Hey Brad, I haven’t weighed it but she’s HEAVY. The chassis is all .090 wall 4130 nothing light weight about that haha. As far as suspension geometry and pickup points it’s all the same as a ZX chassis skidoo. I actually sold both of my spare 141 and 144 M10’s for $100 or something stupid like that.
Zollinger Tube Chassis Restoration
- Thread starter gp800
- Start date
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Just out of curiosity, are you using mobile or desktop? they work on my end using a desktop.
I decided rather than starting a new thread for the 700 restoration/rebuild I would just continue using this one. Here is the condition of the chassis when I began working on it. The prior owners were attempting to swap in a cat 800 laydown motor and diamond drive from an M series into it.
While waiting on material for the patch panel to arrive I began carefully removing all of the un-original brackets and plates that had been added. Unfortunately, this revealed some major damage and holes from blowing through the tubing where they were welding too hot with a mig welder. I had no choice but to replace the damaged tubes.
With the bearing support mounted where I was happy with it I then could get back to the patch panel behind the chaincase. I squared off and straightened the torched edges to make building the patch easier. a cardboard template was made up then transferred to the new material. Once the part was in and I was happy with the fitment I welded it into place. (Note I am not a fabricator or a welder but seeing as this panel is not structural and will be hidden behind the chaincase I decided to give it a try. the rest of the welding will be done by a friend who is a welder by trade.) once that was done the lower hole was cut out.
At this point most of the lower chassis was ready for final welding so I started building the steering hoop structure using the 800 chassis as a template. Not having a tubing bender I use the sand method. Where a cap is welded to one end of the tube, it is then packed tightly with sand then capped off. the bend is made by heating the tube and drawing it around a jig I had built on a small steel table. doing it this way keeps the tube from crushing at the bend keeping the tube round throughout.
here a cap is welded to one end of the tube, it is then packed tightly with sand then capped off. the bend is made by heating the tube and drawing it around a jig I had built on a small steel table. doing it this way keeps the tube from crushing at the bend.
here a cap is welded to one end of the tube, it is then packed tightly with sand then capped off. the bend is made by heating the tube and drawing it around a jig I had built on a small steel table. doing it this way keeps the tube from crushing at the bend.
Awesome work. Love seeing stuff like this.
After the main hoop was finished I needed to build the rear supports, I did make a mistake early on in that I had built them using measurements from the 800 chassis but come to find out the original ones were a little longer and on less steep on an angle. (as made evident by the remains on the top tube where the originals were cut off.) 
We're now almost caught up to where the sled currently sits. (With the exception of the finished steering post which I've yet to take pictures of.) It has been sitting like this for a little over a month now for two reasons, 1. I haven't been able to find a clear photo of the rear tunnel liner section in order to replicate it. I know it was not the same as the 800 so I chose to not copy it. and 2. I didn't have a motor to be able to measure and build mounts off of.
