View Full Version : New Custom Mountain Sled Build: SPAWN
I have been posting this build on my site. I will bring everyone up to speed. I am heading out riding out this coming week, but when I get back, I will be mocking up the cardboard tunnel so I can get it bent up.
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I just picked the chassis for my new mountain sled. I am really only interested in the bulkhead and NUN from this unit. I will, again, be bending up my own tunnel for this project.
Here is the chassis I got today:
http://img158.imageshack.us/img158/8035/newproject.jpg (http://img158.imageshack.us/i/newproject.jpg/)
Here is the brand new take-off 08 XP 154" Hillclimb skid. It comes with rail reinforcements and a custom piggyback shock. I will be changning out the front shock for one from a REV. That will give about 1" more height to the front of the skid. The shock is about 3/8 longer on the older REV's.
http://img190.imageshack.us/img190/8229/newskid1.jpg (http://img190.imageshack.us/i/newskid1.jpg/)
http://img267.imageshack.us/img267/1822/newskid2.jpg (http://img267.imageshack.us/i/newskid2.jpg/)
http://img158.imageshack.us/img158/5192/newskid3.jpg (http://img158.imageshack.us/i/newskid3.jpg/)
I also just purchased an RTI extended chaincase. So...once the summer fixer-uppers are done. I get to start on this new project.
This is going to have a ton of stuff from Dootalk sponsors, RPM Composites, HP Graphics, Big John, Dynamoe Joe and whole slew of others. So stayed tuned to see how this turns out.
I am not quite sure what motor it will have yet. Looking at a Big John 840BB, or a Ski-Doo Race Dept 951...not sure what route to go yet.
I do have the chaincase on the way. Here is the new RSI (not in my sled. LOL)
http://img512.imageshack.us/img512/3958/chaincase.jpg (http://img512.imageshack.us/i/chaincase.jpg/)
Here is the new track I scored today. I had to go to another site. But I wanted a Polaris Series 5.1 163" X 15" X 2.4"
Here is the track I just purchased from SW. (again not on my sled)
http://img512.imageshack.us/img512/1620/polarisfootwellrails.png (http://img512.imageshack.us/i/polarisfootwellrails.png/)
Just picked up my front shock springs. Titanium springs from Shawn @ Al's Snowmobile.
http://img338.imageshack.us/img338/888/titaniumsprings.jpg (http://img338.imageshack.us/i/titaniumsprings.jpg/)
I also picked up the black side panels, console and trunk from Dootalk member, MXZDrew.
I also got a nice custom vented dash pod from Snowest member Skidoo_03.
One of my buddies, Jeff Aiello (Team Summit and the Elevation videos) got me in contact with Sean at West Coast Customs. Once the shop opens back up, I will be a dealer for their light weight control arms.
I just got a set for my new project. I am getting them in raw steel so I can have them powder coated. The are adjustable from 39-41", give you 10* tighter turns and are about 10lbs lighter than the stock ones. Here is a picture of the new arms:
http://img150.imageshack.us/img150/7281/wcs.png (http://img150.imageshack.us/i/wcs.png/)
I forgot. Yesterday I spoke with Raphi at RPM Composites. He is going to be working on a new one-off custom skid plate in blue.
Casey at HP Wraps is going to tweak my other wrap a bit and make it in blue.
Once I get those items in hand, I will post some pictures.
Got back from the Ski-Doo dealer with my new 440X braces. I got the rest of the bracing comming from Matt Santwire. I have decided that the tunnel is going to be in Mini Tech. It is a very fine wrinkle finish, and is a flat black.
Here are the braces:
http://img74.imageshack.us/img74/2060/440xbraces.jpg (http://img74.imageshack.us/i/440xbraces.jpg/)
Here is the new XP cooler that I am going to use. I have another cooler comming from a REV Summit. It has the correct 90* elbows I need to make this work. I will cut the XP cooler to length, cut the elbows off the old cooler then have an end piece tigged to the XP cooler, and have the elbows tigged to the cooler to properly fit the sled.
http://img509.imageshack.us/img509/8378/xpcooler.jpg (http://img509.imageshack.us/i/xpcooler.jpg/)
I got the panel for under the seat of a Summit. At $38 (my cost) it was easier (and cheaper) to just buy it from Ski-Doo than to make it. So the cooler will come out of the 121" chassis, then the plate will go under the seat with recess to allow the hoses to go to the front.
Here is the shot with the cooler in place:
http://img78.imageshack.us/img78/5641/summittunnel1.jpg (http://img78.imageshack.us/i/summittunnel1.jpg/)
Here is where the new center plate will go:
http://img79.imageshack.us/img79/8869/summittunnel2.jpg (http://img79.imageshack.us/i/summittunnel2.jpg/)
I got more parts in the mail today, and some I picked up from Trailways.
I got the other cooler to make the one I need. I will be cutting the elbows off this piece to put on the XP cooler:
http://img269.imageshack.us/img269/9277/spawncooler1.jpg (http://img269.imageshack.us/i/spawncooler1.jpg/)
I got more of the body panels today. I am just needing the exterior air box and hood. At Hay Days, I am looking for a good seat and a clear gas tank.
Here are the body panels that came today:
http://img269.imageshack.us/img269/5844/spawnbody1.jpg (http://img269.imageshack.us/i/spawnbody1.jpg/)
http://img186.imageshack.us/img186/8926/spawnbody2.jpg (http://img186.imageshack.us/i/spawnbody2.jpg/)
http://img269.imageshack.us/img269/497/spawnbody3.jpg (http://img269.imageshack.us/i/spawnbody3.jpg/)
New (to me) track in the hizzzous. BONZAI!!!!!!!!
http://img40.imageshack.us/img40/4669/spawntrack1.jpg (http://img40.imageshack.us/i/spawntrack1.jpg/)
http://img44.imageshack.us/img44/3596/spawntrack2.jpg (http://img44.imageshack.us/i/spawntrack2.jpg/)
I got the new A-Arms back from Cool Concepts. These are the West Coast Customs A-Arms with the Candy Blue poweder coating.
http://img23.imageshack.us/img23/8131/aarms1.jpg (http://img23.imageshack.us/i/aarms1.jpg/)
http://img441.imageshack.us/img441/8996/aarms2.jpg (http://img441.imageshack.us/i/aarms2.jpg/)
http://img41.imageshack.us/img41/9369/aarms3.jpg (http://img41.imageshack.us/i/aarms3.jpg/)
http://img27.imageshack.us/img27/8246/aarms4.jpg (http://img27.imageshack.us/i/aarms4.jpg/)
Thanks. I can't wait to start to work on her.
I just procured the drive axle. It is from an 06 440X race sled.
http://img41.imageshack.us/img41/8436/440xaxle.jpg (http://img41.imageshack.us/i/440xaxle.jpg/)
Here is the new SHR840BB motor. It came with carbs, Boyesen Rage Cages, all electrical and rewind. I will be pulling it apart, phasing the crank to make sure it isn't out of synch and checking all crank bearings. I will hone the cylinders and putting new rings after checking all clearances, putting a new base gaskets and O-rings in it.
I am sending the RKT head to Kelsey and having my stock 800 head cut to fit the domes. I want to have a stock looking 800 motor with no clues as to the BB kit in it.
http://img196.imageshack.us/img196/6531/840bb1.jpg (http://img196.imageshack.us/i/840bb1.jpg/)
http://img13.imageshack.us/img13/482/840bb2.jpg (http://img13.imageshack.us/i/840bb2.jpg/)
http://img35.imageshack.us/img35/360/840bb3.jpg (http://img35.imageshack.us/i/840bb3.jpg/)
http://img24.imageshack.us/img24/7899/840bb4.jpg (http://img24.imageshack.us/i/840bb4.jpg/)
I got the head pulled from the new 840 motor. The pistons, domes, cylinders all look good. I am going to pull the motor apart and true the crank. I am also going to putting all new seals in it just to be safe.
http://img190.imageshack.us/img190/8230/840cylinder1.jpg (http://img190.imageshack.us/i/840cylinder1.jpg/)
http://img207.imageshack.us/img207/1780/840cylinder2.jpg (http://img207.imageshack.us/i/840cylinder2.jpg/)
http://img39.imageshack.us/img39/49/840cylinder3.jpg (http://img39.imageshack.us/i/840cylinder3.jpg/)
http://img38.imageshack.us/img38/8804/840cylinder4.jpg (http://img38.imageshack.us/i/840cylinder4.jpg/)
I also got my new roller clutch today, I got it torn down, inspected, cleaned and the new parts put in it. It got a fresh purple spring, a new guard, a new swivel abutment and new DJ clutch helix.
http://img18.imageshack.us/img18/5402/clutchbefore1.jpg (http://img18.imageshack.us/i/clutchbefore1.jpg/)
http://img18.imageshack.us/img18/9384/clutchbefore2.jpg (http://img18.imageshack.us/i/clutchbefore2.jpg/)
http://img504.imageshack.us/img504/5715/clutchafter1.jpg (http://img504.imageshack.us/i/clutchafter1.jpg/)
http://img269.imageshack.us/img269/9159/clutchafter2.jpg (http://img269.imageshack.us/i/clutchafter2.jpg/)
I also got the new 800HO Y-Pipe in the mail today. It's like Christmas around here all the time!!! LOL
http://img12.imageshack.us/img12/8740/ypipe.jpg (http://img12.imageshack.us/i/ypipe.jpg/)
I just sewed up the deal on a BOSS nitrous set up. Just the level I wanted, too. 30HP.
It comes with a 20lb refill station. That should be good for every trip I take.
I pick it up Saturday. I am meeting the guy in Cedar Falls near the UNI campus. EXCELLENT! I little Kick-a-Poo Joy Juice....
http://img407.imageshack.us/img407/1385/nosa.jpg (http://img407.imageshack.us/i/nosa.jpg/)
I picked up my Boss Noss kit today. I met the guys sister on the UNI campus. It beat paying to ship NOS from South Dakota to Iowa.
I was a little skeptical on what all would be included. I was told it would be the complete Boss Noss kit, and a 20lb refilling station for $280. It was all there including the fittings that he did not use. The refill station is completely full.
There was the same kit on Dootalk For Sale section, but he wanted way more money and no refill station. I went with the setup from SW for $280, and what a deal it turned out to be. I loaded the control module with 8 'AA' batteries, filled the 2lb bottle and hit the 'ON' switch and hit the "GO" button and it released properly.
Just as safety sake, I am going to send the control module to Boss to have them test it properly.
This the stuff at my house, in my garage. This is what all I got. I am so stoked to fire this pig up.......
http://img180.imageshack.us/img180/504/bosskit1.jpg (http://img180.imageshack.us/i/bosskit1.jpg/)
http://img214.imageshack.us/img214/5558/bosskit2.jpg (http://img214.imageshack.us/i/bosskit2.jpg/)
http://img194.imageshack.us/img194/516/bosskit3.jpg (http://img194.imageshack.us/i/bosskit3.jpg/)
OK. I just landed the clear tank I have been looking for.
http://img512.imageshack.us/img512/7595/cleartank.jpg (http://img512.imageshack.us/i/cleartank.jpg/)
http://img3.imageshack.us/img3/7173/cleartank2.jpg (http://img3.imageshack.us/i/cleartank2.jpg/)
I also bought a black hood from a Dootalker, but I haven't heard anything more about it since I paid. We will see.....
I got the top end of the motor torn down. Very bad news.....hidden damage.....severe damage.
Above the cylinder looks fine....kind of.
Below the cylinder is another story. It looks like this motor was hammered on before it was broken in. It has severe blowby on the rings, and signs of cold sieze on both cylinders. The PTO side is not as severe as the MAG side but started on that side as well.
The PTO side RAVE has signs of being hit by the piston, with indentations and pieces missing.
The transfer bridge on the MAG is cracked all the way through, and the bottom of the sleve has also started to crack. The MAG side piston is toast, and the MAT side cylinder will have to be welded and replated.
The RAVE valves have two different spings in them. One is about a half inch shorter than the other.
I am meeting Big John at Hay Days to drop off the parts to see what can be salvaged and what it is going to cost to fix. I am also sending my stock head to be machined to fit the 840 domes.
I need to head over to the shop tomorrow and pull the pistons off the rods. I am almost afraid to pull the bottom end apart.
I guess this motor wasn't such a smokin' deal for me.
