Custom Projects
Have you got a custom project in mind? A dream buggy, an off-road racing weapon or an all-terrain special purpose vehicle?
We can help you get your project from sketches to a fully engineered design with the latest computer CAD modelling software and building from decades of industry experience.
Our engineers can work to your specifications or help you narrow down your project to the optimum design. We are able to provide detailed construction plans if you're looking for the owner-fabricator experience, or in-house fabrication services are available. Contact us to talk about getting your idea rolling!
Over the years The Edge Products have taken on a number of projects as an innovator in off-road performance engineering. Some of our highlights are showcased below. Please note that since many of these were one-off designs or projects, plans are usually not available - but if you feel inspired please contact us and we are happy to help!
Example design process - modelling, stress analysis and final product visualisation.
The Ballistic
The Ballistic, designed for class 1 off road racing here in Western Australia is the largest buggy project The Edge Products have taken on to date.
Constructed from the ground up for off road enthusiast Steve Alford the Ballistic featured a lot of new innovative concepts not yet seen in off road racing. The Ballistic was designed in house on a 3D Solidworks CAD station by The Edge Products owner Tony Sanger & featured components & concepts such as:
- Progressive rising rate bellcrank suspension
- Fore / Aft seating layout
- Subaur WRX turbo EFI motor
- Automatic 4 speed transaxle
- 19" twin-tyre wheels
- Double A-Arm suspension on all four corners
- Collapsible nose cone
- 900kg dry weight
- Spaceframe chassis in CDS tubing
- Removable tail section
- 108" wheelbase
- 78" track width
- 600mm (23") front suspension travel
- 500mm (19") rear suspension travel
Not only was the Ballistic be an interesting off road contender but The Edge Products used it as a testbed to evaluate new ideas & concepts which were used on smaller buggy designs.
NOTE : Please do not ask for plans to the Ballistic as they are not available.
Accessibility for all Drivers
Edge vehicles usually use a combination of hand and foot controls for throttle, brakes, steering and gearshift. Being limited to hand-controls didn't slow down this Barracuda customer, after Edge created a custom control set with everything within easy reach.
The Barracuda below was also fitted with a custom door system to allow the paraplegic driver easier access.
The Hypersprint shown below featured a stretched chassis and modified roof structure to make ingress and egress easier for a driver with unique physical requirements.
Please contact us if you have special requirements for an off-road recreational vehicle. We can work through a full ground-up design or modify an existing vehicle to suit your needs.
The Hypersprint
The Hypersprint buggy was a precursor to the highly successful Barracuda and showcased some revolutionary design features in off-road buggies.
Pushrod-actuated front and rear suspension layouts were wrapped in fully laser-cut housings. These modules were bolt-on subassemblies in later production models.
In 2005 the Hypersprint was superseded by the Barracuda, which offers greater performance in a more cost-effective package. Nevertheless the Hypersprint's technical sophistication is a highlight in Edge's history of innovation.
Trophy Truck Trailing Arms
At The Edge Products our work is not limited to off-road buggies. These trailing arms were designed from scratch for the Outlaws 4x4 Class 8 Extreme 4WD racing trophy truck.
Starting with a handful of overall dimensions the arms' geometry was laid out to suit the truck's spring and damper hardware. Computer simulations were used to put the arms through their paces, before the final design was handed over to the Outlaws team for fabrication.
Laser-cut internal skeleton
Partially completed arms
The Outlaws 4x4 Trophy Truck racing on Edge's custom trailing arms.
Have you got a custom off-road vehicle which requires an experienced hand in suspension design? Contact us to set up a consultation and discuss your vehicle's requirements.
Custom Exhausts
There is no single solution for exhausts in motorcycle-engined buggies. Shown below is a stainless steel 4-into-1 for a Suzuki Hayabusa engine.
Custom Powerplants
Although larger Edge buggies are usually powered by a motorcycle engine several customers have pursued car-based power plants. The modified Hypersprint shown below was fitted with a Subaru 1600 engine and transaxle gearbox.
The XRV Buggy
The XRV buggy was produced by Edge around the 2002 - 2006 period. Over 80 XRV buggies were exported to the Middle East for off-road sand dune adventure tourism.
Military tracked vehicle
This radio controlled tracked vehicle was designed & built for the Australian Armed Forces. Featuring 2 kw of power, full suspension & a fully armoured Titanium hull. It can achieve speeds over rough terrain of 20 kph.
Military target vehicle
A vehicle designed & built for the Australian Armed Forces, this radio controlled vehicle is a target drone designed to aid in the training of troops.
It features electric drive, removable battery pack & bolt on suspension modules.
In training exercises it would be fitted with a car body to simulate a real car.
It was also proven to be a great platform as a stretcher bearer & for general cargo haulage.