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2012 AK sled build

I wanted to get weights of everything this year as I pull it apart so I have some numbers to go off of.

I weighed the turbo kit as pictured with every clamp, screw, gauge, oil line, ect associated with the turbo. I did not include the header since you have to run one on a stock sled. For everything pictured it was 24 lbs.

 

Nice !
A good chunk of weight from the track alone, im really looking forward to see the result of your latest mods.
 
I've been weighing everything as I take it apart this time.

Engine as pictured with the flex joints (found one broken) and oil drained 112.2 lbs


Both skis with the rubbers & mount bolts 10.4 lbs


Complete front suspension without the tie rods 24.1 lbs


Subframe bare 15.5 lbs
 
I've been wanting to weigh the chassis for awhile. I drained all the coolant out first before weighing it.

Weight includes the tunnel, bulkhead, subframe, front seat bracket, seat, exhaust shield, coolers & coolant hoses, hose clamps, coolant bottle, and all related hardware (subframe & seat bolts).
Right under 72 lbs

 
No, and only because I think it would pack snow in between the tubes and body panels. I do however have plans to rework the front of the boards and curve them in. I'm also going to taper the rear of the tunnel quite a bit.
 
Looking forward to se your mods and the final weight (and some more pics and videos of it running).
I have some stuff to do on my sled before the season and i think i will mod a Harley next before i start on my lightweight build.
 
I've been wanting to redo the back of the tunnel for awhile. I'm going for more of a race sled look I guess. the permanent marker line will be the new 1/2 x .035 tube and everything below the line will get cut. I'll end up with less drag, less snow build up, and according to my math, about a 2.4 lb weight reduction.


I'm also changing the running boards. I never stand to the rear and wanted to try having shorter boards to see how I like it. If it works out I'll incorporate them into my next build. Should see a weight reduction of about 1.2 lbs for both sides combined.


Big picture of what's happening


Pulled all of this hardware out of the bulkhead which will be replaced with solid rivets for about a 2 oz reduction.


I'm hoping when I'm done I'll have removed about 4 lbs from the chassis.
 
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Got the outer tubes tacked in place. I'll probably add a 5th crossbar at an angle to ensure a boot can't get stuck.




I REALLY want my skis to be under 5 lbs complete. Alternative Impact is making titanium bushings for the Grippers which I'll have in a few weeks.

Steel washers from one spindle bolt


Aluminum washers for both bolts



I started shaving all the gripper knobs off the skis. It's slowly adding up. I'll cut as much as I need to in order to make the weight goal.

This is from one ski about 70% done.


 
It's always interesting to watch this thread. I think some of your ideas are really innovative ... like the changes you made to the subframe, which really seemed to kick start this build. And I do respect your fabrication skills and creative talents. But I wonder whether you'll be able to notice the difference in weight between a 400 - 410 lbs sled versus the weight you were at this time last year, which seems to me it was something like 460-470 lbs.

I don't have your skills, but if I did I think I'd be trying to build something completely custom instead of working from a OE chassis. You're practically there now with this build. I'd really like to see someone figure out a way to eliminate a CVT and make a sled that is really narrow and nimble. I think that would be game changing as they say. The closest thing to that right now is a snow bike, but I would like to see something with a lower COG than a snow bike and still making decent power, especially at altitude. Great work so far. Keep pushing the envelope! Can't wait to see what you'll do next.
 
I have plans for a full custom sled. I wanted to make everything as light as possible on this one, so I'll know where it's possible and easiest to lose weight on the next one. As I put the sled back together and individually weigh all the parts, it will give me a great baseline to go off of and I'll be able to come up with a realistic custom build weight.

Last time I weighed it, it was 448-449 dry. I'll be dissapointing if it's not close to, or under 420 lbs this time.
 
Finished welding the running boards and then started on the tunnel taper. Took me all day to get the new tube bent up, fitted, and cleco'd in place.

The new 1/2 .035 tube weighs 1.08 lbs.


The removed section is 3.4 lbs


I brought the new tube forward a tad so it would share rivets with the cooler. I also did this so I could fit and cleco the new tube before cutting the old section out. 45 rivets will secure the skin to it.


I still have to finish cleaning up all the edges on the skin and some clean up on the frame, but the hard part is done.


 
Got the skin all cleaned up and the frame trimmed and 1/2" tubes welded. I'm going to end up removing the skin completely so I can weld the tubes on the inside and then repowdercoat the frame.


Fused caps over the holes in the boards where the crossbars were.


Ported the bulkhead side and cut off the lower old body work bung that's yellow.



Cut three of the threaded protrusions out of the chaincase side that were no longer being used.




.100 lbs haha. Every ounce counts.
 
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