Here are the pictures of the damage:
http://img178.imageshack.us/img178/40/shrmotor1.jpg (http://img178.imageshack.us/i/shrmotor1.jpg/)
http://img412.imageshack.us/img412/3863/shrmotor2.jpg (http://img412.imageshack.us/i/shrmotor2.jpg/)
http://img201.imageshack.us/img201/7214/shrmotor3.jpg (http://img201.imageshack.us/i/shrmotor3.jpg/)
http://img185.imageshack.us/img185/945/shrmotor4.jpg (http://img185.imageshack.us/i/shrmotor4.jpg/)
http://img201.imageshack.us/img201/4964/shrmotor5.jpg (http://img201.imageshack.us/i/shrmotor5.jpg/)
http://img89.imageshack.us/img89/6297/shrmotor6.jpg (http://img89.imageshack.us/i/shrmotor6.jpg/)
http://img185.imageshack.us/img185/7729/shrmotor7.jpg (http://img185.imageshack.us/i/shrmotor7.jpg/)
I just got back into town from Hay Days. It could be just me, but (to me) it didn't seam that as many people were there. There were a lot of people there, it just seamed a little thinner.
Stopped by Majors Friday night and said "Hey" to Jim Phelan and Mark Messinbrink. I also stopped by and said "hey" to Big John and Scott with US Chrome.
I got a bunch of repair parts, but only 4 sets of shocks to sell. I couldn't find any rear shocks for reasonable prices. People were asking more to sell than what I can get out of them AFTER I completely go through them. Most piggy-back shocks were set at $350 for the pair with no springs. C36 race shocks were being set at $250 each.
I did get some nice aluminum bodied, front ski shocks. I also found a bunch of used 90lb single rate springs. We got there at 5am to make sure we got a parking spot close to the exit. We ended up making 4 trips back to the truck to unload the wagon. Here are the shocks and springs I got:
http://img34.imageshack.us/img34/4343/haydays2.jpg (http://img34.imageshack.us/i/haydays2.jpg/)
I also got a ton of stuff for the mountain sled. I got the belt guard, the pipe, HPS can, recoil mounting ring, headlight, fender panels, oil tank, coolant tank, rear rack w/tail light, RAVE valves and an almost brand new set of shocks.
I also picked up a nice set of aluminum bodies ski shocks for the wife's 440 fan. I also have a mechanical reverse kit to install and a E-Start to install on that sled before winter.
Here is the stuff I picked up for Spawn:
http://img9.imageshack.us/img9/1992/haydays1.jpg (http://img9.imageshack.us/i/haydays1.jpg/)
I took $1500 with me, $220 for the hotel for both nights, $120 to eat at The Melting Pot on Friday, $10 parking downtown, $90 for gas, $30 to get in, $10 event parking, $60 to eat at Red Robin. $30 for food and beer at event.
I got all that stuff in the pictures, and when I got home, I had about $267 left over. I got all the above stuff for about $663. I don't really count the other stuff in as the wife and have been going to to this event for many years. It is a short get away for us. We would be going even I wasn't buying anything. We stopped as several quilt shops for the wife on Friday, had a nice dinner out at a nice restaraunt on Friday night. We don't get to do a bunch of stuff together for a whole weekend, this is one of our get aways. Do I have a great wife, or what?! LOL
The grass drags, the new models, the factory displays, the free-style jumping....open beer......it's all good.
Motor update:
US Chrome has the cylinders fixed and complete. They are at Big John's right now. I also sent him a dome to get the correct parts. I am just waiting for his new shipment of pistons to come in. I should have that stuff back in a couple of weeks - tops.
I am waiting on my rebuilt crank to get here from Bombardier.
I have the lower cases cleaned up, a new recoil retianer ring (from ebay) and a new recoil (from ebay).
I need to get the head off to Kelsey to get my stock head cut for the cheater domes.
I will get pictures of all the new stuff I have collected.
I have been swamped with shocks so I haven't had any time to start on anything.
I still have to get my trail sled's tail light figured out, the e-start and reverse in the wife's sled and the finishing touches on the old mountain sled.
Here are the pictures to bring everyone current:
I just got the braces from Matt Santwire. He is having me try some more experimental bracing. This is a picture of all the braces, Matt's and Ski-Doo's. These are not only all the 440X braces, but additional, beefier stuff from Matt.
http://img98.imageshack.us/img98/6506/braces1.jpg (http://img98.imageshack.us/i/braces1.jpg/)
http://img12.imageshack.us/img12/9814/braces2.jpg (http://img12.imageshack.us/i/braces2.jpg/)
http://img9.imageshack.us/img9/3951/braces3.jpg (http://img9.imageshack.us/i/braces3.jpg/)
http://img202.imageshack.us/img202/8852/braces4.jpg (http://img202.imageshack.us/i/braces4.jpg/)
Here is the wiring harness I got from ebay, and the MPEM with DESS I got from here on Dootalk:
http://img22.imageshack.us/img22/3806/harness.jpg (http://img22.imageshack.us/i/harness.jpg/)
http://img12.imageshack.us/img12/1372/mpem.jpg (http://img12.imageshack.us/i/mpem.jpg/)
These are the two chaincases I have. I will be cutting them in half and having them TIG'd back together to make a longer case. The RTI case was for a Polaris:
http://img36.imageshack.us/img36/4379/chaincases.jpg (http://img36.imageshack.us/i/chaincases.jpg/)
Here are the pictures of the new airbox I got. It is from an 07 Summit. It has the larger opening and the new snorkel:
http://img21.imageshack.us/img21/5053/airbox1.jpg (http://img21.imageshack.us/i/airbox1.jpg/)
http://img12.imageshack.us/img12/5063/airbox2.jpg (http://img12.imageshack.us/i/airbox2.jpg/)
Here is the new wave brake rotor I got from my Ski-Doo dealer. Someone had ordered it a couple of years ago, and they gave me a smoking deal on it. I also have the Oilite bushings I got from Goodwin Performance. My trail sled also has these on them.
http://img36.imageshack.us/img36/2442/brakerotor.jpg (http://img36.imageshack.us/i/brakerotor.jpg/)
I got the steering stuff from ebay for a little bit of nothing. Everything is nice and tight.
http://img36.imageshack.us/img36/1204/steering.jpg (http://img36.imageshack.us/i/steering.jpg/)
I got a 440X console from the Dootalk picnic:
http://img202.imageshack.us/img202/2393/440xconsole.jpg (http://img202.imageshack.us/i/440xconsole.jpg/)
I already showed the shocks and springs, but here they are complete. I rebuilt and revalved them for my riding.
http://img42.imageshack.us/img42/3746/shock.jpg (http://img42.imageshack.us/i/shock.jpg/)
I decided to not put the controls on the old mountain sled. They work on the sled, I was just going to change them over. This will keep from buying it again.
http://img12.imageshack.us/img12/7497/controlsz.jpg (http://img12.imageshack.us/i/controlsz.jpg/)
Here is the engine in its current state. I am just waiting on the reman crank from Bombardier. Once that is here, the case will get new PTO and MAG side seals, new ISO grease and the crank trued to 0.001".
Hopefully, within the next couple of weeks, the motor will be complete.
http://img196.imageshack.us/img196/718/motor1f.jpg (http://img196.imageshack.us/i/motor1f.jpg/)
http://img96.imageshack.us/img96/3953/motor2r.jpg (http://img96.imageshack.us/i/motor2r.jpg/)
http://img194.imageshack.us/img194/2717/motor3y.jpg (http://img194.imageshack.us/i/motor3y.jpg/)
I forgot - Casey (from HP Wraps) got the proof of the new wrap back. This is the actual finished wrap.
http://img8.imageshack.us/img8/3186/summitwrap.jpg (http://img8.imageshack.us/i/summitwrap.jpg/)
Today was pretty productive. I have a few days with no customers' shocks to work on, so I needed to take advantage and get a bunch of stuff done before the next round comes in.
I got a new crank from Ski-Doo for a rebuilt price. I also got all the parts back from being hot tanked and cleaned. The Iso grease showed up today so it was time to start putting it back together.
I got the lower end all put together. I also installed the new recoil ring and the new recoil. I installed all new seals. The PTO and MAG main seals were replaced. The waterpump gasket was also replaced.
Everything was cleaned before being put back together. Here are the shots from today:
http://img251.imageshack.us/img251/4823/newengine1.jpg (http://img251.imageshack.us/i/newengine1.jpg/)
http://img40.imageshack.us/img40/4150/newengine2j.jpg (http://img40.imageshack.us/i/newengine2j.jpg/)
http://img36.imageshack.us/img36/8130/newengine3.jpg (http://img36.imageshack.us/i/newengine3.jpg/)
http://img36.imageshack.us/img36/5003/newengine4.jpg (http://img36.imageshack.us/i/newengine4.jpg/)
http://img195.imageshack.us/img195/7512/newengine5.jpg (http://img195.imageshack.us/i/newengine5.jpg/)
http://img36.imageshack.us/img36/5153/newengine6.jpg (http://img36.imageshack.us/i/newengine6.jpg/)
http://img269.imageshack.us/img269/8199/newengine7.jpg (http://img269.imageshack.us/i/newengine7.jpg/)
http://img195.imageshack.us/img195/1951/newengine8.jpg (http://img195.imageshack.us/i/newengine8.jpg/)
I forgot - Kelsey got the cheater done up. I should be getting that in a couple of days, he finished it up earlier this week.
The cylinders are done at US Chrome and at Big Johns waiting for the new pistons to get the correct base gasket.
Here are the shots of finishing up. I put the MAG and sensors and flywheel.
http://img26.imageshack.us/img26/3377/newengine9.jpg (http://img26.imageshack.us/i/newengine9.jpg/)
http://img269.imageshack.us/img269/2871/newengine10.jpg (http://img269.imageshack.us/i/newengine10.jpg/)
http://img269.imageshack.us/img269/8499/newengine11.jpg (http://img269.imageshack.us/i/newengine11.jpg/)
http://img21.imageshack.us/img21/4682/newengine12.jpg (http://img21.imageshack.us/i/newengine12.jpg/)
http://img14.imageshack.us/img14/3559/newengine13.jpg (http://img14.imageshack.us/i/newengine13.jpg/)
http://img199.imageshack.us/img199/2601/newengine14.jpg (http://img199.imageshack.us/i/newengine14.jpg/)
http://img26.imageshack.us/img26/3254/newengine15.jpg (http://img26.imageshack.us/i/newengine15.jpg/)
http://img199.imageshack.us/img199/9071/newengine16.jpg (http://img199.imageshack.us/i/newengine16.jpg/)
I got the RK Tech cheater head today. Kelsey does an AWESOME job.....
http://img21.imageshack.us/img21/1862/rktech1.jpg (http://img21.imageshack.us/i/rktech1.jpg/)
http://img39.imageshack.us/img39/3007/rktech2.jpg (http://img39.imageshack.us/i/rktech2.jpg/)
http://img39.imageshack.us/img39/9175/rktech3.jpg (http://img39.imageshack.us/i/rktech3.jpg/)
http://img44.imageshack.us/img44/2711/rktech4.jpg (http://img44.imageshack.us/i/rktech4.jpg/)
I just spent 13 hours today in the shop cleaning and putting stuff away. I have the old mountain sled and the trail sled off to the side. I have a clear shop to start work on the new project.
I just have to put a new reverse chaincase in my wife's sled, and add E-start then I can start the actual build process.
I am going to be bending my own tunnel on the this sled, too. It is going to be similar to a VanAmburg Boondocker style tunnel.
I got the top end back from Big John. I must nice work...VERY nice work. Excellent port work, and a fantastic person to deal with. KUDOS, big guy.
I dropped the pistons off at Cool Concepts yesterday to have the tops coated with a Thermal Barrier coating. I get them back today. Rick at Cool Concepts does exceptional work and has a VERY quick turn around time. He is AWESOME!! If you need any powder or high coating done, he is your man in the MidWest.
I will have pictures of the new pistons and upped end later today after I pick them up.
I am just waiting on a new rider plate for the wife's chain case to put that back together. I also have to machine the S-Chassis cover to accept the down pin and the shifter fork.
This afternoon I will doing the rear skid shocks for her sled and hopefully getting the skid back in her sled. Once that is done, I can the chassis for Spawn on the stand and start the assembly process.
I also picked up the primary clutch and correct oil tank for her. I have a call out to Sean at Al's Snowmobile for a set of titanium rear torsions and center springs. If he can't find them, I may have to step to RCS titanium rear springs for her..OUCH!!
Anyway. I will have pictures this afternoon.
OK. As stated above, I picked up my pistons from Cool Concepts. Rick does excellent work, excellent prices and superior work. Kudos to him.
Anyway. I done with the shocks around 6p, so I decided it was time for a little "me" time. So I dropped Rob Zombie Dragula on the CD player and started to put the motor together.
