How to Build Your Own Kite Buggies

You don't have to live near the ocean to go sailing! With just a few basic materials and tools, you can create a simple foot-steerable plywood buggy. These fantastic and safe recreational vehicles are great for anyone with access to a dry lake bed or large expanse of concrete.

Things You'll Need

  • 4 wheelbarrow wheels, equal sizes at least 12 inches in diameter, 3/4 inch shaft
  • 2 steel axles or shafts, 3/4-inch diameter, 3 feet long
  • 8 shaft collars
  • 5 U-bolts, 3 inches long, 3/4 inches between prongs, threaded
  • 1 sheet of 3/4-inch thick plywood, 2 feet by 4 feet
  • 4 two by fours, 3 feet long each
  • 2 pieces sheet metal, round, 3 inches diameter
  • 8 x 1" 1/4-20 bolts and nuts
  • 10 wood screws, 1 3/4 inches
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Instructions

    • 1

      Build the axle and wheel sets. Fix the wheelbarrow wheels over the axle and secure in place using shaft collars. Cut a 2 inch by 4 inch board to the length of the space between the shaft collars. Drill two holes on either end of the 2 by 4s for U-bolts, then place the board along the axle. Slide the U-bolts through and secure the bolts in place using screw nuts. Reinforce the nuts with threadlocker compound. The axle must be very secure. Repeat the process. This will create your front and rear axles.

    • 2

      Make the chassis (the part of the buggy where you sit). To do this, measure 3 inches on either side of the center of the front part of the plywood. From those two points, cut away the front corners at a 45-degree angle. This will allow the front axle more freedom of movement, so you can steer more easily. Reinforce the plywood base by using two 2 by 4s. Nail them or screw them to the plywood board in a "T" pattern, reinforcing the bottom side of the board.

    • 3

      Attach the front axle. Place the axle assembly underneath the forward end of the chassis. The kite buggy is foot-steerable, so you should be able push one end of the axle forward with your foot to steer the buggy. Drill a hole through both pieces of wood, in the center of the 2 by 4 attached to the axle and also through the forward end of the chassis, a few inches rearward from the edge. Using a pair of tin snips, cut two round pieces of sheet metal, 3 inches in diameter. Drill holes through the center of both pieces. Bolt them all together, with the axle assembly on the bottom, securing both ends of the bolt with a locking wing nut. The axle assembly should move back and forth easily. The two metal pieces reduce friction that would otherwise be caused by the wood.

    • 4

      Screw your rear axle to the rear portion of your chassis using wood screws and secure in place with wing nuts and threadfastener.

    • 5

      Drill two holes in the forward part of the chassis for a U-bolt. Slip the U-bolt through the openings from the top and secure it with wing nuts or nuts and washers. This is where you fasten the kite.