Another NyPro Project

[sportsterdanne]

Installing Hyfax on the Assault skid.

Some modification of the fiberglass sidepanels

Had to cut the molding of the fastener.

Modification of Catch tank.

25mm aluminum tube welded in place

an air filter on the tube..

 

[sportsterdanne]

I bought one more drive shaft that i will use for my MTX drivers.

And i got hold of the protector for the speed sensor.

 

[sportsterdanne]

The Catch tank will be mounted in the front.

The oil tank vent. hose will be routed up to the steering and down to the Catch tank.

I bought the Arctic brake really cheap so i was curious to se if it worked, so i had to mount and bleed it, it worked.

I really want to get rid of the stock throttle housing but it have to wait, i got so much other stuff that i have to buy right now just to get i t running.

 

[sportsterdanne]

Got this today.

Size difference.
I have try it to see if it fits the stock lever.

 

[sportsterdanne]

It will work with stock lever, but i need some more adjustement.

Mounted the relays.

Did some more grinding and filled it with black gelcoat.

 

[sportsterdanne]

Drilled and tapped for a Cable holder from the speed sensor


Did some sanding and polishing, in some spots i overdid it but its ok this will be a good finish for whats to come.

Made a bracket for the Catch tank.

Catch tank, ECU and voltage regulator mounted, this will come off again when i start on the steering.

Clearance to the hood..

 

[sportsterdanne]

Got some parts.


Fuel rail adapter in Place.

The bearing for the steering.

Welded on a piece of steel plate.

Finding position.

Welded in place

 

[sportsterdanne]

Made a reinforcement/bracket.









The position is not ideal but its the only place where it fits to have full steering and to be able to remove the hood.
Now i can remove the hood without any tools and no cables to disconnect.

 

[sportsterdanne]

I got a carbon muffler for free because it was broken, i will try to fix it.
It has the perfect size for my sled.




bracket for steering



Cutting.

Tapping.


Welding and cutting the stock bracket.


Done.

Clearance to the Catch can.

 

[sportsterdanne]

Did some work with the electrical today.
Rear light, brake light switch, battery cables, a resistor instead of the fuel sending unit, and a bracket to the starter relay.

I had a resistor its a 5 watt so its a bit overkill but atleast i dont have to order one right away.






Ground.



Almost there.

 

[sportsterdanne]

I have to renew my membership, ill be back !

 

[Norway]

I have to renew my membership, ill be back !

LOL!

Good one, please stay with us man.

 

[sportsterdanne]

Now im back.
i was able to post but not read what i posted
I have lots of pics to post so i will do it later when im on my computer !

LOL!

Good one, please stay with us man.

 

[sportsterdanne]

Built a simple battery holder.



Fixed the broken muffler that i got for free.



Exhaust.



And i got a wrap, it was named Frankensled



Exhaust routing, it was tight.



Heat shielding of gastank.



Some exhaust wrap.




Battery in Place.




New fuel pump and filter.




Removed the internal fuel pump and added one more fuel pick up to the front right corner.




Got very high temperature in the exhaust, got worried that it was a lean fuel mixture.



So i got a water temp gauge.




And a AFR gauge to monitor the Fuel, it did not run lean, so i Think i has to much backpressure in the exhaust.
The muffler has smaller inner diameter than the rest of the exhaust so im going to try a straight tube with larger diameter instead of the muffler to se if it gets better.

 

[sportsterdanne]

Started to Close off the area around the gas tank filler.



Flexible speaker grill cloth.



Soaked in resin.



Fiberglass reinforced bondo.



Removed it and put some fiberglass over the front.



a couple of layers of bondo and some sanding and then some wrinkle paint.
and a cutout for the fuel gauge and some holes for thether, ignition key and some switches for light and hand/thumb warmer.



installed a narrower bar, handwarmers, grips and the aluminum throttle block.



This saturday the sled will be in a snowmobile show so after that i will get back to my exhaust heat problem.

 

[sportsterdanne]

A pic from yesterday when i arrived at the snowmobile show.




it was fun to be there with my build and i met alot of people that follows my build on the swedish snowmobile forum.

 

[sportsterdanne]

Got me some aluminum sheets and a larger perforated tube for the muffler.

 

[sportsterdanne]

First start up.

http://www.youtube.com/watch?v=JgPaACuuN1o

Outside.

http://www.youtube.com/watch?v=IMyOgFhLUus

 

[sportsterdanne]

Had a few Days off the build, it was a bit intense for a while because i wanted to start the Engine while i still had warranty on it and then i had a deadline for a Magazine and then the Snowmobile show....
But today i started on the muffler.
Now it will be able to Breathe a bit better i hope that this mod will make the header run a bit cooler.

 

[sportsterdanne]

Finished the Muffler and did a testrun.
I saw that the Carbonfiber was damaged due to my earlier heating issues but usead it anyways.....
it did not hold up.
The positive was that it seemed to run cooler with the larger inner tube.
Now i need to find a new outer tube, im thinking aluminum this time.