This is a good shot of the quality of work Big John does. I can't imagine anyone taking of business better than he does. Big John and Sled Head Racing are top shelf all the way.
Kelsey's head machining is second to none. Everything bolted in place, everything dead on....and it still looks like an ordinary 800HO motor.....mo-ahahahahahahaaaaa.
I assembled the motor with Ski-Doo mineral oil. That is all the all the oil I use, even when riding. That is another thread at another time.
Here are the shots from this evening's build:
http://img163.imageshack.us/img163/6313/assem2.jpg (http://img163.imageshack.us/i/assem2.jpg/)
http://img189.imageshack.us/img189/1094/assem3.jpg (http://img189.imageshack.us/i/assem3.jpg/)
http://img163.imageshack.us/img163/4887/assem4.jpg (http://img163.imageshack.us/i/assem4.jpg/)
Here are the pistons back from Cool Concepts with the Thermal Barrier coating. Big John's pistons come with poly on the side skirts.
http://img163.imageshack.us/img163/8855/assem5.jpg (http://img163.imageshack.us/i/assem5.jpg/)
The old RAVEs were junk from piston contact. So I have BJ machine some new ones from a good set I had here.
http://img36.imageshack.us/img36/3699/assem6.jpg (http://img36.imageshack.us/i/assem6.jpg/)
These are the new caged bearings that went into the brand new 800HO rod:
http://img4.imageshack.us/img4/7830/assem7.jpg (http://img4.imageshack.us/i/assem7.jpg/)
Ready for final assembly with bearings, wrist pins and circlips in place:
http://img192.imageshack.us/img192/3053/assem8.jpg (http://img192.imageshack.us/i/assem8.jpg/)
http://img28.imageshack.us/img28/4617/assem10.jpg (http://img28.imageshack.us/i/assem10.jpg/)
http://img28.imageshack.us/img28/358/assem11.jpg (http://img28.imageshack.us/i/assem11.jpg/)
http://img4.imageshack.us/img4/9366/assem12.jpg (http://img4.imageshack.us/i/assem12.jpg/)
http://img132.imageshack.us/img132/4629/assem13.jpg (http://img132.imageshack.us/i/assem13.jpg/)
This is installing the Boyesen reeds. I will get stainless bolts to hold them upon install in the sled:
http://img132.imageshack.us/img132/1752/assem14.jpg (http://img132.imageshack.us/i/assem14.jpg/)
I always use Nordloc washers on the Y-Pipe. I have the pipe installed for now to keep dirt and the like out. I will be sending that in to be coated in matte black high temp along with the expansion chamber and HPA can.
http://img138.imageshack.us/img138/2610/assem15.jpg (http://img138.imageshack.us/i/assem15.jpg/)
http://img138.imageshack.us/img138/9720/assem16.jpg (http://img138.imageshack.us/i/assem16.jpg/)
Done....looks completely stock.
OK. So I got the garage rearranged today after finishing up the wife's sled. I put new shocks all the way around on that, HPG's in the front, and FOX in the rear, put new hyfax on it, removed (meaning had to press out the rear axle) and re-greased all those up, put an E-Start on it, put mechanical reverse in it and it is ready to roll.
I also did the once over on the trail sled and changed fluids, as I did on the mountain sled. I just have to hook up the throttle cable and put the axle bolts in that it is ready to roll.
The shock business, the wife's sewing room, her sled, my sleds have been keeping me hopping. I took off an extra day last week to get caught up. That gave me 5 days off from Toyota and I got a TON of stuff finished up.
I also got Spawn on the rack.
I put the chaincase on it, put the track under it and put the axle in place to check clearance. I have just short of a half inch clearance. I am going to run with that, then I don't have to make a new chaincase for the drop and roll. That made life a little easier.
This week I am going to work on getting it stripped down and the tunnel cut off. I can then get that over the powder coaters. Then I can do the tunnel in one piece and send that off then connect them when they are back.
Here are the shots from today.
http://img24.imageshack.us/img24/511/chassis1.jpg (http://img24.imageshack.us/i/chassis1.jpg/)
http://img697.imageshack.us/img697/1449/chassis2.jpg (http://img697.imageshack.us/i/chassis2.jpg/)
http://img684.imageshack.us/img684/4913/chassis3.jpg (http://img684.imageshack.us/i/chassis3.jpg/)
http://img684.imageshack.us/img684/3462/chassis4.jpg (http://img684.imageshack.us/i/chassis4.jpg/)
I did some test fitting tonight. I wanted to make sure the A-Arm bushings and aluminum sleeves fit the delrin bushings.
I also wanted to make sure all the West Coast Sled stuff bolted up. Of course it all fell right into place.
I have the A-Arms installed for fit, with the shocks and the titanium springs and the Pilot 6.9 skis (that aren't exactly in great shape like the seller claimed.)
Here are some shots of the test fittings. This weekend the bulkhead is coming apart and the tunnel is getting cut down so I can get the braces installed and to the powder coater.
http://img41.imageshack.us/img41/1560/wcsarms1.jpg (http://img41.imageshack.us/i/wcsarms1.jpg/)
http://img6.imageshack.us/img6/9377/wcsarms2.jpg (http://img6.imageshack.us/i/wcsarms2.jpg/)
http://img6.imageshack.us/img6/2418/wcsarms3.jpg (http://img6.imageshack.us/i/wcsarms3.jpg/)
Thanks, but I will keep the belt guard. When the clutches are dialed in properly, heat shouldn't be an issue. I will be putting vents in though. I just haven't decided what, yet.
I got a couple of days off with no shocks (a bunch coming in this week, though) and did some PR on a fun run with the Snow Pioneers this weekend.
I got 130 miles in on Saturday with temps below zero all day. When I left at 9a it was -15* and when I loaded up last night it was about -9*.
I tested the new knees out proper and they are a little light in the endurance, but everything else worked fine. My shoulders and arms are more sore than my legs from the hammering they took pounding moguls.
Anyway, today I got to work on Spawn. I got it all stripped down to the tunnel. I got a bunch of stuff ready for the powder coater that I will be taking over this week.
This week I hope to get the tunnel cut from the bulkhead. MY VanAmburg footwell edges will be here this week so I can start mocking up my running board so I can get the Snow Eliminators ordered.
Once I get everthing fitted up and the tunnel bent up. I can ship the bulkhead off to be powder coated and I can work on the rear section with the side bracing and rear grab bar.
http://img195.imageshack.us/img195/4297/stripped1.jpg
http://img710.imageshack.us/img710/8044/stripped2.jpg
http://img706.imageshack.us/img706/4815/stripped3.jpg
This is next round of powdercoating. It is the all of the pyramidal supports and and a few other items. Tomorrow, I need to drill out all the rivets and get the plastic off of it, then off the Cool Concepts.
http://img140.imageshack.us/img140/9890/stripped4.jpg
Well, I had to work today and delivered a ton of shocks I got from guys on the fun run last weekend. I took Thursday off to get a bunch of them done up and delivered.
I had to work at Toyota today until 1pm. When I got home I started drilling out rivets.
I will have pictures tomorrow.
Today I laid in the rear skid to measure the clearance on the extrovert drivers and took a bunch of measurements. It looks like I am going to be doing my original plan of 1.5" set-back.
I ordered the .080 5052 sheet of aluminum this morning. I can pick it up Monday.
My VanAmburg rail edges came Friday. I ordered them bent, but not to have the end plates welded. They sent them as ordered.
I also ordered my rail extensions. I get them from WildChild. His stuff is top notch. All my extension are from him. I am going to be putting 9" rear wheels with a 2 wheel kit on the inside.
I also got the rear cooler roughed in. I got the pyramid support brackets drilled off, the seat mounts drilled off and rear brackets for the seat plastic drilled out. I got the front of the NUN drilled out and removed and the MAG side support drilled out and removed.
I had to do some body work on the chaincase side lower chassis area. It looks like who owned it hit something pretty hard. I got it smoothed out pretty close to stock.
Tomorrow, I am going to be cutting the tunnel off the bulkhead.
OK. I got some pictures done up today of the progress.
I got the bulkhead removed from the tunnel today and the A-Arms tabs finished up.
Here are the pictures of the bulkhead with all the stuff removed so I can start installing the Matt Santwire bracing. I have the front of the NUN removed and the MAG side bulkhead brace removed in these pictures.
http://img194.imageshack.us/img194/6278/bulkhead1.jpg
http://img251.imageshack.us/img251/2703/bulkhead3.jpg
Here is the body work I did on the area under the chaincase. I didn't take any before pictures (sorry, I forgot) but you can see the "message" marks from hammering it out.
http://img251.imageshack.us/img251/814/bulkhead2.jpg
Here are the parts that were removed.
http://img251.imageshack.us/img251/1705/bulkhead6.jpg
I removed the pyramidal support brackets and seat brackets.
http://img30.imageshack.us/img30/866/bulkhead4.jpg
http://img33.imageshack.us/img33/1129/bulkhead5.jpg
I removed the steel footwell supports so I could cut out the bulkhead. The new bulkhead will over lay in that area.
http://img36.imageshack.us/img36/4987/bulkhead7.jpg
Here is the bulkhead removed from the tunnel. I left a tab for each area around where the A-Arms mount. The new tunnel will tuck up under the factory locations in front, but my own area on the rest.
These are the rought cuts. The tabs will be filed down so they are straight, and the old rivet holes will be tigged up and then DA'd to smooth out before the powder coater takes over.
http://img200.imageshack.us/img200/2143/bulkhead8.jpg
http://img508.imageshack.us/img508/7285/bulkhead9.jpg
http://img163.imageshack.us/img163/2505/bulkhead10.jpg
Ford428CJ
02-13-10, 06:23 AM
Nice build-up Maize!!! Thanks for sharing that with us.
Got back from Eagle River Monday night, I had Tuesday off work, so I got some custom sled time.
Today I got the bulkhead finished up and ready to be sent to the welder. I am having all the old rivet holes welded back so there are no 'extra' holes in the bulkhead.
I also cut fillets in the tabs for the front arm mount. I wanted that to be double walled. I also will reinsforcement on the sides. I cut the size down on the sides.
l also got the tunnel mocked up in cardboard. Here is what is similar to what will be on the sled.
I have the VanAmburg running board edges, they will need to be cut to length and the end plate welded. The back of the running I am going to leave open for two reasons. There isn't anything to attach the piece to, and my High Jacker will fit through it then.
http://img85.imageshack.us/img85/6493/tunnel1.jpg
http://img29.imageshack.us/img29/1622/tunnel2b.jpg
http://img651.imageshack.us/img651/6562/tunnel3.jpg
http://img707.imageshack.us/img707/3297/tunnel4.jpg
http://img18.imageshack.us/img18/8693/tunnel5.jpg
http://img404.imageshack.us/img404/6656/tunnel6.jpg
I took the afternoon off work today and worked on the bulkhead. I got the old holes welded up, and one side finished and ready to go.
Here is a picture of the holes welded on the one side. I had a little warpage, but not bad. The finished side is shrunk, and hammered back into place.
Here is the welded side:
http://img203.imageshack.us/img203/3748/welds1.jpg
Here is the other side completed: (I am not sure how well the shots come out, so I had two different lightings)
http://img211.imageshack.us/img211/8509/welds2.jpg
http://img43.imageshack.us/img43/669/welds3.jpg
Tomorrow night I am going to finish up the other side. I will also be laying out the tunnel on the aluminum to get the cut out. I am hoping to get the tunnel cut out this weekend and bent up one night after work next week. Then I have to get the cooler cut to length, cut the elbows off the old cooler and get that all welded up and pressure tested.
I am hoping to get the tunnel attached to the bulkhead next weekend, but we will have to see. I have to order some bracing from Ski-Doo and we will have to see if it all gets here.
Ford428CJ
02-18-10, 09:42 PM
Nice work!!! Keep the pix coming....
I got the final design cut out of the sheet today. I am hoping tomorrow I can get it bent up and start to put on the bulkhead this weekend. Once I get the tunnel together I can get the cooler made up and welded. Then it is off to the powdercoater.
I also got my WildChild extensions and axle kit. I had him make them up to fit my 154" skid, with a 1.5" set back and to accept 9" rear wheels. That will put me in the perfect range for the new 163" track.
The pictures show the axle in place with the factory 8" wheels, but the new ones will pretty much be from the guys at, www.tricked-toys.com.
I am going to throw their book at it, with 9" rear wheels, 4 bogey wheels, billet choke lever, billet gas cap and billet brake cover.
