The RZR build begins

Big-R wrote:

Dam Joe. I guess you want to get a full weekend of riding next time out....

Was online ordering all new suspension bolts from polarispartmonster.com. Out of curiosity I checked the price on a new XP frontdiff...$739 shipped. Could not resist so a new XP front diff is on the way. The one I have now already has a billet carrier. I'll put in new seals / bearings and keep it for a spare.

polarispartmonster.com seems to have some of the best prices around and they are centrally located in Charlotte NC.

kick ass, looks loke a rock crawler from hell

stoneman wrote:

kick ass, looks loke a rock crawler from hell

Thanks!!!

A work in progress, to me half the fun is building it. Well actually it's only fun as long as your not fixing it on the trail

are you going to have it at the white knuckle ride? Like to see it in action

Could not pay me enough to venture out in that druken crowd

We will not be back to Brimstone until July. We are staying from 7-1 to 7-8. I think some of the forum guys might come up as well, your welcome to join in.

appreciate the invite, Im only 2 hrs so not that far to drive

Updates: Been busy trying to fix/upgrade stuff.

New LED light bar:


Front chassis with gussets & weld washers welded in place:


New diff & Gear One rack installed:


I orginally bought a new XP front diff but due to fitment issues I swapped it for a older model S. I figured I would install my billet carrier and pinion support. It seems Polaris finally got it right. After disassembly for inspection I found they have upgraded the plastic carrier to metal and increased the front pinion bearing size. Props to Polaris for reconizing problems and resolving them in new parts.

Rebuilt front suspension: The a-arm bolt holes were enlonggated allowing more play than I liked. I drilled them out and welded in chromly weld washers so this will not be an issues again. Replaced ALL the crappy SuperATV heims with quality FK heims. Thier piss poor design used aluminum bushings on the outside of the heims only. Really SuperATV????? You can imagine what the aluminum bushings looked like after a short period of time. Anyway, had a local machine shop make me some out of 4130 for both sides of the heims and new spacers between the heims. Sweet....no play at all!! Also installed new Blue Torch Fab XP king pins & missaligment bushings. I welded the king pins in place for added strength.





Billet hubs with updated front bearings (Same as XP, made by Moose) and rebuilt front brakes.



So basically everything on the frontend is new or rebuilt. I repacked the front u-joint but wanted to update them to greasable units. Anyone got a Napa cross reference?

338

Wow looks good Joe

stealth wrote:

338

Thank you sir. Is that standard or S model?

Baditude wrote:

Wow looks good Joe

Thanks, maybe one day I it will be finished ...nah that will never happen

RZR_Joe wrote:

stealth wrote:

338

Thank you sir. Is that standard or S model?

There both the same.

Damn Joe, nice work. I hope the rear holds up....

Looks killer Joe!!

Don't jinx me Ronnie. The rear is gete the same treatment.

RZR_Joe wrote:

Don't jinx me Ronnie. The rear is gete the same treatment.

Update:

No more FRICKIN MUD! Front suspension is done! Replaced everything with new components. I really like this new rack! The steering is super smooth and effortless now. It has a very positive feel and no slop. Added a 30" LED bar to the top and a 12" LED bar in the front bumper. Installed the UTV inc alternator setup. has a very nice seal/bearing for the slutvh cover. The alternator mounts to the seat bar. The cross bar for the seats is only bolted on two spots. This allows the bar to flex forward/backward causing pully alignment issues. Fabbed up a support bar that links the seat bar with the front cross bar. This solved the flexing issue, UTV inc should have done this from the start. So far not over impressed with anything I have ordered from them.

Rear suspension: Weld washer and gussest are all welded in place and painted. New wheel bearings installed, installed new heim joints & bushings in the a-arms, billet hubs, and everything cleaned and ready to go back together. Hopefully I can wrap up the PO PO POS in a day or two.

Oh by the way, did I say NO MORE FRICKIN MUD!