RMK 800 modsled buildup

[FORMULA51]

Finally getting all the parts together for the big boy track on my sled. I'm doing a 156", 2 1/4" lug edge track on my shorty gen II. The tunnels on the genII polaris are actually a 121 tunnel with a 136 extension on it. So i decided to use a EDGE XC 121 - 156 tunnel extension. I'm eliminating the rear cooler and using 2' of heat exchanger material. I'm cutting the tunnel longways, and am running the new cooler under the tunnel like on the ski doo.

I'm taking all my skid parts minus the pretzeled rails, and putting them on the new edge 156 rails. I have some minor cutting and drilling to do, but so far it's going as planned.

I'm using the SLP anti stab kit, which is shortening the front of my rails to stop the rails from stabbing thru the driver windows, also creating a lot less friction on my track. I'm doing a big wheel kit and using ice scratchers to keep the hyfax cool. I'm gearing much lower to climb like a madman. I believe the gearing is 19/41 but not quite sure off the top of my head. I'll have to double check tonight when i get home.


I figure i have about a month left until i need to be ready...

Pics to come soon of the transformation. :thumbsup:


Comments, questions?

[diesel-hunter]

Sounds like a good swap, interested to see how it turns out. Better get it done quick, riding is all I can think about.

[CSP]

So will the coolant still flow through the rolled portion of the running boards/footwells?

If not you might consider altering the running boards so that snow will fall through them instead of having to kick out chunks of ice as you ride.

Sounds like a good plan. Are you having to remove the tunnel from the bulkhead? That would suck. I did it once and hopefully never again.

[FORMULA51]

So will the coolant still flow through the rolled portion of the running boards/footwells?

If not you might consider altering the running boards so that snow will fall through them instead of having to kick out chunks of ice as you ride.

Sounds like a good plan. Are you having to remove the tunnel from the bulkhead? That would suck. I did it once and hopefully never again.


ya i'm still using the rolled running boards. I have a piece of heat exchanger and am running the hoses out of one end. The heat exchanger has 2 channels. Here's a cross section of it...

http://startinglineproducts.com/img/products/large/cooler-material.gif


I'm going to cap one end and notch the same end so it flows in one way and out the other. (in one one rail and out the other).

I'm putting the flaps down so i get more snow / surface area to the cooling surface area.


I'm not removing the tunnel from the bulkhead as i only need to fit the XC tunnel extension on, so i'm doing drop brackets in the rear to clear the tunnel with the deeper lugs and the cooler running longways in teh tunnel, like the new rev.



here's where i'm at tonight. i got the suspension from my gen II mocked up to the edge rails w/ the anti stab kit and such, and decided to throw the skid uner the sled...

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1130.JPG

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1131.JPG

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1132.JPG

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1133.JPG

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1134.JPG




so i need my big wheel kit and my tunnel extension, and other than that i should be good to go other than cosmetics... :thumbsup:


any questions comments or flames?


Let me know as this is the first swap i've done like this before. :beer:

[MN-XJ]

Looks good. :thumbsup:
I used to work @ Hot Seat Performance back in MN. LOVED sleds, and I sold
mine before I moved out here for school.

Good call on the running board heat exchangers. Alot of people don't understand that on a powder sled, those heat exchangers are litteraly dragging through the snow, cooling down much better.
And as far as the heat exchanger on the rear 'tail', they are pretty much worthless.

I shoulda never read this thread, 'cuz now I miss my old sled. :drool:

Oh, and you'll notice a nice difference in less friction with the big wheel kit. The smoother you can make those curves the better.

[CSP]

I think I've mentioned it before, but since you have it apart I'll mention it again. A roller secondary clutch would give you a lot more seat of the pants, noticable increase in performance than the big wheel kit.

I've done pipes, clutching spring changes, air box changes, etc. and none of them were as noticable as swapping in a roller secondary. There's a whole lot more reduction in friction there than you get from the big wheel kit (not that I'm discouraging the big wheels).

Just food for thought since it is all torn down and you're spending some coin on it. :beer:

[FORMULA51]

ya i'm not doing the big wheel kit til next year when i run a 159. looking around for the roller secondary, may need to hold off a week or two to get one. I found one on ebay for roughly 200. seems like a good deal.


Last night i didn't make any progress as i was hanging shop lights. I'll be choppin and hackin things until my rear idler shows up.




It's not as bad as it seemed before i started. I need to find a place that sells small enough fittings that i can weld onto that heat exchanger. Anyone know of any good sources?

