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2012 AK sled build

Thanks! I'll get the Cat lever on as soon as I get a new brake line made up. I finished the electrical tonight and put a gallon of gas in it so I could run it. Fired right up and no electrical issues to speak of. I'll post pics in the morning.
 

x2 on the plastidip idea.......VERY NICE!!!! I really enjoyed the whole build, thank-you very much for your time posting such a time consumng thread. i read it all last night at the cottage, no f**kin snow and can't ride but after all that snowmobile info a nice soothing sleep full of snowmobiling dreams....LOL

ps...thanks again and well done
 
Nikolai said:
I'm surprised nobody caught my wiring mistake in this picture. I was double checking a few things on the wiring today and wasn't getting any power in the harness. Not suppose to have power wires bolted to grounds, duh. It's now resting peacefully on the starter relay where it belongs. Thanks to my dad who found it, I've had a few too many late nights I think.
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The only thing I noticed is that all your hard components are upside down. Voltage regulator, ECU. Normally the connectors are on the bottom so that water and other foreign materials can't get in there.

Probably won't make much of a difference though..
 
You make a good point, Drew advised against that a couple years ago. I've always kept them packed with DC4 and so far i haven't had any problems. Mounting them with the connectors down would be ideal but there wasn't a clean way to do it.
 
Wiring is 100% done. It's as clean as I could get it for now, I might try and clean it up a little better this summer if I have time.

Trimmed the tether to follow the contour of the post mount. Ran the wires underneath it through a grommet.
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Few shots of the empty engine bay.
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Thats a clean engine bay.

What about a small sheet above the steering post to close it off from snow even more ?
And the thermostat housing, what about replacing it with a 90 degree bend with heat sensor bung in it and a connection from the throttle heaters.
 
There will be a small plate to cover the opening above the post, just haven't got around to it yet. A fabbed 90 to replace the thermostat housing would be cleaner and when time permits ill make one and incorporate a cap into it as well. I actually have a second thermostat housing ive had in the toolbox for a year so I could do this haha. It would also allow me to toss out the 1x3/4 reducer I have in line by welding the 90 with 1" and 3/4" ends.

Even when the sled is done ill have weight to lose. If I can get a small argon chamber fabbed up this summer id like to build titanium a-arms and rear skid arms. Should be good for another 10 lbs.
 
Ok.
but when i think about it, why not get a 90 degree hose and make the filler cap/reducer/coolant sensor unit as a straight piece.
Have you seen any negative effects of running without a thermostat ?
and how is it working out to fill and bleed the coolant with the inline filler cap and running without a expansion bottle ?

ill hope you dont mind me spamming your thread with questions and suggestions.
 
I've never had any problems running without the t-stat. Filling and bleeding is as easy as stock.

I posted some wrong info before. The mountain max bottle im running has a 3/4" and 1" end. The reducer is in the line going to the front cooler.
 
Stupid question but how did you get that bar worked out so the plastic side panels would fit on? I think back to a bare tube frame chassis I cant think of a way to have that tube there in perfect position then to get all the tabs welded on in the correct spot. Looks awesome to be able to use the same plastics. Nice job
 
I cut the side panels to the general shape I wanted which there weren't many options. I basically just cut the panel off underneath the large oval vent. Once the panels were roughly cut I wrapped bungee cords around them to hold them in place and I started bending tube. Most of layout I do like that is with 1/2" aluminum tube because it's only $1/ft. (1/2" 4130 is $6/ft.) Once I get one correctly bent out of aluminum I make one out of chromoly and duplicate the other side. It's a pain and I have a bucket full of 1/2" aluminum bent tubes to show for it. Duplicating the other side is the hardest part. Have to make sure the tube bender is level in the vice, then use degree finders and levels to roll the tubes in the bender where they need to be. Gotta be careful since the other side will be bent the opposite direction. As for all the tabs, once the bars were tacked in place I used safety wire and wire tied the tabs tight to the tubes to hold them in place. Then I put the sidepanels on and rolled the tabs to the correct angle. Angle finders before tacking made sure both sides were the same and I just used a tape measure for the spacing I thought was best. It really was a slow and tedious process. Throughout the build Ive had the plastics on and off this thing more times than I can count.
 
Nikolai said:
I cut the side panels to the general shape I wanted which there weren't many options. I basically just cut the panel off underneath the large oval vent. Once the panels were roughly cut I wrapped bungee cords around them to hold them in place and I started bending tube. Most of layout I do like that is with 1/2" aluminum tube because it's only $1/ft. (1/2" 4130 is $6/ft.) Once I get one correctly bent out of aluminum I make one out of chromoly and duplicate the other side. It's a pain and I have a bucket full of 1/2" aluminum bent tubes to show for it. Duplicating the other side is the hardest part. Have to make sure the tube bender is level in the vice, then use degree finders and levels to roll the tubes in the bender where they need to be. Gotta be careful since the other side will be bent the opposite direction. As for all the tabs, once the bars were tacked in place I used safety wire and wire tied the tabs tight to the tubes to hold them in place. Then I put the sidepanels on and rolled the tabs to the correct angle. Angle finders before tacking made sure both sides were the same and I just used a tape measure for the spacing I thought was best. It really was a slow and tedious process. Throughout the build Ive had the plastics on and off this thing more times than I can count.
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That is what I thought, just hoping you had a easy way LOL Wow you have more patience then god. Nice work pretty much my dream build right there functional wise.
 
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