherever he wants, wheel it for the day, and then bring it back home to charge for the next outing.
I’m not sure what more you could ask for from a homebuilt crawler.
Ian Lane-Lohse
Have a tip or question for the author? Contact them directly: [email protected]
Other articles
Lexus V8 Supercar May Be Postponed Following Goodwood Tease That Keeps Fans Anticipating | Carscoops
Although the delivery of the road car might be postponed, the deliveries of GT3 race cars could commence by the end of the year.
Thieves Steal Catalytic Converters, Disrupt Indiana School Bus Fleet, Drive Students to Online Learning
Overnight, catalytic converters were taken from over a dozen school buses, leading an Indiana district to cancel in-person classes.
Chinese Smartphone Giant's Expansion into European EV Market Could Create Challenges for Tesla | Carscoops
The Chinese technology giant is expected to introduce its complete range of electric SUVs along with the SU7 sedan to Europe.
No Tax Credit? No Problem, Lucid Offers a $7,500 Discount on the Gravity | Carscoops
The company will incur a loss of $7,500 for every Gravity it leases in order to make it available to as many customers as possible.
Cupra’s New Visionary Concept Offers Drivers an Unprecedented Experience | Carscoops
The Cupra Tindaya concept takes its name from a volcanic island and aims to provide a distinctive experience for the driver.
Range Rover Velar EV Caught on Camera with Unusual Aerodynamics and Camouflage
The prototype of the Range Rover Velar EV was seen with its trunk open as well, revealing a look at the clamshell rear door.
This DIY Electric Vehicle Buggy Conquered the Rubicon Trail, Achieving Victory Two Times.
An onboard inverter quickly charges the golf cart batteries when needed, eliminating range anxiety—particularly on low-speed trails.