2012 AK sled build

[Nikolai]

Had a fairly productive day. Since I get teased for building a mini super cub, I figured I might as well do all my riveting according to the Standard Aircraft Maintenance Handbook. Good thing solid rivets are cheap.

Got the tunnel extension in place and all my holes drilled. Rear suspension mounts finished up and I added another hole 1.25" higher while I was at it.

I have no doubt .040 will be plenty strong enough. With just clecos and the chromoly tacked in place it's extremely rigid, and I'm glad I kept the 45'd corners all the way back now. I did manage to get all my foot bars cut tonight so I'm hoping I can finish the running boards Friday.

 

[Nikolai]

Didn't make it anywhere on the running boards, the tunnel extension and rear tunnel tube took all day. I forgot how time consuming sheet metal work is.

Had to pull the chromoly sides off so I could take the tunnel pieces in to shear. Laid the sides on top of each other out of curiosity(to see how I did) and I couldn't have got them any closer without a building a jig. That was a big relief.

After I sheared both pieces I put them back together to drill the holes out. I like to initially fit everything using #3 clecos.

With half the holes cleco'd I drilled out the other holes for a #4 rivet(1/8").

Removed the #3 clecos and drilled the remaining holes for #4's.

Cleaned up front section ready to rivet.

Tunnel extension ready to go.

Finally ready to set some rivets.

I left a few out because I may be putting a 4130 bracket there for my running boards to tie into.

Ready to go. The tunnel skin is 10 lbs as pictured.

I bent a 1/2" .035 tube to tie the two sides & tunnel together. I wanted to end the tunnel with a nice tube instead of just sheet metal. Had to massage the corners of the sheet a little to fit the radius of the tube but I ended up with a fit I'm very pleased with. And yes, there will be 17 rivets going into the 1/2" tube haha.

As it sits tonight.

Maybe I will get to running boards tomorrow.

 

[HYFLYR]

Dog is getting bigger!

 

[Nikolai]

He's a beast.

 

[Sportsterdanne]

Lightweight dog to match the sled

 

[mike g]

I bet you could save a couple more ounces if you shave the dog

 

[HYFLYR]

More redbull!

 

[Nikolai]

Running board tubes cut and cleaned.

All tacked up.

 

[Sportsterdanne]

Nice work !
What skid are going to run with the longer track ? Extend your cat skid ?

 

[beeze455]

You guys migging you boards? What kind of setup are you using to shape the pipes. Been thinking about buying a drill press.

 

[Nikolai]

I'm going to run 2012 153 HCR rails.

Everything Rick and I do is TIG. I have a Miller Diversion 165 and he has the 180. I'm using Rick's Rigid ratcheting conduit bender for the 3/4 .035 and I have a Rigid 1/2" tube bender. Both work great.

 

[beeze455]

Heard alot of good things about the diversion 165. I need to decide what I am going to do about my boards. How much of a pain is drilling those chromo tubes? Looking good and staying tuned for the steering.

 

[Nikolai]

The chromoly drills fine. Boelube helps makes the hole saws and drill bits last longer.

 

[Modedmach1]

Nice work!!! That thing is looking sharp...

 

[Alatalo]

I would like to get the Ski-Doo Summit designers opinion on your amount of rivets in the dropbracket area...