[mdurbahn]

i just picked up a team clutch on snowest for 110 shipped, see them on there for about 150 alot

[dave m]

I had an 02 800 156, and never had any overheating issues with it. So based on that, I would have stuck with the rear heat exchanger as it is rivet on and go. You're just making it harder than it needs to be. Another point is that you will need to keep the tunnel mounted exchangers at the back of the tunnel as the track will actually contact the top of the tunnel towards the front.

[FORMULA51]

Ok. i got all my big parts parts that i needed to get it moving. Tonight i'll be putting the chaincase back together, putting my tunnel extension on, drilling 1" holes the length of my track down the center, then mounting the track.


Other than that it will be cosmetics! I'll post up some pics tonight.


Oh, and i'm still doing the heat exchanger that i got from SLP.

[FORMULA51]

Due to my girlie's birthday party festivities, i had to put the sled on hold for a week. Here's what i have left...

my chaincase to be assembled...

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1252.JPG

my rear drop brackets to be installed...http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1253.JPG



and my cooler to be mounted, rear flap, and rear bumper....

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1250.JPG

much better from this action from last year...



http://www.colorado4x4.org/gallery/files/4/6/0/8/RMKCRASH2007002.jpg


lotso work has been done, and yet lotso work to be done. I plan on having this thing moving on its own by thanksgiving.


money money money :thumbsup:

[mattpenhollow]

siiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiick sled

[CSP]

Did you find the caps for the heat exchangers? What rail extenders are you using?

Good thing there's no decent snow out there now. I'd be riding your a$$ for taking so long! :flipoff2:

[FORMULA51]

Did you find the caps for the heat exchangers? What rail extenders are you using?

Good thing there's no decent snow out there now. I'd be riding your a$$ for taking so long! :flipoff2:


sure did. I'm using edge 156 rails, with no extenders...

If there were snow i don't think i'd have a girlfriend right now! jk babe! :D


You gonna ride this year CSP?

[CSP]

I sure hope to. I'm trying to wrap up my "must do" project list on my new house soon. Last weekend we installed 550 sq ft. of hardwood floors so I only have baseboard trim that absolutely has to be finished before the big snow flies. My big sled has been dead since last winter and I haven't had the five minutes it takes to determine if the problem is the CDI or the stator. That has sucked cause there's been no wheeling either. My CJ hasn't moved for 4.5 months.

Good call on the 156 rails. I should have gone that route and gotten rid of my Xtra-10 suspension in favor of the Xtra Lite. Maybe on the next go round.

[FORMULA51]

ya i haven't wheeled my built jeep since EJS. No wait, come to think of it, my clutch went out the moment i dropped into steelbender going backwards. Nothing like trying to back out of that creek up that rock ledge with no clutch. :thumbsdown:



i looked like such a sissy having to be winched out of that creek by my ass end :shrug:

[FORMULA51]

http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1288.JPG


http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1289.JPG


http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1290.JPG


http://www.colorado4x4.org/gallery/files/4/6/0/8/100_1286.JPG


just need to put my bumper on, 2 lower wheels, ice scratchers, and my chain and i'm ready!! :thumbsup: oh and i need to tighten my track.



oooooooh ya!


and i put on my SLP high flow air box... more go!



eventually i'm going to figure out how to protect those hoses in the rear. I can't wait to see green blood pumping thru the veins of this beast :evil:

[Bauer]

:drool: :drool: :drool:


Giddy up :hail:

[CSP]

[QUOTE=FORMULA51;944162eventually i'm going to figure out how to protect those hoses in the rear.[/QUOTE]

When you do, try and incorporate some sort of rack to carry a gas can, or gear bag in at the same time. I made a really simple one out of some flat aluminum stock bent into 90? and some aluminum solid rod, drilled and tapped to tie the sides together. I'll try and snap some photos for you.

Congrats on getting it together.

I have to get my electrical problem figured out so I can unload the sled from the trailer and use it to move someone. :rolleyes:

[FORMULA51]

ya i definitely need a gas can rack, and a beer holder err i mean a gear holder :D


i'm very impressed as this is my first ever sled build up that's not a "bolt-on" thing.


when our sleds are up and going, lets tear up a mountain or two?

[FORMULA51]

guess who's ready to ride?

[sonofmayhem]

Not CSP:flipoff2: And i don't have one. So I am gonna guess you are!:D

[FORMULA51]

thats right mo fritter!!! i've already been riding it around the neighborhood to make sure i don't have anything going wrong....


LET'S ROLL!

[CSP]

I finally got my computer at home set up, so here's some pictures of the simple gas can rack I built along with my homemade tunnel extension (pre-polishing).

http://www.dana60.com/csp/tunnel2.jpg

http://www.dana60.com/csp/tunnel3.jpg

[sonofmayhem]

Nice, snow mobiling seems so much different. There must be tons of variables while riding. I hope to get to do it one day.