Here are some shots of the WildChild rear axle and extensions:
http://img31.imageshack.us/img31/7892/wc1g.jpg
http://img8.imageshack.us/img8/9123/wc2l.jpg
http://img42.imageshack.us/img42/4492/wc3w.jpg
Well. The bells quit ringing (I have been off all week with a concussion) so I decided to work on the sled today. I got the tunnel bent up and all the test fitting done.
I can now get the rear cooler cut down, the elbows cut out and the whole thing welded up.
I got the footwells where I want them so I can order the set of Snow Eliminators tomorrow.
Here is all the tunnel parts test fit and tweaked. I have to make the side supports for where the VanAmburg edges will bolt to the side of the tunnel.
That should make them extremely sturdy. It will have the edges welded to plates and those will bolt to the side. It will have the rear drop brackets for more rear support, the Snow Eliminators in the center, and the front metal footwell fittings as well as the front footwell sides and braces.
[img]http://img694.imageshack.us/img694/3192/tunneldone2.jpg
http://img3.imageshack.us/img3/228/tunneldone3.jpg
http://img638.imageshack.us/img638/1378/tunneldone4.jpg
http://img11.imageshack.us/img11/9079/tunneldone5.jpg
http://img535.imageshack.us/img535/6742/tunneldone6.jpg
http://img517.imageshack.us/img517/7782/tunneldone7.jpg
Well. I got off work today and hit the shop. I got some guys from Illinois coming tomorrow to have their shocks done up.
Today, I got the VanAmburg rails fitted to the footwell and tunnel. The plates on the back will be TIG'd to the board for support and then bolted with a backing plate to the tunnel. I got the measurements to Terry at Snow Eliminators last night so I should have them next week.
I got the cooler cut to length, tomorrow after I get the shocks done up and then go bowl for Big Brothers and Big Sisters I need to get the elbows cut off so I can get them TIG'd up this week.
I am sending the cooler to Liberty Anodizing in West Liberty, IA. They are going to anodize the cooler black so I don't lose any cooler capacity. Once the tunnel is done up I can TIG the brace on the bottom and then ship it off to be powder coated. Hopefully, I can that finished up this week, too.
Anyway, you can see how much wider I made the running boards for this sled. That leaves a lot of room to move around for boonedocking. I also included some shots of the rear drop brackets I use. These are from the older summits. The give excellent support for the running boards.
http://img205.imageshack.us/img205/3496/tunone1.jpg
http://img41.imageshack.us/img41/2033/tunone2.jpg
http://img528.imageshack.us/img528/4303/tunone3.jpg
http://img684.imageshack.us/img684/1258/tunone4.jpg
http://img291.imageshack.us/img291/7124/tunone5.jpg
http://img299.imageshack.us/img299/6172/tunone6.jpg
http://img72.imageshack.us/img72/9553/tunone7.jpg
http://img205.imageshack.us/img205/3416/tunone8.jpg
I got a lot of work done on the sled in the last few days. Tonight I got the welds done up for the MS bracing, the VanAmburg running board edges and the cooler done up.
Unfortunately, I forgot to take pictures of the cooler before I got it packed to be shipped to Liberty Anodizing to be anodized black. I will get shots of that when it gets back.
Here is a shot of the brace welded in place:
http://img294.imageshack.us/img294/1903/pan1l.jpg
Here are a couple of shots of the VanAmburg running boards edges welded up and ready for final fitment. Once fitted, I can get them to the powder coater.
http://img717.imageshack.us/img717/3013/pan2.jpg
http://img297.imageshack.us/img297/379/pan3.jpg
I also got the rest of the titanium springs for the skid. I got rear torsion springs from GLHPerformance here on Dootalk (thanks, BTW) and the center dual spring set up from Renton Coil Springs.
Here are the rear torsion springs:
http://img195.imageshack.us/img195/1130/tispring1.jpg
Here is the dual-rate set-up:
http://img237.imageshack.us/img237/6114/tispring2.jpg
Nice work! Can't wait to see it all put together.
Hope you are doing ok... getting your bell rang is not a good thing!
The shock business is kind of winding down for the season. I got to work on the sled all weekend.
I got the extensions fitted up, the rear skid torn down for powder coating, and some other pieces ready for the powder coater. I still have many other items to go to powder coaters, but need to wait until I get the items test fitted with the new powder coating.
Here is the extension for the 154 to 163" with the 9" 2-wheel offset axle.
http://img203.imageshack.us/img203/9133/wcrail1.jpg
http://img291.imageshack.us/img291/8854/wcrail2.jpg
Here is the first load of powder coating stuff to go to Cool Concepts. I thought I had enough solid rivets to do the tunnel. I forgot I gave the rest of mine to a buddy to put his extension on and work on his stuff. I am waiting on a new batch from Fabcraft so I can connect the tunnel to the bulkhead.
http://img242.imageshack.us/img242/8741/cc1d.jpg
http://img294.imageshack.us/img294/3227/cc2j.jpg
I am also stoked that Brian from Tricked Toys got me hooked up right proper for some bling.
I am getting 9" double-5 spoke rear wheels reverse powder coated blue, 4 bogey wheels to match. A billet brake res cover, brake lever and choke lever. I am also getting a gas cap. All of these will be reverse powder coated blue.
These aren't the actual wheels yet, they are pictures from his site. Saaaweet!
http://img246.imageshack.us/img246/6997/wheels1i.jpg
http://img69.imageshack.us/img69/3151/wheels2.jpg
http://img535.imageshack.us/img535/3558/wheels3.jpg
http://img692.imageshack.us/img692/7828/wheels4.jpg
http://img651.imageshack.us/img651/3313/wheels5.jpg
I dropped the stuff in the previous pictures at Cool Concepts this afternoon.
When I got home, I started to work on the tunnel pieces. I got the edges perfectly straight with a long file, and the curves smoothed out and everything is ready to rivet to the bulkhead. I may take a day, or afternoon off this week and get it ready to go to the powder coaters.
Here are the pieces ready to be assembled:
http://img41.imageshack.us/img41/9017/pc2aa.jpg
I got the rest of the pieces of the sled ready for powder coating this afternoon, too. These are the rest of the pieces:
http://img36.imageshack.us/img36/9919/pc1ha.jpg
I almost forgot that I picked up a set of XP handlebars. I still have to order the Sea Doo risers and get those fitted up. That should be the last of the modifying, though. That is simple compared to what has already been done.
http://img199.imageshack.us/img199/5261/pc3q.jpg
Well. I was hoping to get my cooler back this week, but not with a letter and a COD that said they do not do any prep work. It needed to be completely clean and the steel center rivets needed to be removed. It would have been nice to know that before I sent it. Oh, well. No biggie.....it's only money, right?
Since I didn't get any shots of the cooler before it went. Here it is completely cleaned, the rivets removed, the ends welded up, the elbows welded one and ready to head back for anodizing.
I am taking a half-day off work tomorrow to attach the bulkhead to the tunnel. I am hoping to that done up and ready to be shipped to the powder coater.
I have set a deadline to have the sled done. June 12, 2010. I want to show it at the Cedar Rapids Corvette Club car show. I showed Madness there and got second place in the alternative vehicles. (I got beat by a T-bucket with a Ford motor. He should not have been in the class).
http://img689.imageshack.us/img689/9028/cooler1x.jpg
http://img35.imageshack.us/img35/6753/cooler2.jpg
http://img133.imageshack.us/img133/213/cooler3w.jpg
I didn't get anything I wanted to get done, done today. I took off work at 2:30p. I was going to get started on riveting the tunnel to the bulkhead.
Anyway, I ran to the Ski-Doo dealer to pick up my R footwell support that was backordered, I can't get the tunnel finished without it.
Yesterday, the home computer took a dump. The surge protector is protecting from surges any longer. I guess they wear out over time too. I did not know that. Leason learned. I took the old unit to Jeff at Midwest Computer Brokers, the guy is a wizard with a computer and cheap. Geak Squad wanted $129 to come out and just look at it.
It ended up having several capacitors blown on the mother board. Jeff hooked me up with another Dell unit like my old one, took both hard drives out and exchanged them and cleaned up the system for $107.00...that includes the cost of the new CPU.
I got home, then got a call from Rick at Cool Concepts. My first batch of powder coating was done.
So here it is 7:47pm and I just got home and got the stuff unloaded and pictures taken. I won't be starting it this evening. But this weekend is going to rock on it.
Here are some shots of the stuff I got back tonight. I REALLY like this Candy Blue:
http://img38.imageshack.us/img38/3227/cc1ya.jpg
http://img97.imageshack.us/img97/8643/cc2n.jpg
http://img717.imageshack.us/img717/9813/cc3.jpg
http://img28.imageshack.us/img28/586/cc4.jpg
I tried to get a couple of shots so you could see how the candy makes it really pop. I don't know how well it shows up on the computer, though:
http://img696.imageshack.us/img696/6094/cc5n.jpg
http://img689.imageshack.us/img689/9384/cc6.jpg
LOL....well....here is some more 'eye candy'. I got the rear skid put together today. It isn't completely finished. It required some 'massaging' of the powder coat to get everything to fit, that and I forgot to tell them to tape off the wheel mounts so I had to sand/file those down as well.
http://img514.imageshack.us/img514/9194/skid1.jpg
http://img535.imageshack.us/img535/5539/skid2.jpg
http://img130.imageshack.us/img130/3295/skid3.jpg
http://img269.imageshack.us/img269/5443/skid4.jpg
http://img17.imageshack.us/img17/8770/skid5.jpg
Tomorrow is all day on the tunnel and bulkhead. I had to run to Dubuque this afternoon to pick up some shocks, so I took today to work on the skid. I should have the tunnel and bulkhead in one piece tomorrow.
I also found that I have to left footwells that go under the running board. Talk about "2 left fee", eh?
I have to wait to get the cooler back from anodizing to completely get the rear portion riveted in place. I am hoping to have everyting back and ready for the powder coaters by next Sunday.
I also have to wait for Terry to get me the finished Snow Eliminators so I can get the running boards cut before it goes for powder coating. I spoke with him Friday, they are done and ready to ship so I should have those this week.
Brian with Tricked Toys said the wheels are all done up, and heading to powder coating, too.
Once the tunnle gets back from powder coating.....it starts going back together. BONZAI!!!
Ford428CJ
03-14-10, 06:29 AM
That is going to be one Bad Azz sled! What a work of art....
That is going to be one Bad Azz sled! What a work of art....
Thanks. That is the beauty of powder coating. It takes abuse. My last is over 5 years old. You can tell by looking at the paint it has been through the trees MANY times, the windsheild is taped together (because I have decals on it that I can't replace - The Buckhorn from Cali - Animal Memorial from Snowest, etc.)
But the powder coated stuff looks as good today as it did when I got it home.
Awesome stuff. And Cool Concepts charges me less than what it cost to paint the stuff....so it is win/win for everybody.
I got the tunnel connected to the bulkhead, and they are perfectly in line with one another. I am going to wait until I get the cooler back before I finish putting the rest of the rivets in place.
I have it lined up so they match and are parallel from the sides, but I want to have the cooler in place and clamped down before I square up the side to side.
I also have to wait for the other side running board support. That support has the mount for the front arm of the rear suspension so I want to get those drilled out and in place before I rivet them into place.
Here is the bulkhead and tunnel as one.....as it should be:
http://img215.imageshack.us/img215/3483/tunnelin1.jpg
http://img535.imageshack.us/img535/97/tunnelin2.jpg
http://img651.imageshack.us/img651/432/tunnelin3.jpg
http://img387.imageshack.us/img387/4434/tunnelin4.jpg
I also got ahold of bigwormskidoo05. He is going to do the oil pump modification to both my sleds. I just have to get the trail sled one off to get to him. Don't know if that will happen today, but it may still. It is only 1pm, so I may be able to get off today. We'll see.
Here is the fix for the oil pump I was talking about. This is the fix that bigwormskidoo05 came up with. It is a permanent solution to the issue. This will fix the issue without spending $225 on a new pump.
bigwormskidoo05 does this fix for $75 shipped back to you.
Here is the shaft that goes into the pump notice the top one that is how it come and bottom is the machined one with bearing.
http://img532.imageshack.us/img532/2855/oilpumpfix1.png
Here is the bore machined bigger for the bearing and bearing installed
http://img532.imageshack.us/img532/2075/oilpumpfix2.png
http://img202.imageshack.us/img202/7646/oilpumpfix3.png
Here is the shaft installed.
http://img535.imageshack.us/img535/8231/oilpumpfix4.png
http://img26.imageshack.us/img26/4529/oilpumpfix5.png
http://img96.imageshack.us/img96/8171/oilpumpfix6.png
The action of the lever is way smoother i believe this will eliminate the sticking problem
Ford428CJ
03-14-10, 04:37 PM
Quick Q for ya! Are you using solid aluminum rivets??? And if you are using blind rivets, what type? Cherry Max or Q-Rivets (Aluminum or Stainless)? Just hoping that you would help a brother out. Thanks...
