2012 AK sled build

[Tarzan]

Man this thread is cool to watch. Great works gents!

x10

 

[Sportsterdanne]

Its going to be awesome !
This build, the tubie and skuzzball threads is the reason im visiting this forum atleast two times a day looking for updates ! keep it up guys !

How come you cut the rear corners of the diecast sides if you going with the tapered tunnel ?

 

[Nikolai]

The primary reason for cutting the die cast corners was to allow room for a diagonal tunnel brace running from the rear suspension mount to the bulkhead.

 

[Nikolai]

Sleeves for the 3/8" suspension bolts

Brackets for the tunnel braces

Tunnel braces will be riveted every 3"

 

[Alatalo]

Tunnel braces will be riveted every 3"

Now we are talking...!

Seriously, I am very interested in how that 7075-T6 tunnel project turns out, from a professional as well as private point of view. You might not realize it, but you are breaking trail....!

Talking about tunnels and choice of materials, does anybody know the exact material specs of the OEM tunnels...? Shitty old 1050...? Slightly higher spec 5052, 5083 or 5754...? No way 6082-T6 since they are usually bent to tight radiuses...? Maybe a project for the locals around Roseau, Thief River Falls and Valcourt...? Get down to the local pub and just listen...

 

[Sportsterdanne]

Wow !
Looks like its going to be rock solid.
What are your thoughts with the tunnel and the material used. is it lighter and thinner than a stock tunnel ?
The bracing will take away lots of stress from the aluminum sheet, i presume you will make some nice integration with the runningboards and the front suspension mount ?

 

[LSXM3]

Are you going to wrap that brace in some sort of foam or something to take away the pain you will get from your knees hitting it?

 

[Nikolai]

No, there's room between my knees and the braces.

 

[Nikolai]

Wow !
Looks like its going to be rock solid.
What are your thoughts with the tunnel and the material used. is it lighter and thinner than a stock tunnel ?
The bracing will take away lots of stress from the aluminum sheet, i presume you will make some nice integration with the runningboards and the front suspension mount ?

Stock tunnel is around .050 I think. A lower 1 x 1/2" tube will tie into the bulkhead down low and tie in close to the rear arm mount. Another 1 x 1/2" tube will run vertically from the lower tube to the upper tube with a sleeve for the front arm mount. When it's all done the sheet shouldn't be supporting much.

 

[ruffryder]

Is your tunnel narrower than the stock one?

 

[Nikolai]

It's stock width.

 

[mike g]

so clean

 

[Nikolai]

Lower die cast braces

Lower bars welded up. I failed miserably on the drill press aligning the cross bar holes. Hopefully it's not too noticeable when it's all done, but that's what I get for being in a rush.

Front swing arm mounts, figured I'd add an extra lower hole while I was at it.

Won't be able to work on it until next Saturday again.

 

[rlcofmn]

Looking awesome Caleb! Good work!

 

[Super Sled]

On jumps and off trail riding, won't you rack your legs on those support beams? Maybe I'm missing something tho, won't be the first time...

Otherwise looks great!