Summer overhaul, opinions please!

[CDK]

Got my first batch of powdercoated parts this weekend, finally.

I also got my new ProTaper Evo / RSI 5" riser bar setup installed. Added a ProArmor tether, RSI throttle block, made a bracket to mount my Koso dual EGT's at the base of the riser, and installed a gauge lifter with custom gauge bracket (needs to be p-coated yet). I flush mounted my Innovate AFR in the console for a clean look. Pretty happy with how it all turned out.

 

[CDK]

Got the skid put together. Still looking for a good deal on some billet wheels for a little extra bling. Please nobody crucify me for using rail extensions; I get a good deal on powdercoating so I just did the factory rails until I pick up a new skid some day.

Made my own two-wheel kit from the factory 3 wheel setup. I just trimmed down the spacer inside so I could fit another wheel in there, then cut down the inner axle to match. Getting the adjusters flipped to the inside took some doing, due to the extensions. I also had to drill and tap one end of the inner axle, but other than that it was about a 30 minute project.

I slid just the rails under for an idea of how it will look.

 

[CDK]

Z-Broz front end, white grippers, Van Amburg bumper, and green vents. Still working on fabbing a headlight delete.

Side shot of my progress so far.

Guess what else showed up?

 

[CDK]

After a long wait, I finally got some Tig-welded art from Bryan at B&M fab. I have to give him props, he built these custom to my measurements, working over the phone and off a few pictures. They turned out awesome, the fit is exactly what I was looking for. I know this is a crazy time of year for them, and he still made time to do my custom work. I would recommend anyone to B&M, based on the customer service and product quality!

Couple shots of them on the sled. I'm stoked on how well they fit my tunnel extension.

Best part is, I think I can reuse the outer part of my factory drop bracket, so that just saved me a bunch of fab work. We haven't got snow here yet, but it's coming anyways and I want this thing together so I can start tuning the ViPec!

 

[B&M Fabrications]

The rear tube might be the only one that doesn't hit the drop bracket since that part had to be done out of the jig. They do look like they fit good though. Glad I added that tube, makes them look complete.

Now get it done so we can see it complete. Haha.

Thank you again.
Bryan

 

[CDK]

I think we'll be good Bryan. I'm going to tilt the outer drop bracket slightly to match the tilt of the boards, the weld up the factory rivet holds and drill new ones. I might have to slightly bend the one tab to meet the running board tube. Once its powder coated to match, I think it's gonna look pretty slick.

 

[Lind]

you are running a 39 kit from zbroz right? are you running a spacer on the spindle? and if so could you take a picture of your front end to show where...

i wrecked half a 42 set the last time out west last year and ran a 39/42 front end while out there and noticed the 39 side was rubbing on the spindle where the lower a arm mounted... i ordered a 39 kit from zbroz this year and wondering where they are running the spacer...

heres a pic of it on the sled right now lol

http://imageshack.us/a/img23/8772/06g0.jpg

 

[CDK]

Yes, running the 39" zbroz kit on '13 spindles. I noticed them binding on the lower a-arm as well, so I ground down the spindle so they wouldn't rub. Wish I would have done this before powercoat, but it's on the bottom side of the spindle so you can't see it.

Not sure what spacer you are referring to, maybe that's for a '12 spindle?

 

[VTMTcowboy]

Awesome job on this Pro! The colors are great as well. Thanks for the posts, really cool to see a sled be broken down and then come back together even better!

 

[CDK]

Awesome job on this Pro! The colors are great as well. Thanks for the posts, really cool to see a sled be broken down and then come back together even better!

Thank you very much! I think the color scheme is gonna rock when it's all done, especially when the tunnel is two-toned to match. I'm with you, I love detailed threads that show everything. I'm doing my best to snap pictures every time I stop for a beer, especially of any custom stuff.

I'm also in full blown panic mode, cause it is DUMPING snow like crazy right now!

 

[CDK]

I'm two weeks away from having this monster rideable, so might have to bust out the backup sled. It ain't a Pro, but it's louder than high hell and goes like a rocket! Best $1500 I ever spent.

 

[akpowderhound]

Damn that was one ugly sled!
What was Polaris ever thinking with the " aggressive " chassis. They looked good before and after. That sled weighed I think 50+ lbs more that the predecessor.

 

[CDK]

Yes, they certainly were hideous. I found this one 4 blocks from my house, and there wasn't a scratch on it, so I just had to own a prime example of Polaris' bad decisions. Plus nothing beats the howl of a triple at 9000 rpm......

 

[akpowderhound]

They do scream man!
That does look like a clean sled for its age too.

 

[CDK]

Got my drop brackets finished last night. All I had to do was trim the rearmost tab on the upper part of the bracket to match the running board tube, and hog out the bolt hole a little with a dremel tool. Fits pretty nice actually, and I'll use solid rivets to tie it into the aluminum tunnel side and inner factory steel bracket once everything is power coated.

I bolted the inner shaft from the rear suspension arm into the brackets, and jumped up and down on the boards. Everything feels rock solid, and I haven't even riveted the boards on yet. Hopefully this tunnel will be strong as hell once it's all done. Next step is building the rear bumper.....

 

[CDK]

Took the easy route, had the machine shop cut the side plates and weld up my back bumper. The tube is 1 1/4" tubing, 1/8" wall, welded to 1/8" steel plate. Should be pretty much bombproof, plus if somehow I destroy it, one phone call and I can have another one made in a day.

Had them make a couple solid cross tubes as well. The design may be a blatant rip off, but they say imitation is the finest form of flattery.......

That's the end of the tunnel fab work, now to ship everything off for powdercoat. I've been working on the wiring harness for my Vipec for a couple days now. Had to add another pin to the factory connector for the signal from my Innovate AFR, and made a connector with a switch so I can power up the ECU off my battery. I'll post more pics once I start to power things up and run through the setup. Bryce from Turbo Performance is going to be setting me up with a base map and assisting with the initial N/A tune.

 

[CDK]

Well, I'm stuck right now waiting for all my parts to come back from powercoat before tunnel reassembly. The sled is pretty much ready to fire, except I'm waiting for a box full of Deutsch connectors to show up before I finish the wiring harness. I could just twist the connections together and go, but I want to do this right, so gotta be patient. In the meantime, I installed my Mountain Fit headlight delete kit. I was 3/4 the way through fabricating one, but I broke a critical piece and said to hell with it and bought one. Oh, and I decided to do a little wrapping.........

Pretty excited with the green!

 

[CDK]

Last batch of parts showed up from powdercoat! I installed all the solid rivets in the tunnel last night. The factory drop bracket turned out pretty good riveted on top of the new aluminum side. You can also see how I got busy with a jig saw and hole saw, and swiss cheesed the tunnel sides.

You can also see my tunnel wrap I put on. I used some plain gloss vinyl above the SCS decal, and right in the footwell in order to clean it up and hide some of the bare aluminum.

Here's the completed tunnel, after I drilled, tapped and bolted on the cross tubes and new bumper.

 

[CDK]

Couple shots of the completed tunnel, with running boards also installed.

Sure looks mean, I think!

Tonight I'll throw the skid under it, and it will officially be ready for the snow! Couple hours of ViPec tuning to go, but the hard part is over.

 

[MDEVO]

Couple shots of the completed tunnel, with running boards also installed.

Sure looks mean, I think!

Tonight I'll throw the skid under it, and it will officially be ready for the snow! Couple hours of ViPec tuning to go, but the hard part is over.

Update?