2010 Boondocker Kit

[Pastor]

I had the opportunity to see the new 2010 Boondocker kit with the new oil res, muffler that meets forest service noise regulations, new control box, the patent pending exhaust system that will not plug ... etc.

This really looks like a great set up.

I expect to hear great things from those of you that chose this kit.

I think you are really going to like it.

 

[MCIVER]

I think this will be a good thread once people start getting their kits. It will be nice if the people with bd kits have somewhere to go with questions, comments and helpfull tips and tricks.

 

[eludnu]

I spoke with BD about upgrading my 08 Race gas kit to include the new improved oiler. They aren't ready to release a price yet, but the told me they plan to price it so that we will be encouraged to update. The new overboost function sounds sweet too.

 

[JHG]

I also got to a chance to work with one of the new kits this last weekend. I really like the way they setup the oil system and the new exhaust. The oil dipstick/filler is also pretty sweet.

 

[bart0678]

I also had a hand in this install and was very impressed with the fit and finish of the 2010 BoonDockers kit. I researched several turbo companies last season and felt BD had the best kit at the time, so i ordered a 2010 pg kit. With all the new additions they have added, better oil tank, electronics, ect, the 2010 kit is the best on the market in my opinion. For everyone waiting for their kits to arrive for this season, sit tight it will be worth the wait!

A big thanks to Justin at Code Red Performance.
Adam

 

[badass1000]

what is the aluminium tank mounted close to the coolant overflow bottle?

 

[JHG]

what is the aluminium tank mounted close to the coolant overflow bottle?

It's a catch tank for the Oil Reservoir. When the sled rolls it supposedly catches any excess oil that comes out of the Oil Reservoir. My understanding is that the new oil system prevents oil from dumping back into the turbo when the sled is upside down. Maybe Justin or someone from Boondocker can shed a little more light on it's purpose and function.

 

[badass1000]

typically don't you just run a vent with a check valve in it so that when it rolls upside down oil can not come out of the vent? I could see oil going back into the turbo and posibly leaking through the seals and into the turbo if the turbo sat upside down for a decent amount of time. 5 min or more.
Were people really haveing problems with the older style oil reservoirs? I have just never seen a two stroke turbo with the seperate reservoir to hold the oil if the sled is upside down. So is their a check valve or ball in the drain comeing out of the turbo so that when it is upside down oil can not go back into the turbo?

thank you for the pics and info.

 

[EEEK FACTOR]

In the pics it looks like the exhaust is awfully close to the coolant line, any concerns there?

 

[JHG]

In the pics it looks like the exhaust is awfully close to the coolant line, any concerns there?

I do have concerns there. I've been told that the muffler has a ton of packing in it and won't get that hot but I'm not sure I buy it. We are undecided about what to do about it. I think we are leaning toward draining the cooling system and cutting about a 1/2" off the coolant line where it goes into the tunnel. If you do that it will move the line closer to the tunnel and away from the muffler. I think with that and the supplied heat tape it will be fine.

 

[colorado logger]

Holes

I've been stressing over cutting holes in tunnel and foot well. My instructions say to use hole saw and then grind to fit. In the pics you tunnel hole is a nice fit. Looks like the foot well hole is square, did it just end up that way. Or is it just better cut to it out square or do the hole saw and grind? Thanks and keep the pics and info coming.

 

[JHG]

Dwaine-
I think the hole saw way is the best. The hole you cut will be pretty small for the pipe to go through. I used an air body saw to trim the top and square it up a little. The pipe is square across the top so I just kind of tried to match it. I didn't take much off the bottom and used a die grinder on the sides. It took a long time to get it right and I'm still going to clean up the top of the hole with a die grinder before it's all over. It's an exercise in patience to get it right and not hack it up. If you don't have a spring puller I would pick one up to get the spring on the bottom of the muffler. Also watch your track when you get the body saw in there, I ended up having to put a piece of 1x2 in there to push the track up out of the way.

 

[hatchers]

I would add a heat shield between the collant and can...thats just me

Those pics make it hard to see how the drain fitting from the bottom of the turbo has a seal on the oil tank that wont allow oil to come out when the sled is upside down...can someone post some close up pics and explain?

damn i love the color of a new turbo, looks sweet

 

[badass1000]

I know their is a seal so that the oil tank does not leak. I believe the purpose of the new oil catch tank is so that when the sled is upside down oil does not backup into the turbo and leak past the seals. The oil goes in the catch tank when the sled is upside down.
I just didn't know that this was a problem. I don't know how long the sled has to sit upside down before this becomes a problem. I have not seen any other turbo sleds with a catch tank when the sled is upside down. Does any one use some sort of check system so oil does not go back into the turbo if the sled is sitting upside down?

 

[colorado logger]

More holes

Question, when drilling hole in tank, whats the best way to deal with shavings that might get in the tank.


next question, is alright to touch the turbo, because that damn thing is so sweet

 

[badass1000]

apply air presure to the gas tank with a air hose while you drill so the shavings blow out while you drill.

 

[MCIVER]

how are the new EBC's doing ? are they worth the money ?

 

[jijohans]

The install manual could be downloaded from BD's site... Can't wait to get my kit..

 

[bart0678]

how are the new EBC's doing ? are they worth the money ?

Boondocker hasn't released them yet. Im hoping to get my hands on one next week. Ill keep you posted.

 

[Nubulin]

I got my kit last week. PG M8 kit. No EBC though. Just a note saying "DO NOT RUN THIS KIT WITHOUT THE EBC". So basically just a bunch of worthless parts at this point. Thanks BD. LOL....