Quick Q for ya! Are you using solid aluminum rivets??? And if you are using blind rivets, what type? Cherry Max or Q-Rivets (Aluminum or Stainless)? Just hoping that you would help a brother out. Thanks...
They are steel rivets. They are solid rivets.
I don't know who makes them. I get them from Fabcraft. They solid, 3/16" x 3/8" & 1/2" lengths.
I use a tool fitted to the rivets and a body block on the back side to set them.
You can get them directly from Fabcraft. They $6 for 100 of them.
I just got home from picking up the second round of powder coating from Rick at Cool Concepts. He does killer work:
http://img219.imageshack.us/img219/5430/coolconcepts1.jpg
http://img716.imageshack.us/img716/8260/coolconcepts2.jpg
http://img411.imageshack.us/img411/237/coolconcepts3.jpg
http://img8.imageshack.us/img8/5647/coolconcepts4.jpg
Anything that is a high wear area I have coated in Micro Tech. It is a really tight-pattern wrinkle finish. It holds up VERY well even on the high side of foot edges. I am not sure how well it will show in the picture:
http://img381.imageshack.us/img381/5889/coolconcepts5.jpg
Here is what the rest of the sled will be coated in. A matte black. The tunnel and bulkhead will also be coated in this finish:
http://img18.imageshack.us/img18/7415/coolconcepts6.jpg
I dropped off another round tonight. After this, I just have the exhaust and HPS can to do. It too, will be done in a matte black finish.
I got some more powder coating back today:
http://img202.imageshack.us/img202/6567/coolconcepts7.jpg
http://img263.imageshack.us/img263/9680/coolconcepts8.jpg
http://img263.imageshack.us/img263/5352/coolconcepts9.jpg
Ford428CJ
03-20-10, 05:21 AM
That looks good! Thanks for the info on powder coating material.
I had to work today, but when I got home Terry from Snow Eliminators had my boards here.
I got the boards tweeked to fit around the flares.
The area just in front of the boards is going to get the flares like my other mountain sled. I will 3 or 4 holes and then flare those.
After all of it was marked off, I cut out the board openings with my DeWalt jigsaw w/metal cutting blade, and clamped it all back in place.
Here is what I got done today:
http://img687.imageshack.us/img687/6664/se1l.jpg
http://img260.imageshack.us/img260/7044/se2lo.jpg
[img]http://img146.imageshack.us/img146/9682/se4n.jpg
http://img441.imageshack.us/img441/2143/se5r.jpg
Liberty Anodizing called yesterday, and they have the cooler anodized black for me. I should have that here on Tuesday.
Once that is here, I may take a day off work and put the whole together so I can get the tunnel to the powder coater.
Maize, Keep posting as you progress... I'm one off the others who is watching your project!!!
Nice work.
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Things are moving.
Brian about has my billet stuff done up.
I got the cooler back from anodizing today. It turned out better than I expected:
http://img641.imageshack.us/img641/6384/cooler1.jpg
http://img710.imageshack.us/img710/6753/cooler2.jpg
I took tomorrow off, so I am hoping to get the tunnel finished up so I can get it to powder coating.
Well, Spawn drew first blood today. LOL
I cut myself good on the edge of the running board. I was drilling rivet holes, when it cut through on a low rivet and my knuckle got caught between the running board and the drill.
I couldn't get it to stop bleeding. I kept dripping blood all over the tunnel. Carb cleaner didn't even get it to stop.
So I had to shut down early today.
http://img641.imageshack.us/img641/503/spawnwound.jpg
I didn't get to work on the sled yesterday. One of my buddies had his batchelor party. We spent the day shooting skeet (I would say well over 2000 shells and over 5 boxes of clay pidgeons), then we 4X4'ing, a couple of guys got stuck (we hadto get the skid loader for one guy who went over a log and we had to lift him off the log), then we back to the shop and had a tractor pull (my buddie is big into it so he made a mini pulling-sled and we used pedal tractors. I played a few games of Eucher (sp?) and came home. I left home at 9a and got home about 10:30p. I am sure the rest of the guys went until daylight.
I had to work on the sled today, though.
So....here is what I got done. I got all the chassis bracing in, the front arm supports, the pyramidal supports, the seat hold downs, the rear arm, drop brackets, the tip-up supports, the tail section and the cooler fitted up.
The only thing left is to grind off some rivets under the PTO side support, and finish putting the field rivets in place and it is off to the powder coater.
http://img401.imageshack.us/img401/3442/td1h.jpg
http://img401.imageshack.us/img401/8829/td2.jpg
http://img401.imageshack.us/img401/9493/td3.jpg
http://img401.imageshack.us/img401/8210/td4.jpg
I put the VanAmburg edges in place, and the custom Snow Eliminators in place for their final fitting.
http://img180.imageshack.us/img180/1471/td5.jpg
http://img401.imageshack.us/img401/1197/td6.jpg
http://img691.imageshack.us/img691/5348/td7q.jpg
Here is custom made cooler for its final test fit. Everything is coming together nicely.
http://img180.imageshack.us/img180/9773/td8.jpg
I got all the rivets in the field today after work. All the rivets are done, the tabs are put in place for the wiring, the foots got the flared holes and it is ready for powder coating.
I will call the powder coater tomorrow to see when he can get me in. Advanced Coatings has to do this one as Cool Concepts oven is too short by about 1ft.
http://img695.imageshack.us/img695/6323/pc1y.jpg
http://img694.imageshack.us/img694/3401/pc2xq.jpg
http://img337.imageshack.us/img337/1668/pc3.jpg
http://img340.imageshack.us/img340/3170/pc4n.jpg
http://img340.imageshack.us/img340/1970/pc6m.jpg
http://img694.imageshack.us/img694/5329/pc7r.jpg
Here are the flared holes for the footwells.
http://img695.imageshack.us/img695/2108/pc5e.jpg
I just got a goodie-box from Brian at Tricked Toys. The stuff looks absolutely SIC!!!!!
I will get pictures of all the stuff tonight when I get home after golf.
Totally SIC!!! Brian....TOTALLY off the HOOK!!!
I couldn't wait to get home from golf tonight. It was like X-Mas in March!
Brian (from Tricked Toys) did a killer job with all this stuff.
Here is what I got. I got 2 - 9" rear wheels, 4 idler wheels, choke lever, gas cap, brake lever and reservoir cover and I also got the spring adjusters.
I may opt for getting two more idlers, but may not. I am not sure how they will. I will how they line up with the track. I may just leave the stock black in place.
Here is all the stuff unpacked:
http://img94.imageshack.us/img94/7655/tt1u.jpg
http://img98.imageshack.us/img98/7624/tt2a.jpg
http://img714.imageshack.us/img714/8688/tt3x.jpg
http://img268.imageshack.us/img268/7505/tt4k.jpg
http://img51.imageshack.us/img51/7418/tt5n.jpg
http://img32.imageshack.us/img32/4679/tt6f.jpg
http://img706.imageshack.us/img706/3281/tt7h.jpg
[/quote]
Here is the skid (just about finished). I have to tighten some bolts, and rebuild the shocks. I think I am going to add a FOX Podium to the fronts and center.
I just became dealer for FOX shocks, and I am going to have Kelsey from RK Tech make me some low compression domes so I can ride it in Iowa if I want.
Anyway....here is what the Tricked Toys rear skid looks like. It has Cool Concepts power coating, Tricked Toys wheels and spring adjusters, RCI titanium springs, BC3 spacers and A-MAIZE-ING KUSTOMS shock work. It sure is purdy....LOL
http://img359.imageshack.us/img359/563/ttskid1.jpg
http://img140.imageshack.us/img140/3877/ttskid2.jpg
http://img31.imageshack.us/img31/6632/ttskid3.jpg
http://img229.imageshack.us/img229/3928/ttskid4.jpg
http://img696.imageshack.us/img696/7179/ttskid5.jpg
http://img249.imageshack.us/img249/6594/ttskid6.jpg
http://img638.imageshack.us/img638/6407/ttskid7.jpg
http://img12.imageshack.us/img12/1600/ttskid8.jpg
http://img716.imageshack.us/img716/2492/ttskid9.jpg
http://img340.imageshack.us/img340/7744/ttskid10.jpg
You're not gonna want to ride that thing when it's done maize... :D
You're not gonna want to ride that thing when it's done maize... :D
Oh, yes I will. That is why all the powder coating. It takes a beating, scratching, pounding and still looks like new.
I built my last custom sled 5 years ago. The hood has some battle scars, but the rest of the sled looks just as good today as it did when I built it.
I am going to skip the airbrushing on this sled, and just get Casey's (from HP Wraps) sled wrap and paint the hood and console a flat black to match the side panels.
I'll post some pictures of my last personal montain sled when I get home tonight.
OK. For eveyone that thinks my sleds are trailer queens. Here are some of my past personal sleds.
The Sickness and Madness sleds were in the videos from Jeff Aiello called Elevation. I was in Season II and III with them.
Here is the last mountain sled I built 5 years this summer. It has a custom VIN and is registered as an 05 Summit. This sled has been to Toqwotee at least 4 times, Laramie at least 20 times, Iron Mountain outside of Fresno, LoLo, Priest Lake, Buena Vista, the Collegiate Mountain Range, Steamboat and ditch banged in Iowa many times.
Here are the battle scars on the hood:
http://img263.imageshack.us/img263/3085/5yr2.jpg
http://img237.imageshack.us/img237/2575/5yr3.jpg
I would get another windsheild, but then I would lose my Buckhorn (from the Fresno ride)and Animal decals. So I used clear duct tape and put it back together.
http://img9.imageshack.us/img9/7030/5yr4.jpg
I never ride in the mountains with my High Jacker or my Bungie Cord.
http://img101.imageshack.us/img101/9336/5yr5.jpg
http://img693.imageshack.us/img693/5525/5yr6.jpg
http://img709.imageshack.us/img709/4513/5yr7.jpg
Here is the whole sled:
http://img265.imageshack.us/img265/8548/5yr8.jpg
Here is the engine bay. After every season I metiulously clean each sled before they are stored.
At the beginning of each season, the carbs are gone through and the clutches cleaned and gone through. Any marginal parts are replaced before the season begins.
I start right after Hay Days and when the Jet Boat is put away. Which is another story that I rebuilt.
http://img266.imageshack.us/img266/2531/5yr9.jpg
http://img215.imageshack.us/img215/5108/5yr10.jpg
http://img413.imageshack.us/img413/3310/5yr11.jpg
If anyone is interested in the complete build. It can be seen at my website. Here is the direct link to that build:
http://www.maizekustoms.com/pages/madness-build.php
Here are some more of my builds:
This was my old trail sled, and the first airbrushing I did on my snowmobile. I have done many since, but the first is always kind of special: LOL
http://img188.imageshack.us/img188/7265/asickness1.jpg
http://img535.imageshack.us/img535/557/asickness2.jpg
http://img253.imageshack.us/img253/8743/asickness3.jpg
If you are interested in the build of that sled, it can been seen on my website @ http://www.maizekustoms.com/pages/sickness-build.php
Here is my current trail sled.
Here is what it started life as when I brought it home:
http://img260.imageshack.us/img260/5143/ablade1.jpg
Here is what it looks like now (BTW...it has over 7,000 miles on it):
http://img41.imageshack.us/img41/8598/ablade2.jpg
You can also see the complete build on my website @ http://www.maizekustoms.com/pages/blade-build.php
Here is the Jet Boat I was referring to above:
Here is what the engine bay looked like when I brought it home. The rest of the boat matched this condition:
http://img12.imageshack.us/img12/1565/speedster1.jpg
Here is the shot of the same engine bay after both motors have been rebuilt, both jet drives rebuilt, the seat completely done up, a stereo added and all the lights changed over to LED's.
http://img215.imageshack.us/img215/3371/speedster3.jpg
http://img715.imageshack.us/img715/7594/speedster4.jpg
http://img338.imageshack.us/img338/8360/speedster5.jpg
http://img405.imageshack.us/img405/7905/speedster6.jpg
The build of this boat can also be viewed on my website @ http://www.maizekustoms.com/pages/sea-doo-speedster-build.php
There are more builds from sleds to stroker Jeep motors on my site at www.maizekustoms.com
Outstanding.
keep em coming...http://i16.photobucket.com/albums/b7/JohnnyCharger1968/Emoticons/popcrn.gif
Well. I got the tunnel/bulkhead back this morning. It really isn't a flat black like I wanted, but it is a semi-gloss. It may make the blue stand out even more than the flat black.
