Kingers BOOSTED garage....

[Irv]

Looks good Kinger

Just curious where you purchased that Vulcanizing glue?

I have a pull through on my XLT and although it is in the middle of the track and is likely ok to leave it be, I would still like to seal/patch it up.

Thanks

 

[kinger]

I got it on amazon.com its used for tire repairs on bicycles or tube tires. Just get the Rema brand by far the best.

 

[Irv]

I got it on amazon.com its used for tire repairs on bicycles or tube tires. Just get the Rema brand by far the best.

Thanks

 

[kinger]

I got it on amazon.com its used for tire repairs on bicycles or tube tires. Just get the Rema brand by far the best.

Thanks

I'll see if it holds up. If the track comes loose at 150mph and I die in a firey crash....sue Rema for me..HAHA.

 

[Irv]

I got it on amazon.com its used for tire repairs on bicycles or tube tires. Just get the Rema brand by far the best.

Thanks

I'll see if it holds up. If the track comes loose at 150mph and I die in a firey crash....sue Rema for me..HAHA.

Will do!

 

[kinger]

Had a nice Fathers day weekend in the garage and got a lot more done. Here is the ZX2 151" finished up!

I used the bushing between the shocks and marked the center then cut out 1/4" from each side so it will sit flush against the middle bogey wheel I added for the narrow 13.5" wide track

Finished bushing:

Finished and everythign fits perfect for the center bogey wheel WITHOUT THE shock guards on:

Because this is a 151" now the manual for the ZX2 is really CLEAR they want you running the limiter strap short...why? Dont know but I set it per the manual on the tightest setting:

Finished 151" ZX2!

Next I swapped the track and checked out the condition of my AVID drivers they look new after 1000 miles they wear really nice!

Next up I notched the rear exhaust cradle as per the members on this site have indicated it can rub in extreme bottoming out of the ZX2. Finished notch was 1" tall by 14" wide

 

[Super Sled]

This is gonna be wicked when you are done Jesse!!!!

 

[kinger]

Next up was the Hartman 151" tunnel extension. I was hoping this was going to be the easiest part of the job it was not. I bought a custom U cooler over on snow west for what I thought was cheap and wanted to use that. Well it was NOT going to fit in the stock holes with out butchering the cast aluminum exhaust cradle and even then the u cooler wouldn't sit flush to the top of the extension and Im sure would fail at some point. So I pulled the U cooler back and drilled new 1.5"D holes in the extension (painful to do if I screwed up I was in trouble LOL)

No you can see the u cooler hose ends line up with the holes. I had to keep it as far foward as I could so still have the stock side covers hide the rubber pipe.

Here it is all mounted and thought I was done!

I was WRONG again, forgot about the bumper braces Harman sends! Doh!

So those had to be trimmed, I probably weakend them a little but I figured out a way to add material in later to make up for the notch

Final U cooler mount:

The pictures make it look like the hose is going to hit the top of the hole I drilled but the hose ends of the U cooler are angled and the hose sits flush in the middle of the hole.

Heading to a parts store this week to see if I can find a hose to fit everything and a rubber grommet to go around the hole and protect the hose.

More to come...

 

[kinger]

Oh yeah as you can see I got the custom yoshi pipe set up mounted and I fired it up before I drained the coolant and its sounds AWESOME in the garage. Very deep sounding much deeper then stock. Blipping the throttle it doesn't bark much but its hard to say till you get it out on the trail. So far I am thinking between 0-4K rpms its not any louder then stock just deeper. I'm hoping for no drone on the trail but I will see and give a full review once she is on the snow. As much as I HATE swapping the exhaust I hope it works out and I wont have to go back to stock.

 

[kinger]

Happy Fathers day to all the dads! Here is my little Lu (her name is Luella, but she has a million nicknames lol) already loves the snowmobile.

Right now its tore apart in the garage and as SOON as she sees its when I take her to daycare she says "Broke" LOL she is 20 months and starting to talk but how she knew that I wont know. She rules....

 

[yamadoo]

WOW just reviewed the whole thread and you are doing an amazing job. Beautiful sled with power to burn I am sure. Glad to here of you good reliability.

Yamadoo

 

[Redbeard]

I appreciate your enthusiasm...and "Yes" installing the Hartman tunnel extension requires some modidfications and patience. I made a goof installing mine and had to fire up the tig welder to make a repair. Cutting the holes to mount the Nytro taillight housing took some patience also.

I will say I have some interest in a ZX2 for my next skid. My M10 air rides like a Cadillac, but lacks aggression. I will probably wait, however, until I buy another new sled and keep the Vector for my dad.

 

[kinger]

Yes the M10 will trail ride better then the ZX2 no doubt about it, but not by much. Get into the rough and you cant wipe smile off your face the ZX2 rules that stuff. You have to ride it though, faster the better, you have to committ and focus and just hammer down. If you lolly gag and half azz it it will bounce you around a little bit not horrible but not as fun as hitting the stuff at a higher clip of speed and just not bottoming out...ever. On the M10 you can go slow and it will eat them up, go fast and you get the front jarring and the rear. On teh Zx2 with the transfer set right I lean back a little hammer and the front barely hits the bumps and the skid does all the work. Its a fun skid to RIDE!

 

[kinger]

Mock up done, just need to secure the extension in place. I think I will use small bolts vs the rivets I can see me removing this sometime in the future since I never leave anything alone!

Also got a part on the way thanks to Nick1945 that will allow me to finish up the coolant install and button this baby up. Thank you Nick!!!

 

[kinger]

Cleaning up more loose ends. Its always the small details no one sees that take the longest but in the end make for a successful installation with nothing coming apart on the trails!

First up was my exhaust shield that was modified to fit the yoshi pipe. You can see the previous installation of a single rivet cracked the hole and no doubt wont support the pipe as all the weight of the pipe is hanging from this location:

So I mocked up part of the old snow flap aluminum that I had destroyed from too many tail stands, I cut it out and bent it into a curve to match the stock heat shield:

Riveted in place to make a nice strong plate for the exhaust to bolt to:

Next was securing the rear of the heat shield now that there was no 30lb boat anchor to bolt it to. There were "L" tabs on the heat shield for marking the height but I couldn't get to them after the tunnel extension to remove any bolts. So I decided to fab up some brackets I found in the parts bin and bolted them where the old muffler used to sit:

You can see on the inside there was a little 'finger' that supported the shield and the rivet bears no load it just holds things in place:

Another thing I found after I was all done was the shield was rattling? WTF everything was tight and after careful inspection I found the rivets included in the hartman kit that I used all had loose mandrels in them! I have never seen this before in a rivet it basically pulled the outer shell tight then left the madrel in to be all loose. So out came some JB weld and I covered the rivet inside with it to keep the madrel from vibrating. All quiet now!

Back on the exhaust I drilled out the bracket on the Yoshi pipe and tapped it with a 5/16" tap.

While I had the JB weld out I affixed the nut under that tab for extra security. Its not needed since the strap is tapped but now things cant vibrate loose and just avoids any issues later, the rear end of the sled gets a pounding so I wanted it to be secure

Almost done and can get everything buttoned up before I start on the next project on the sled!