Let the Polishing & Mods Begin

[racerrob]

Did not want to steal srv540 "mods" thread so added the "polish" part as this is a big part of where this project will go.

Started over a month ago, then got interrupted by a serious health situation with my Mom that cost me over 3 weeks but am now back at the "project". So here are some "before teardown pics" & then will follow up with how it sits today.

[Ike]

WOW!

This is interesting! I´ve been thinking the same thing. Post pics soon!

Ike

[racerrob]

The mods & upgrades will include the following:
A) 2004 RX1 Pro Action Skid
B) New Camoplast Predator Track
C) New Carbon Fibre Reeds
D) 800 Drive Line Conversion with 800 Secondary
E) Tunnel Paint & Decals Stripped
F) Tunnel, Ski's & Engine Bay Aluminum will all be Polished
G) Pipes Cleaned, Blasted & Painted with Oven Baking to cure high temp, 1500 degree paint
H) Panels, Nose, Hood, etc stripped of decals, repainted Gloss Black, then custom "small" graphics.
I) New Low Black Windshield
J) Customized Seat
K) 2" Riser on handlebar
L) Carbs Cleaned
M) Blueprint the driveline & track
N) Steering rod & handlebar replacement
O) New Hauck 43-37 Helix

This should keep me busy the next few weekends huh? Kinda glad the snow is being a bit slow to pile up as I will be lucky to get this back together for the shake down run by early Feb. Here is how it sits today, just finished stripping tunnel paint, top side & did some "rough polishing" on the right side to see how its gonna look.:rockon:

[racer7x]

Looking good Rob, keep the pics coming...

[hontri]

Sweeet!!! More pics:rockon:

[Roadrunner]

Rob,
Looks great. I can't wait to see the tunnel finished!
Doug

[AL P]

Yeah, lookin great! cant wait to see it when its finished!

AL

[racerrob]

Ha, gotcha yat to look!!! :eck02:
Its just stripped "naked"- "au-natural" aluminum, all the paint is now gone!!!:clap:

And the tunnel polishing has now commenced. Still need to do some fine polishing clean up in the frame areas then have to do the ski's & the new skid yet. So here are today's progress pics:

[RDL 93 V-MAX4]

This is some great work your doing with your sled. I't's going to be so cool when all is done. Looking foward to seeing more photos as you progress.

[Ken]

Rob,

Looks good!

Did you use chemical stripper to remove the paint?

I noticed that you are going to use an 800 secondary with a 43-37 Hauck Helix. Did you get a 43-37 cut for the 800 secondary? The 800 secondaries usually run steeper angles than the 750 due to the design of the clutch.

Ken

[racerrob]

Hey Ken:
I used 2 types of "spray on" stripper. 1st was "Aircraft Paint" stripper from a local auto body/paint supplies store. Was told that "this was the GOOD sh*t"
Anyhow, it worked okay, but during last weekend when I ran out of the stuff, had to go to a NAPA store that was open during the holiday weekend. Got their own "NAPA Paint Stripper".
Now THAT stuff was excellent!!! One heavy coat.......... let it sit 15-20minutes & the paint literally would start to fall off. Funny, worked better that the "aircraft" stuff, & was $6.95 per can VS the $12.99. Shouldve known, when "airplane" is attached, the price goes up!!! LOL The expensive stuff took 2-3 coats & lots of scraping.

In regards to the helix, I appreciate the heads up. I ordered it for an 800 but,
I am not 100% sure that is what Hauck sent me so I have emailed them to clarify & confirm. Did not realize that there was a differance, should have figured that there was more to it than the spline & everything else!!!

Thanks again, Rob:rockon:

[racerrob]

Okay, got the following done now:
A) RX1 Suspension now has the extensions from Tracks USA mounted, new bearings & polished the supspension rails. Should have new "red accent wheels & red hyfax" hopefully this coming week to get this portion done. Also got one of the ski's polished up. They actually can clean up pretty good.:4fzfpi:

[racerrob]

B) Cleaned carbs & installed the new carbon fiber reeds. Actually am now getting to the "put stuff back on" mode. I think I am done tearing stuff off.:4fzfpi:

C) Also "broke the motor loose" for when I blue print the driveline-track etc.