I ordered the satin-black automotive paint for the hood and console today, too.
Here is the tunnel when I brought it home and test fit all the parts back on it:
http://img25.imageshack.us/img25/6347/powdercoat1.jpg
http://img194.imageshack.us/img194/9318/powdercoat2.jpg
http://img200.imageshack.us/img200/8004/powdercoat3.jpg
http://img232.imageshack.us/img232/6794/powdercoat4.jpg
http://img179.imageshack.us/img179/8701/powdercoat5.jpg
http://img200.imageshack.us/img200/2739/powdercoat6.jpg
http://img709.imageshack.us/img709/3326/powdercoat7.jpg
http://img522.imageshack.us/img522/8227/powdercoat8.jpg
I also took another load of stuff out to Cool Concepts. The Y-Pipe, expansion chamber and HPS can, a few more brackets, the Snow Eliminators and the nitrous bottle to be coated. This should be the final load.
All said and done, powder coating ran me about $600 for everything. It looks good and will stay that way for a very long time.
I got two more of Matt Santwire's braces in place. I still have the side bolts to put on top of each side, but the front plate is on. The side braces are lined up but I still need to buy the stainless bolts to put them in place.
Here they are lined up and in place:
http://img14.imageshack.us/img14/1008/powdercoat9.jpg
http://img196.imageshack.us/img196/9004/powdercoat10.jpg
http://img132.imageshack.us/img132/8653/powdercoat11.jpg
"Holy powder coat batman..."
Ford428CJ
04-04-10, 05:34 AM
What a work of art!!! I would hate to see how much time you have in this sled, besides the money! LOL. Very nice! I hope that mine comes out 1/2 as nice as yours LOL.
What a work of art!!! I would hate to see how much time you have in this sled, besides the money! LOL. Very nice! I hope that mine comes out 1/2 as nice as yours LOL.
Well, the time is just time. If I wasn't working on this project, it would be something else.
I find it relaxing (at least when things go the way they are supposed to - LOL) working on this stuff.
My shock business was very good this winter. The shock business completely paid for everything on the sled - between that and my business partner's help - it is all coming together for a lot less than you would think.
I am thinking of having some pictures with models (from the local Gentleman's Club) taken with a professional photographer once they are done. I will have to see how expensive that will be. But I may have them made into poster's for sale on my website. They would be similar to Double X-Treme calendars.
Got quite a bit done today. Had to go to the inlaws for Easter Dinner. After that I got to work on the sled.
I got the front cooler put in place:
http://img63.imageshack.us/img63/2376/together1.jpg
http://img176.imageshack.us/img176/6792/together2.jpg
I also got all of Matt's bracing put in place, including the new prototype upper pyramid bracing:
http://img688.imageshack.us/img688/2677/together3.jpg
http://img717.imageshack.us/img717/7840/together4.jpg
http://img121.imageshack.us/img121/7162/together5.jpg
http://img203.imageshack.us/img203/3435/together6.jpg
http://img249.imageshack.us/img249/8867/together7.jpg
I also go the right side foot well done. I am just waiting for the Snow Eliminators to get back from powder coating. That should be later this week.
http://img340.imageshack.us/img340/4705/together8.jpg
http://img340.imageshack.us/img340/4705/together8.jpg
I did some finish work on Matt's bracing, and filled in the field tonight.
http://img256.imageshack.us/img256/8646/matts1.jpg
I also put in the stainless bolts to hold the tower braces in place.
http://img255.imageshack.us/img255/8059/matts2.jpg
http://img535.imageshack.us/img535/6049/matts3.jpg
I got the left side footwell completely done up:
http://img512.imageshack.us/img512/6169/left1q.jpg
http://img196.imageshack.us/img196/1905/left2u.jpg
http://img691.imageshack.us/img691/467/left3.jpg
http://img143.imageshack.us/img143/551/left4.jpg
Here is the right side finished up with the hold downs riveted in place.
http://img697.imageshack.us/img697/5072/right1.jpg
Now, I am just waiting on my Snow Eliminators to come back from powder coating. Once they are back, then I can rivet them in place and put the Van Amburn edges on permanently.
I have 3 pieces left to be powder coated. I have to modify the belt guard yet. And a couple of little pieces. Then the big stuff starts going on.
I ordered the new bearings, gears, chain and seals for the chain case.
Here are some more shots of the powder coating I got back today:
http://img21.imageshack.us/img21/4722/final1zh.jpg
Here is the Rick did with matte black ceramic coat:
http://img709.imageshack.us/img709/856/final2ju.jpg
http://img684.imageshack.us/img684/8088/final3a.jpg
I also got the seals for the chain case. I am hoping to get the axle and track in this weekend. But, Sunday I am playing golf, and I have to work tomorrow.
I have to stop by Custom Hose and pick up the fittings for my shocks. I am going to add remote ressies to the front and center. I am getting low compression domes from Kelsey so I can run it here in Iowa. With the ressies, I can put them over to trail, or mountain settings.
I am also going to install the sway bar with a delete kit to help with ditch banging.
I had to work this morning, and move my mom back home for the summer. She stays in the winter with us as she lives alone and is 75 years old. So we have a room for her at the house.
Anyway. I got home about 4pm and put the chaincase, axle, track, jackshaft, brake rotor, brake caliper, speed sensor and greased the left side bearing.
I still need to figure out the gearing, but I think it should be around a 19/43. I haven't put the pencil to the paper on that yet.
http://img163.imageshack.us/img163/5020/10april1.jpg
http://img43.imageshack.us/img43/8724/10april2.jpg
The clearance looks a little tight, but it is about a 1/4". It is dropping straight down, but when pulled back is more distance away from the cooler.
http://img710.imageshack.us/img710/88/10april3.jpg
http://img130.imageshack.us/img130/309/10april4.jpg
http://img301.imageshack.us/img301/3871/10april6.jpg
I also got the Snow Eliminators test fitted and ready to rivet in place. I also put the body panels in place Gleco'd them in place to make sure everything fit. Tomorrow I have to make the bracket to hold the nitrous bottle in place. Once that is done, I can start hanging panels on for good.
http://img40.imageshack.us/img40/5403/10april5.jpg
http://img149.imageshack.us/img149/4900/10april7.jpg
http://img406.imageshack.us/img406/5997/10april8.jpg
http://img217.imageshack.us/img217/5118/10april9.jpg
I put the rear rack in place, some people don't like them. I like them. They are good source to store things for survival gear.
http://img576.imageshack.us/img576/6752/10april10.jpg
http://img714.imageshack.us/img714/2673/10april11.jpg
http://img21.imageshack.us/img21/9652/10april12.jpg
I did some work today on the sled. Nothing really ground shaking, but some things are getting done. I went after work tonight to Custom Hose and had the hose made for my remote ressie on the center shock.
Here is the test fitted center shock. I haven't decided yet, but I think I am going to go with a different shock fitting. The banjo bolt ground down may give about 1/2" more clearance.
Here are the shots of the 90 elbow. Once I get it compete, I will post a finished shot:
http://img687.imageshack.us/img687/8365/13april1q.jpg
http://img46.imageshack.us/img46/2827/13april2.jpg
I also got a big box from BRP today. It had a bunch of bushings I needed, me skid adjuster, my skis, my riser, by wind deflectors, my gas tank mount and my handlebar wiring harness.
Here is the skid adjuster installed on the new skid. I lost another chunk of skin. This sled wants blood.....LOL!!
http://img7.imageshack.us/img7/2963/13april3.jpg
http://img90.imageshack.us/img90/3774/13april4.jpg
http://img90.imageshack.us/img90/3774/13april4.jpg
I know this is kind of menial, but it did get done tonight. Spawn got its eyes tonight.
http://img24.imageshack.us/img24/1328/13april7.jpg
http://img193.imageshack.us/img193/6408/13april8.jpg
Here is the new Sea-Doo riser. Tomorrow night I will be modifying the steering post to accept it.
http://img641.imageshack.us/img641/1046/13april9.jpg
http://img412.imageshack.us/img412/5557/13april10.jpg
Eyes eh???
Click here (http://www.entertonement.com/clips/pdqfzsdhsv--It%27s-Alive) while viewing picture below!
ROFL, Pete you crack me up!
Appropriate, though!
I'll save that snip it for when the engine fires up.
When the engine is ready to fire up, Rob Zombie Dragula will be playing. That is the song that has been playing when all my creations of late have come to life. LOL
I had to work until 7p today, so I couldn't get a ton of work done.
I went to Custom Hose this morning to have the ski shock hoses made up.
I got the shocks all mocked up tonight. Here are the fronts ready to be rebuilt:
http://img441.imageshack.us/img441/3181/14april1.jpg
I wasn't going to put ressies on the front or center, but then decided that I wanted to be able to ditch bang it here. I want to be able to set them for riding here and in the mountains, so I added them.
Here is the new center shock mocked up with a banjo bolt instead of an elbow. I ground the head down to about half its size to give more clearance:
http://img15.imageshack.us/img15/6053/14april4.jpg
I also got the 440X steering post ground down to fit the Sea Doo riser:
http://img94.imageshack.us/img94/2330/14april2.jpg
http://img208.imageshack.us/img208/5480/14april3.jpg
I got a bunch of stuff done today. I got the wiring harness in place, the rear heat exchanger hoses, the gas tank, tank braces, oil tank, coolant reservoir tank, voltage regulator, electric start harness, steering braces, steering boots, exhaust stoppers and the belt guard put in place.
I took the side off of it for better cooling. I then cut the sides of the cover down to make it look like it is supposed to be that way.
http://img709.imageshack.us/img709/9770/17april1.jpg
http://img580.imageshack.us/img580/6937/17april2.jpg
http://img404.imageshack.us/img404/6807/17april3.jpg
http://img580.imageshack.us/img580/9154/17april4.jpg
http://img255.imageshack.us/img255/3294/17april5.jpg
http://img52.imageshack.us/img52/5323/17april6.jpg
http://img515.imageshack.us/img515/4215/17april7.jpg
http://img535.imageshack.us/img535/345/17april8.jpg
http://img9.imageshack.us/img9/1397/17april9.jpg
Tomorrow it is going to be putting the front plastic on, the rear skid in the sled, the Snow Eliminators riveted in place, the Van Amburg edges bolted in place the rear bumper and rack put in place.
More pictures tomorrow...
Well...another day of working in the guy-rage (as the wife call's it).
I got the Snow Eliminators and the VanAmburg edges on. I got the cooler riveted in place and the center piece in place. I got the rear bumper and rack put in place.
I didn't get the front body panels on as I had to change the oil and rotate the tires on the Tacoma and remove and install a new golf shaft in a buddies 9 iron. So that took some time away from the project.
When I put the adjusters on the inside, the bolts that hold the adjuster hit the bolts that hold the extension in place. I had to make a spacer plate to give clearance. That was another hour killed.
I also got the rear suspension under her, but it needs a little finese to get bolted in place. I had to cut up boxes from supplies and parts that came in this week. That took over an hour. By the time that was all done up, I decided to call it quits for the day...
This is what I got done today:
http://img101.imageshack.us/img101/7617/18april1.jpg
http://img200.imageshack.us/img200/9094/18april2.jpg
http://img411.imageshack.us/img411/331/18april3.jpg
http://img192.imageshack.us/img192/3326/18april4.jpg
http://img52.imageshack.us/img52/1774/18april5.jpg
http://img194.imageshack.us/img194/127/18april6.jpg
http://img208.imageshack.us/img208/5141/18april7.jpg
http://img339.imageshack.us/img339/2550/18april8.jpg
http://img9.imageshack.us/img9/8997/18april9.jpg
Ok...don't know where the measurements went wrong, but apparently the XP skid is mounted in a different location.
According to regular calculations, a 2" rail extension should have been fine. With the 154" skid and a 163" track, that left a 9", subtract 2" for the 9" wheels, that leaves 7" and divide that in half should be 3.5". I set the skid back 1.5" from the stock location, so that leaves 2"
Well....not! It is still 70mm (2.75") short. So I contacted Wild Child to get a new set made ASAP.
The angle of the skid must also be different, as I think I have to lower from front A-Arm mounts. I just have to wait and see after I get the front suspension on tomorrow.
