Broken Bulkhead

[sledmontana]

Hey anyone had this happen? I had a pretty tough hit on a rock last year and I bent my stock spindle; think that may have cracked this originally. Replaced that with the Barkbusters which are GREAT! Since then the plastic bushings have compacted and it has a lot of play in the front end; but this finally happened last week. So, i tore it down and have the parts on the way(both bulkheads and Oilite bushings). Gonna overhaul front end with Oillite bushings and maybe even Fox Floats. Also thought about a oil filter relocation. I'll get some pics up tommorrow of it tore down, but got both bulkheads out today; WHEW! Any other suggestions while I have it all apart? Tips on reassembly?

 

[sledmontana]

You may also see that the aluminum A arm bolt broke too. If you have BarkBusters I recomment still using your stock steel pins/bolts. the other ones I removed were slightly bent also...

I love the barkbusters, but those aluminum pins are weak.

The top right one; I already replaced a couple months ago with stock steel.

 

[bjowett]

Thoughts of some quick gussets or straps between mounting bolts would do wonders for strength.... I am not convinced they break here to save something more expensive down the line. If one views pictures of the old Nytro snowcrossers the front aluminum bulkhead is replaced with a tubular steel structure.

Triangles are stonger but this would probably do it. There's room at the rear mount points to do something like this also...

 

[sledmontana]

Brian, thanks for that idea and illustration. I am looking into fashioning something of the sort. At least on the bottom, beacuse if you take a hit from rock, drift, etc, it will pull out on the lower. Uppers compress. But your idea is worth it there, because thesea are a BIG job to replace.

 

[LazyBastard]

Why are you replacing? Get the piece welded back on and add the straps and it'll be stronger than new at a cost of only about $30.

 

[sledmontana]

LB, I guess I didnt consider the strength I could get back by welding, but with the bracket and both of you guys help, i will do that. Save my $ for Fox Floats! Thanks!!!! I still have them out, but will make the insertion of Oilite bushings, welding, etc easier with room to work. The holes where the bushings have worn, so I mayhave the welder build it up too. The plastic bushing was blown out on the upper right rear a-arm when i bought sled with 350 mi. on it and wore a few mm, made front end sloppy. I hope the metal bushings will keep it real tight. If I use AIR shocks, do i need the torsion bar/sway bar still?

 

[jkenosh]

i had the same thing happen on my apex with a 10 mph hit on a 45 degree angle. Im going to replace the right bulhead and all the a arms which are bent and the bolts that look like pretzels. i had to grind the bolts thru on both sides of the lower a arm to get em out. going to build a gusset for the front end, in the mean time i bought a srx and am going to ditch-bang with that instead

 

[SharkAttak]

wow, what did that?

 

[jkenosh]

i think its when you hit them on a angle that the motion has no where to go i see it alot on skidoos also

 

[sledmontana]

Ya, I caught a SOLID rock with my carbide and I think that is when it cracked; you can see the darker area of the broke off piece. Then after time( about a year) it finally weakened and blew out because I never really hit anything too hard since then. i'm stkoed to get it all tightened up again though. this sled is awesome! I have Nytro too an love to switch back & forth. The Ape has that extra pull that is soooooo addicting!