And of course, some additional detail polishing, getting real close to having that done where I can put on the "sealer". This almost seems never ending as ya can "keep" shining for ever to get rid of finger prints!! LOL :frech32:

Next weekend, driveline & start to layout & prep for the RX1 skid.

[IZZ]

Man Rob that polished aluminum looks nice!! If you get time could You detail your polishing process and what tools you used especially on your skid and ski's? Ive considered doing mine but have been put off up to this point by all the angles, nooks and crannys! You also mentioned a sealer. What are you gonna use for that?
Thanks for the post! Your pics are inspirational.

[Roadrunner]

Rob,
Very awesome!! It sure does look great! I know what you mean when you say you can keep going on forever shining.
Doug

[vmax4rules]

Very nice!

[racerrob]

Thanks guys, the polishing sure does set the machine up to look good. Cannot wait to get it in the sun & on snow. Should be pretty dam "bright"!!

IZZ, in regards to the "polishing tricks" etc. Well, as you know how ya did your tunnel, it just takes a bunch of work.

I tried some "shortcuts, powered this & that" & in the end, it came down to
ALL HAND work. The skid, tunnel, skis, all by hand. Tried the Mother's Powerball with drill, it is okay for the initial 1st layer removal IMO, but in the end I have been applying the Wizards just with my fingers, rubbing it in, then removing the residue with towels-rags.

WORD OF CAUTION: If using hands-fingers, make sure you have ALL sharp objects ( rivets-sharp corners etc) de burred. Ya can slice a finger open pretty easily in some of the hidden frame corners etc. Been there-done that.
So in areas I could not see etc. I ran some 0000 scotch brite pads over corners etc to sort of de burr any "surprises. Has worked so far!! No Blood Spilled!!!:4fzfpi:

The biggest item I found to help was using Wizards Metal Renew. That is very good stuff. I have used Mother's Mag stuff for years & was happy with it but, Wizards is by far a superior product. It "cuts" deeper, seems to get the shine with a little less "elbow grease" etc. The tunnel, skid & ski are the result of at least 4 "polishings" & as Doug-Roadrunner knows, ya can keep polishing on & on. The other key to the polishing from my experience is to use good terry cloth towels. The newer the towel, the more effective the shine will be. So ya tell your wife she needs new towels & you grab the "old ones"

Ya "score" on both points, she has new towels & now you have "rags for polishing" LOL:smilielol

Wizards also has the "sealer" which is applied after ya have the look ya want & supposedly seals the metal to the elements. Cannot confirm this yet, will know how good it is after the sled is in the elements & how it looks after a few months of use!!:2dontknow

Rob

[IZZ]

Thanks Rob!
Ill have to look into those Wizards products.
Well keep up the good work, cant wait to see pics of that thing done, I cant imagine the anticipation you must have! Its gonna be Awesome.

[racerrob]

Slowly getting there. To date have the following done.
A) All paint stripped from tunnel
B) Tunnel, frame, guards, misc aluminum parts, ski's & new skid are all "polished" now. Tunnel will get a major "once over"& sealing job once new skid is installed. Get rid of any "unsightly marks" LOL
C) New skid gone thru, new bearings, wheels, Tracks USA extension for 136 track installed.
D) Carbs removed, cleaned
E) New carbon fiber reeds installed.
F) 800 Drive shaft & secondary clutch in place. ( Waiting for correct helix, Hauck screwd up!!:cussing: )
G) New rear flap installed.
H) PSI quad pipes "blasted, baked & repainted with 1500 degree paint.

Am now waiting for some "other additional" parts that were wrong & aluminum flat stock for the "spacer tunnel re inforcement" part. Hopefully next weekend will be skid install weekend!!!

Body panels & hood are supposed to be done by this Friday, will see. Here are a few pics as it sits now.

[hontri]

Lookin good Rob:rockon: Makes me want to start building another one!

[racerrob]

Thanks Norm, kinda fun gettin it this far, am really lookin forward to gettin it back together & get it outside in the sun. I think its gonna look pretty good in the sun & snow.

How much snow have ya got there in BC. Seems like you guys been gettin a little up there so I presume you have been getting some good riding in??