Anyway, the wife put the rear skid in the sled tonight. LOL. Here is a shot of here putting in the front A-Arm bolts. LOL I love a woman who can turn wrenches....
http://img24.imageshack.us/img24/4453/20april1.jpg
Here are some shots of the rear skid in the sled.
http://img255.imageshack.us/img255/558/20april2.jpg
http://img101.imageshack.us/img101/9950/20april0.jpg
I also got the steering post and Sea Doo riser back from Cool Concepts. Here you can see the extra bracing from the race sleds that I put in place. I still have to put in the bolt on the left side.
http://img706.imageshack.us/img706/510/20april3.jpg
http://img651.imageshack.us/img651/2990/20april4.jpg
You can see that it is a total of 10" of riser from the console. That is just perfect for me.
http://img62.imageshack.us/img62/8494/20april5.jpg
http://img691.imageshack.us/img691/6518/20april6.jpg
As stated in earlier posts, I took today off work and worked on the sled. I got a bunch of stuff done on the front end today.
I got ahold of Wild Child for the new rail extensions. I got the front end on the sled and all the panels riveted in place.
I took all the foam off the under side of the panels and used adhesive remover to get all the guey stuff off. I removed all decals and residual stuff. I cleaned all the panels and cut the holes for the remote ressies. The right side I had to angle down a little more to make enough clearance for the nitrous bottle.
I also put the reflective sheeting on the exhaust side of the panels. It was a bunch of little things that just took time. I got it all done up today though.
I also got both front shocks done up today. I used a set of Adrenaline shocks for the mock-up as I didn't have to mess with the ressie flopping around. I just have to put the nuts on the A-Arm bolts and they are complete. I had to file down the West Coast Sleds bushings to get them to fit the spindal with the powder coating.
I am on track to drop the motor in the sled for the weekend.
http://img694.imageshack.us/img694/9827/21april1.jpg
http://img406.imageshack.us/img406/5986/21april2.jpg
http://img18.imageshack.us/img18/4614/21april3.jpg
http://img156.imageshack.us/img156/5366/21april4.jpg
http://img9.imageshack.us/img9/6779/21april5.jpg
Here is getting the hose fit to the body panels to get the holes in the correct location. Then in place then with the side panel on it.
http://img638.imageshack.us/img638/3623/21april6.jpg
http://img532.imageshack.us/img532/3449/21april7.jpg
http://img227.imageshack.us/img227/2575/21april8.jpg
Here are some shots with the panels on
http://img94.imageshack.us/img94/9940/21april9.jpg
http://img227.imageshack.us/img227/3118/21april10.jpg
Here are some shots of the whole thing with the panels in place and the front suspension on the sled with the new Pilot 6.9's. I am going to try these skis to see how they work. They are brand new and cheaper than Powder Pros. If they don't work out, I can always get the Powder Pros.
http://img96.imageshack.us/img96/5269/21april11.jpg
Here is a shot of the sled set at the proper ride height. I will have a settle-in of about an inch.
http://img341.imageshack.us/img341/9180/21april12.jpg
Here is the shock installed and ready to go.
http://img179.imageshack.us/img179/7153/21april13.jpg
Well, I got the engine dropped in the chassis today.
It dropped right in place, no issues. I also got all the coolant lines & hoses hooked up. I also got all the electrical harnesses put in place, and the starter on it.
Tomorrow I have to stop by Menard's and pick up some stainless bolts for the Boyesen's. I still need to go through both carbs and rebuild them and make sure they jetted properly.
I spoke with Big John today to see what the starting point should be for jetting. Big John is awesome. Taking customer on a Saturday is above and beyond.
http://img16.imageshack.us/img16/3518/24april1.jpg
http://img232.imageshack.us/img232/2483/24april2.jpg
http://img180.imageshack.us/img180/8426/24april3.jpg
I got the oil pump hooked up (what a PIA THAT was!). I got the fuel lines on, the oil hoses connected, the Boyesens on and the carbs rejetted and the correct needles put in. I also rebuilt both carbs and synched them. I also made sure the air box fit and that I had the room put the Boss Noss controller between the gas tank and the air box.
This is also the improved flow airbox from the 07 SummitR.
http://img691.imageshack.us/img691/7841/27april5.jpg
http://img11.imageshack.us/img11/9397/27april75.jpg
http://img63.imageshack.us/img63/7671/27april1.jpg
http://img689.imageshack.us/img689/231/27april2.jpg
I also got the controls put on, the handle bar wiring done, the new brake switch put in, the handwarmers on, the J-Hooks in place, the master cylinder put in and the billet stuff from Brian at Tricked Toys installed.
http://img517.imageshack.us/img517/2944/27april6.jpg
http://img219.imageshack.us/img219/8251/27april7.jpg
http://img200.imageshack.us/img200/2532/27april4.jpg
I am still waiting on some parts. I am off work tomorrow, I will doing some polishing tomorrow and getting the exhaust finished up. I need to take the y-pipe off my other mountain sled (it the EGT bungs welded in) and change it out with this one.
The rest of the day I need to regroup in the garage. Now that things are getting hung on the sled, I need to clean.
I ran into a setback yesterday.
The steering riser harness won't work with the 03 harness I have. The kill switch won't work. I did some wire tracing and one side of the ground goes to an open spot on the main harness connection.
I don't if just wiring in a spot to ground will work. I am going to tray that today.
I also hooked up the used tach to my 04 trail sled and the tach won't move. The high beam light comes on when you use the switch, but the brake light will not come on either.
Does anyone know if you have do anything different to get the SummitX style tach/speedo to work, or is this unit just toast?
OK. I figured out the Tach. Had to switch a pin around to get it to work properly.
Unfortunately, I also got the kill switch to work by tying it into another ground wire. However, the 03 harness is missing some of the wires to make it work with the newer Tach/Speedo.
I ordered a new wiring harness so I will have to wait until that comes in to fire it up.
I got a big SkiDoo order in today.
I put the new brake line on (the other was too short), I put the brake pads in, put the gears and chain in (21 top 45 bottom w/74 link chain), put the hand guards on, put the mountain strap on, the chaincase cover went on and the battery tray went in place.
The handle bars are now finished.
I got the new extensions from Wild Child today. I test fit those and tightened the track. They are prefect length, now. I then dropped them off at Cool Concepts to be powder coated.
I got everything squared away with Joey last night. The new kit was sent today so I can put the other roller clutch on my old mountain sled.
Yesterday I got the RPM Composites one-off stuff. I will get some pictures of that tomrrow.
I also got everything to set up my primary clutch. I got a used Thunder Shift kit with oversized rollers to used on this one.
Here are some shots of tonights progress. I am hoping the harness is here tomorrow.
http://img59.imageshack.us/img59/1581/4may1.jpg
http://img29.imageshack.us/img29/5449/4may2.jpg
http://img683.imageshack.us/img683/7981/4may3.jpg
http://img693.imageshack.us/img693/7937/4may4.jpg
http://img710.imageshack.us/img710/5047/4may5.jpg
Looking like it'll be "alive" soon!!!!
CrescentLake
05-05-10, 06:12 AM
Great job of posting pictures and write up. Can't wait to see the finished built.
Not many pictures from the weekend as everything looks pretty much the same.
I had to tear the plastic back off the sled, the gas tank, the seat and rear seat cover off.
I got the old wiring harness out, and the new harness put in place.
I also got the primary clutch set up with the new 415 ramps, a new primary spring and the Thundershift arms set up were I want to start with them.
Joey's new helix should be here this week so I can get that set up. I have new internal parts on that, too. I did tear down all the rollers and cleaned them all up.
I just need to drop the swing down a bit, get the Y-Pipe off the old sled and get it added to the new sled and add the exhaust.
Next is just put gas and oil in her and she will be ready to fire up.
I am also going to change the top gear per Big John's suggestion.
OK....I ordered the last of the stuff I need to finish the sled. Some gaskets for the exhaust, the quick clickers, and floating secondary but and the sway bar disconnect.
I picked up the WildChild extenstions from Cool Concepts tonight, and dropped the rear suspension to relocate the front arm down about an 1".
I also got some shots of the stuff Raffi (from RPM Composites) whipped up for me. Thursday those will get put on. I had weddings over the weekend, and Mother's Day so not much got done over the weekend.
Here are some quick shots of the stuff.
This should give pretty good coverage for "float" on the front end.
http://img683.imageshack.us/img683/2021/11may1.jpg
http://img205.imageshack.us/img205/946/11may2.jpg
http://img693.imageshack.us/img693/4463/11may3.jpg
I got the new 19 too0th top gear in the mail today, so that will be changed out.
I got the new holes drilled for the front arm. The skid is back under it. WildChild's rail extensions are in, and the track tension set.
The skid sits perfectly now. The back tips up like it is supposed to, and the front of the skid is level.
Tomorrow I can pick up DJ's helix. It should be finished up this weekend. Just waiting on the wrap from Casey and the windshield. They sent the yellow one instead of the smoke one I wanted.
http://img30.imageshack.us/img30/1940/13may10.jpg
http://img21.imageshack.us/img21/599/13may11.jpg
http://img21.imageshack.us/img21/2544/13may12.jpg
I got Raffi's Kevlar/Carbon Fibre skid plates on tonight. Tomorrow, I will put the A-Arm protectors on.
I also got the snowflap on.
I Dynamo Joe's new helix in the mail and got the secondary done up.
I will be getting the rear rack and bumper permanantly mounted, along with the rear wiring and wire cover plates on.
I need to switch out y-pipes with my old sled as it has the EGT's in it. I thought I might fire it up this weekend, but I don't have the Y-Pipe bolts, Nordlocks or either of the donut gaskets. So I will have to wait until next weekend when my order comes in.
I need to order new fuel jets for the Boss Noss. So I can get that all plumbed in. I think I will wait to get the engine running then install the Boss Noss and Digitron on the same weekend.
I will have more shots (with better lighting), and some good shots of RPM Composites stuff. When I have the A-Arm protectors on, I will get it up in the air for complete shots.
http://img171.imageshack.us/img171/6587/14may1.jpg
With Raffi's skid plates, and Matt Santwire's bracing, it makes a VERY rugged chassis. I lawn darted my trail sled with this same setup, and just sheered off some skid plate bolts. Without them, I would have been replacing a NUN.
Here are some complete shots of the sled with better lighting.
http://img101.imageshack.us/img101/3980/14may3.jpg
http://img514.imageshack.us/img514/756/14may2.jpg
Here is a better shot of the rear skid with lighting:
http://img97.imageshack.us/img97/2285/14may4.jpg
She-La and I went to Perkins for breakfast, I watched TV for a bit, played with Olivia for about an hour, hit some shag balls and then worked on the sled.
I did a bunch of odds and ends today that needed to be finished up.
I got the rest of Raffi's stuff from RPM Composites put on. I had to modify them some to fit the West Coast Sleds arms. But they came out just fine.
http://img27.imageshack.us/img27/8595/15may2.jpg
http://img88.imageshack.us/img88/3323/15may3.jpg
http://img33.imageshack.us/img33/8549/15may4.jpg
That should give the REV the extra "float" it needs from losing the bellypan.
I also got the bumper, rack and wiring loom finished up. I also got the rear of the VanAmburg edges bolted into place.
http://img249.imageshack.us/img249/6298/15may6.jpg
http://img30.imageshack.us/img30/3458/15may7.jpg
http://img85.imageshack.us/img85/6557/15may8.jpg
Tomorrow, I am going to get the gearing changed out from the 21 top tooth, to the 19 tooth and then make up the nitrous bracket to hold the bottle.
Thanks guys.
Hey Lund. I don't know if I will get any riding on this one, this year. But I think I am heading to The Snowies next weekend, or the following.
I would love maybe schedule something for next season, though.
Anyway....I got the last of the fabrication done today. I made the bracket to hold the nitrous bottle.
I did manage to get a large bucket of golf balls in, wash the Tacoma and play with Olivia for an hour, or so again. She then came in the garage to help.
I got it all torn back down and will drop it off to the powder coater tomorrow.
I routed the nitrous line from the bottle the controller. While looking closely over the jets and where I was going to mount them, I found someone had drilled a very tiny hole in the one fuel jet. It is a smaller size than the jet size, but it is all the say through.
I will put a tack weld over it and it would be fine. Interesting though as to why someone would do that...I HOPE nothing malicious.
http://img704.imageshack.us/img704/2907/16may1.jpg
http://img692.imageshack.us/img692/1520/16may2.jpg
Here is the bottle mounted with the HPS can also in place.
http://img405.imageshack.us/img405/431/16may3.jpg
This the plan is to get the nitrous all hooked up, the jets plumbed and the controller mounted.
The last of the stuff I ordered should also be here this week. The windshield, the exhaust gastets, Nordlocks and some other stuff. If it is, I am hoping to have this fired up next weekend
Ford428CJ
05-17-10, 09:13 AM
That thing is a work of art!!!! Luv it!!!:D
I am going a different direction on the sled wrap.
I am going to be working with Jordan from ArcticFX on a new wrap.
This wrap is going to really pop. Even though I designed the orginal, which was great for my trail sled. I just didn't want it looking the same sitting next to it.
So Jordan is fixing me up properly. We are taking one of his designs and tweaking it somewhat to be custom on my sled.
Here is the base design:
http://img195.imageshack.us/img195/3427/risingsun.jpg
He is going to using flat black for the background so it matches the panels. He is going to be doing a piece that goes up onto the windsheild, a piece that goes on the trunk and the base under the trunk.
Jordan is great to work with. I sent him a piece with the candy blue on it, so he can match the colors up. He is going to be putting Summit on the sides in a shaded blue instead of white, and instead of Ski-Doo on the hood, he is going to put A-MAIZE-ING KUSTOMS across it. I will then pain the screens in the hood to match the graphics.
This is going to really 'pop' when it gets on the sled. I can't WAIT!!!!!!!
89sandman
05-22-10, 11:44 AM
looks nice.
Thanks, Sandman.
I got some stuff done this weekend. But I ran a little snag. The HPS can is apparently not for a REV, it is for any XP. I pulled my Rumble Pack off the trail sled and it fits. The HPS can is about 1 3/4" too tall.
So I need to sell the really nicely fresh coated HPS can for an XP, and get one for a REV. If anyone is interested, I'll sell it for $200 shipped in U.S. or $220 to Canada.
I got the nitrous all plumbed up including fuel and nitrous lines. I got the rest of the exhaust in, and both clutches finished up. I got the new ramps done, the quick clickers in place and new springs in both clutches with a free floating washer in the secondary with DJ's new clutch helix.
Here are the clutches in place (I still have to put the new belt on), and the belt guards. I cut the edge of the belt guard and filed it down so it looks like it is supposed to come without the plastic cover:
http://img25.imageshack.us/img25/5468/22may7.jpg
Then I got the Y-Pipe mounted up with fresh gaskets, new bolts and Nordlock washers:
http://img517.imageshack.us/img517/424/22may10.jpg
Then I dropped in the expansion chamber:
http://img14.imageshack.us/img14/964/22may9.jpg
Here you can see how the Rumbler Pack fits with nitrous bottle in place:
http://img188.imageshack.us/img188/7929/22may8.jpg
Next I got on the rest of the nitrous. I had to cut the fuel supply line and install the T for the nitrous. Then I had to drill an 1/8" hole in each boot for the fuel jets. I then routed all the fuel lines and fuel pressure controller. I then hooked up all the lines to the controller.
Here is from the other night in getting the nitrous jets mounted. This is a shot of the jets installed on the inside of the air-box:
http://img72.imageshack.us/img72/4496/22may1.jpg
Here is the box reassembled with them in place:
http://img690.imageshack.us/img690/1408/22may2.jpg
Here are fuel jets all plumbed up and ready to go:
http://img404.imageshack.us/img404/5483/22may5.jpg
Here is the fuel pressure regulator and the controller mounted up:
http://img4.imageshack.us/img4/3720/22may6.jpg
This week I will prime the oil pump, try to find an HPS can, finish up the coolant lines to the carbs and top hose, bleed the brake, fill the chaincase, prime the fuel pump and see if I can't breath some life into this thing.
IT'S ALIVE!!!!!!!!!
I got off work at 4:30p, stopped by the Post Office to pick up my Certified Check for my Jeep stroker motor, then stopped by and got some 110 race gas....then I got home around 5:45p, filled up the gas tank, added some oil to the fuel and primed the oil pump.
I put in Rob Zombie's Dragula.
I hit the starter a few times to prime the fuel pump.
Once fuel started in the lines it fired right up. I held open the oil pump until is started to smoke really good.
I am letting it cool down right now, then I will fill up the coolant and she is ready to roll.
CrescentLake
05-26-10, 07:53 AM
Congratulation, It's been fun watching (reading) you build your "new" sled. Now to see pictures of it on the snow this coming winter. Good luck!!
Congratulation, It's been fun watching (reading) you build your "new" sled. Now to see pictures of it on the snow this coming winter. Good luck!!
It isn't quite done yet. I still have to clean all the tape residue off the inside of the panels, put on the wrap, and some other decals, put on the windsheild, get the HPS can coated, get some velcro to hold the Boss controller, and after tonight, take the recoil off as the knot came out of the handle when I tried to pull it over and the rope went into the recoil.
I worked on the Sea-Doo Speedster trailer this morning until it got too to hot outside.
Jordan (from Arctic FX) came through with flying colors.
Last week, I sent Jordan the trunk. His kits don't normally come with trunk covers. I sent him the trunk and did a really nice job whipping something up to put on it.
He also wanted a piece that is powder coated so he could match the color. He hit it dead-on.
I got the wrap done up in the cool garage with the central air on. LOL
Here is the sled with the wrap on it. I am still waiting for my windsheild so I can get that wrapped. The pattern continues onto the windsheild.
http://img12.imageshack.us/img12/1940/sledwrap1.jpg
http://img227.imageshack.us/img227/7233/sledwrap2.jpg
Here is the trunk cover Jordan did. I had him make sure to put his logo on it. He also whipped up a new logo for me.
http://img4.imageshack.us/img4/1145/sledwrap3.jpg
The color almost looks like it was laid over foil. It really pops when the sunlight hits it, just like the candy blue.
Maize
It has been fun watching the progress. Every time you post an update I question whether I would have the patience and motivation to see a project like this through, or complete it in a reasonable amount of time. It looks awesome. What's next?
Ben
Maize
It has been fun watching the progress. Every time you post an update I question whether I would have the patience and motivation to see a project like this through, or complete it in a reasonable amount of time. It looks awesome. What's next?
Ben
Well. This one isn't quite finished yet. It will be completed by next weekend.
I am already working on other projects.
I have the trailer for my boat in pieces in my driveway right now. I have the axle and hubs apart. I am sending those, along with the wheels, to my powder coated. The axle and hubs are going to be done in black, and the wheels silver.
I will be grinding down the trailer to metal, then using epoxy primer on the frame and painting it. I will be putting a new wiring harness and LED lighting on the trailer.
Two summers ago, I spent the summer competely rebuilding a 1997 Sea-Doo Speedster twin engine jet boat. Since I had both knees replaced last summer, I did not get a chance to get the trailer finished up before winter.
Here are some shots of the Speedster that after it was done:
http://img109.imageshack.us/img109/1565/speedster1.jpg
http://img704.imageshack.us/img704/5790/speedster2.jpg
http://img218.imageshack.us/img218/3371/speedster3.jpg
http://img245.imageshack.us/img245/7594/speedster4.jpg
http://img525.imageshack.us/img525/8360/speedster5.jpg
Here is the current state of the trailer:
http://img526.imageshack.us/img526/5357/trailer1.jpg
http://img9.imageshack.us/img9/6329/trailer2lf.jpg
Then after I get the trailer done, I will be pulling the motor in my trail sled. I am working with Kelsey from RK Tech to do a complete build for an 827 BB flatlander sled.
I am also on the lookout for a new sled for my wife. I would like a 500SS or a 600 SDI for her. It will get torn down and completely done in flat black and pink.
So I have a few things in the works. I will be posting pictures
theregularguy
06-01-10, 06:13 PM
all i gotta say is you are the man for taking the time in these projects. thank you for sharing.
all i gotta say is you are the man for taking the time in these projects. thank you for sharing.
Thanks! I appreciate that.
My Dad brought me up that way. Either right the first time, or don't do it.
I just wish I had more than a couple hours per day to work on them.
I work a full-time job doing warranty claims for Toyota. In the winter months I am building customer's shocks.
So it takes a little longer than I like to complete them. But once I am done, I know they are done correctly.
Today I got the rest of the kit from Jordan. The fill-in pieces. I got those applied, and the grills painted to match the graphics.
I also got the guage rings painted. The new windshield and tach will be here on Tues. I can get the rest of the wrap on it.
All I have left is to wire up the activation switch, wire up the 'call' switch for the nitrous, install the tach, install the HPS can when it gets back from coating and put the wrap on the windshield and it is done. Oh, and align the skis.
Everything but the tach and windshield will be done tomorrow. (It is supposed to rain, so I won't get to paint the Speedster trailer.
http://img72.imageshack.us/img72/4158/4june1.jpg
http://img535.imageshack.us/img535/8810/4june2.jpg
http://img99.imageshack.us/img99/2750/4june3.jpg
http://img217.imageshack.us/img217/168/4june4.jpg
I got the rest of the stuff tonight. The only thing I have left to do is put the Ice Scratchers on the rear skid. Then it is ready for the show Saturday. If I didn't have the company spring dinner tonight, it would be done. I have to leave for that in about 9 mins.
Here are some (pretty much) finished shots:
http://img17.imageshack.us/img17/2867/8june1.jpg
http://img541.imageshack.us/img541/8537/8june2.jpg
http://img686.imageshack.us/img686/1952/8june3.jpg
http://img268.imageshack.us/img268/8006/8june4.jpg
http://img251.imageshack.us/img251/9219/8june5.jpg
http://img62.imageshack.us/img62/8069/8june6.jpg
Wow! That thing is beautiful.
Thanks, Master! That sounds wrong, for some reason....LOL...Yes...Massster.
Stick a fork in this one.....it is DONE!!!!!
I called Eric Sloghterman from the DNR today. He is coming by Friday afternoon to look at it. He will then get my VIN for it. It will be registered as a 2011 Summit.
Here are some shots outside (I took it for a spin down the block and back. LOL
Here it the extra room I have now - LOL - YEAH!!!!
http://img59.imageshack.us/img59/5741/9june1.jpg
Here is the sled with sun on it. The blue really pops more than the red....
http://img541.imageshack.us/img541/3086/9june3.jpg
http://img810.imageshack.us/img810/2623/9june2.jpg
http://img20.imageshack.us/img20/7379/9june4.jpg
http://img10.imageshack.us/img10/8131/9june5.jpg
http://img812.imageshack.us/img812/7115/9june6.jpg
http://img814.imageshack.us/img814/408/9june7.jpg
http://img820.imageshack.us/img820/8357/9june8.jpg
http://img813.imageshack.us/img813/3340/9june10.jpg
I have to give credit, where credit is due....
Without the help of so many people, this thing would be a bear to put together.
I need to thank so many:
Big John from Sled Head Racing
Kelsey from RK Tech
Joey from Dynamo Joe
Raffi from RPM Composites
Jerry from Snow Eliminators
Wildchild Rail Extensions
Brian from Tricked Toys
Jeremy from West Coast Sleds
Jordan from ArcticFX
BC3 (Bob) from TrickSleds
Sean from Al's Snowmobile
Jason from Midwest Sports Salvage
Scott from Recreational Motorsports
Matt Santwire's Bracing
Jim from Sta Cool
A special big THANKS to Rick from Cool Concepts
I have worked with all of these guys, and they are the best. If ever need their services, give them a call....you will be happy you did.
See John....I TOLD you I would get you on there. LOL
http://img824.imageshack.us/img824/1516/sponsor1.jpg
http://img815.imageshack.us/img815/9928/sponsor2.jpg
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IT'S ALIVE!!!!!!!!!
We need video... (with the audio of Dragula and sled noise!!!!)
CrescentLake
06-10-10, 07:54 AM
God I love that sled :D
It was the WORST day for an outside show.
It started thundering and lightning around 2:30A, and just poured rain up to about 6:30A. It stopped about 7:45A.
Registratrion was from 8:30A to 11:30A - We got there around 8:45A. I got everything unloaded, the covers off the sleds, the tent set up and just got sat down and it started to rain again.
It rained until about 1:30p. Then cleared off about 2:30P, trophy presentations was at 3:00P.
There are usually about 225-250 vehicles at this event. This year, there was only 137, due to the weather.
They put me a class with the tuner cars. I got 2nd place with Spawn, and 3rd place with Blade.
Even though it rained, there were still quite a few people there. It was still a lot of fun, met a lot of good people, and got hang out for the day with some friends who show Vettes and Mustangs.
Here are some shots of the event:
http://img808.imageshack.us/img808/786/2010carshow1.jpg
http://img38.imageshack.us/img38/884/2010carshow2.jpg
http://img34.imageshack.us/img34/760/2010carshow3.jpg
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http://img197.imageshack.us/img197/4883/2010carshow5.jpg
http://img441.imageshack.us/img441/7229/2010carshow6.jpg
And here is the hardware:
http://img231.imageshack.us/img231/548/2010carshow7.jpg