Our base at the Mt Bachelor area has finally got up there a bit. We are any where from 80 to 115" above 5500', so it is time to get this thing together!! Been pretty cool here in Bend the last 2 weeks & we just had a shot of snow in the Portland area that pretty much screwed them up today. I am on "this side" of the mountains and am always amazed at how these people can get so screwed up in 3-5" of snow. It is truely an "idiot fest" to watch.

Hope your having some good riding up there!!:party:

Heres lookin for more :snow: :snow: :snow:

Rob

[AL P]

Dang, you aint messing around are ya..gonna be killer when she`s done!!!
keep up the good work, and keep posting pics, love seeing mods in progress!!

[hontri]

Hi Rob...yup were gettin some good ridin in up here. Been out every weekend since the end of October. Got some massive dumps in the Revelstoke area. Some days it is hard goin' but still a rip! More snow in the forecast:4fzfk2: .... Your build is looking sweet! Keep the pics coming. I was watching the traffic carnage in Portland on the news. What a gong show!!

[racerrob]

Hey Norm:Good term, Gong Show!!!!

You probably saw the video that guy shot from on top of his apartment of those cars crashing all over the place.
The real idiot from what I saw was the guy in the Volvo SUV, I can understand sliding down the hill on the ice, but after he hit the power pole, you could see he hit the gas, then took off & plowed into those other cars etc, he hit 3 more things before he finally came to rest against the group of cars. INSANE!!

I am just amazed that no pedestrians were hit during all of that!!:3speechle

All the schools etc are still closed today in PDX. Am going into the "heart"
of it today on business, ought to be interesting!! I will be on serious "idiot driver" alert!! LOL:smilielol

[mark the shark]

Great work, Rob. She's gonna look better than new when you get done!:rockon::rockon:

I just saw that video last night. Loved the idiot mashing on the gas and hitting everything in the intersection. Good thing they parked the fire truck in the middle of the road as a roadblock! I found it here: http://www.break.com/ It's probably on the second page by now.

Shark

[racerrob]

Okay, while this has taken MUCH LONGER than anticipated, made good progress last weekend.

Using Wildmax's dimension as a guide & input from others here, I have made the following progress. First pics show where the new front mounting hole locations are & how I modified the original front mounting brackets to help "guide & space" the front location points. What was not mentioned in Wildmax's posting was how the right side front hole ends up directly behind the right heat shield which is really fun to get the new mounting bolt in when ya have "fat hands & fingers"!!!:cussing:

Then because of this tunnel being a stock ST tunnel, there apparently is more bracing than the 121 tunnel so there was some machining requirements to make the spacer bar fit properly & had to "massage" the width of the skid mounting shafts to fit inside when using the 1/2" aluminum spacer bar. Additionally, welded "tab" where mid shaft would mount through for added strength.

So while there was a fair amount of :frech32: :frech32: going on, it is finally getting there.

[racerrob]

So, the skid is in with the front shaft bolted in, drivers & track in.

Next will be getting the other mounting shafts bolted to the sled etc.

Hoping to make serious progress this weekend & shooting for firing it up the following weekend barring any unforeseen "screw ups" on my part!! :3speechle

:snow: :snow:

[racerrob]

FINALLY!!!!!!
Got the skid installed.......... WHOO HOOOOOOOO:party:

And now..........progress as it should be !!!!
Got the clutch & motor aligned.......wow........ darn thing was out almost 1/4"
center to center!! Had to crack the torsion bar between the motor & driveline bearing carrier which was factory set from what I can tell.

Carbs & air box installed & set the PSI in place & right side body panels "lightly bolted" in. Hope to fire the old girl up next weekend!!!:4fzfpi:

[racerrob]

Also pics of hood with powder coated grills installed.
All hood & body panels have been repainted

[BUBS SRX]

Nice job Rob!

[AL P]

SAAAWEAT!!
Lookin great man!!!


AL

[quadzillaracer]

Beautiful Job racerrob, lots of hard earned man hours involved...but looks well worth it! Glad the "blueprinting" went well for your build!

[racerrob]

Thanks for the compliments guys, I think its lookin pretty good now.

You are very correct Quadzilla, I have way more hours in the "polishing portion" than I ever thought would happen, but, once ya start & see the results, its tough to stop as it "shines better" each time ya go over it.:4fzfpi:

I thought the paint stripping portion would be bad but that actually was the easiest portion of this project!!:2dontknow

Cant wait to see it in sunlight with all the body panels & hood back on it.
Am hoping like heck to get it fired up Sat & have a buddy who will go with me on a "shake down" ride on Sun with "tow rope" & tools for the "aw sh*t" part in case I forgot to tighten something important!!! LOL :frech32:

Will be going thru it with a fine tooth comb..er wrenches Sat after its running!!

[Skinner]

Sled looks "BAD ASS", can see the Bucu hours that went into that project.
Looks great, very nice job!!! How did the shakedown run go?

[Roadrunner]

Rob,
Very awesome job!! Your sled looks great. I can tell how much polishing you did and it turned out very nice. Hope your fingers don't start cramping up on you after all that work!!
Doug

[racerrob]

Okay, am behind on supplying the latest updated pics.
Will go in order of what was done.

I would guess that many here have seen how the seats look after 12-13 years & mine was no different. While the cover was okay, I wanted to "customize" the hieght of the seat itself, so, tore into it & here is how it looked as oem & how it now looks with the "mods".

[racerrob]

Added 3" of foam for the higher seating position.
While I "lost" the Yammie logo, I like how it sits now, particularily
with the RX-1 Skid.!!:4fzfpi:

[racerrob]

Pics of the reassembly of the "important" parts!!:4fzfk2:

[racerrob]

And finally, body panels, hood seat etc.:4fzfpi:

[racerrob]

Well, its together & have "fired" it up on the stand & aligned everything & it all seems to be working!!!:

Many,many thanks to all of you guys that "helped" with advice,ideas & great pointers & pictures. Could not have done the project without the valuable input from the awesome guys here!!! WHile the project took much longer than anticipated, I am pleased with how it looks & am confident it was worth it.

Skinner, to answer your question, she hasnt been on the snow yet. Things got a bit delayed so, am now planning the "shakedown" ride this Sat morning. Will head up tp the sno park & ride a couple of the shorter "loop" trails so I can be close to the truck & trailer "just in case" there is an oops!!:frech32:

Since it has just been run on the stand, am guessing I will have some clutch tuning & track tightness issues to play with but am pretty sure I wont be "dropping nuts-bolts & stuff" on the trail!!! LOL:cussing:

The good news for me is we are finally getting some more snow so should have some fresh stuff to ride on. We have been a bit "dry" with all of the storms either being too warm or heading way north. Our snow pack is a bit low, but we have a pretty solid base so hopefully it will keep snowing now for the next month or so. Am hoping to ride into May or so at the higher altitudes.

Doug & Skinner thanks for the compliments on the "polishing". You are very correct in "lots & buccuu time" !!!:3speechle

I did have sore & stiff fingers from all of the detail work. I did not keep a log on the time I spent detailing the darn thing but, I am willing to bet I have over 40 hours in just polishing the aluminum on the tunnel & ski's!!
While that may seem a bit crazy, I am thinking she will look pretty darn nice in the bright sunlight & snow. Cant wait to see how that looks!!

One thing I know for sure....... there isnt another sled like this one in the area!! My hope now is that it runs as good as it looks!!!!

Again, many thanks to all who helped. I learned alot about the old Max & some "tricks" of the trade. And, I have literally a few hundred pics of the stuff that I did with alignment, skid installation etc. so if someone else attacks a similar project, I have a pretty good "library" of what to do now!!

Last thing to go on the sled will be some custom graphics that are still in the"design stage" which is fine as the painted body panels & hood need another 3 weeks to "fully cure" before graphics can be applied. That also means I wont be "boondocking" too aggressevily in the small trees. Hate to get any scratches on the new paint!!!:cussing:

Of course, it'll be like a new truck, once ya got the 1st scratch, ya dont care anymore!!!LOL:smilielol

[Ike]

That is great result what you have accomplished there. Man, that is shiny!

kudos for the hard work and elbow grease.

Ike

[allarson]

has any body done a drive belt installation in place of the chain case as this eleminates a lot of rotating mass which frees up horse power, that drive belt is the same type that u use on a blower like belt drive so that elminates the oil too