Spawn Build Ongoing

OK. So I got the garage rearranged today after finishing up the wife's sled. I put new shocks all the way around on that, HPG's in the front, and FOX in the rear, put new hyfax on it, removed (meaning had to press out the rear axle) and re-greased all those up, put an E-Start on it, put mechanical reverse in it and it is ready to roll.

I also did the once over on the trail sled and changed fluids, as I did on the mountain sled. I just have to hook up the throttle cable and put the axle bolts in that it is ready to roll.

The shock business, the wife's sewing room, her sled, my sleds have been keeping me hopping. I took off an extra day last week to get caught up. That gave me 5 days off from Toyota and I got a TON of stuff finished up.

I also got Spawn on the rack.

I put the chaincase on it, put the track under it and put the axle in place to check clearance. I have just short of a half inch clearance. I am going to run with that, then I don't have to make a new chaincase for the drop and roll. That made life a little easier.

This week I am going to work on getting it stripped down and the tunnel cut off. I can then get that over the powder coaters. Then I can do the tunnel in one piece and send that off then connect them when they are back.

Here are the shots from today.

After getting everything set up.? I wanted to see what I had for clearance with the chaincase, driver shaft and track installed.? All my preliminary measures said it would fit.? All the research I have done says it wouldn't.

After all was installed, I have 3/8" clearance with no tension on the track.? I am not going to make a custom chain case, and can use the stock chain case.

I did some test fitting tonight. I wanted to make sure the A-Arm bushings and aluminum sleeves fit the delrin bushings.

I also wanted to make sure all the West Coast Sled stuff bolted up. Of course it all fell right into place.

I have the A-Arms installed for fit, with the shocks and the titanium springs and the Pilot 6.9 skis (that aren't exactly in great shape like the seller claimed.)

Here are some shots of the test fittings. This weekend the bulkhead is coming apart and the tunnel is getting cut down so I can get the braces installed and to the powder coater.

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I did some test fitting tonight. I wanted to make sure the A-Arm bushings and aluminum sleeves fit the delrin bushings.

I also wanted to make sure all the West Coast Sled stuff bolted up. Of course it all fell right into place.

I have the A-Arms installed for fit, with the shocks and the titanium springs and the Pilot 6.9 skis (that aren't exactly in great shape like the seller claimed.)

Here are some shots of the test fittings. This weekend the bulkhead is coming apart and the tunnel is getting cut down so I can get the braces installed and to the powder coater.

Thanks, but I will keep the belt guard. When the clutches are dialed in properly, heat shouldn't be an issue. I will be putting vents in though. I just haven't decided what, yet.

I got a couple of days off with no shocks (a bunch coming in this week, though) and did some PR on a fun run with the Snow Pioneers this weekend.

I got 130 miles in on Saturday with temps below zero all day. When I left at 9a it was -15* and when I loaded up last night it was about -9*.

I tested the new knees out proper and they are a little light in the endurance, but everything else worked fine. My shoulders and arms are more sore than my legs from the hammering they took pounding moguls.

Anyway, today I got to work on Spawn. I got it all stripped down to the tunnel. I got a bunch of stuff ready for the powder coater that I will be taking over this week.

This week I hope to get the tunnel cut from the bulkhead. MY VanAmburg footwell edges will be here this week so I can start mocking up my running board so I can get the Snow Eliminators ordered.

Once I get everthing fitted up and the tunnel bent up. I can ship the bulkhead off to be powder coated and I can work on the rear section with the side bracing and rear grab bar.

                                       

This is next round of powdercoating. It is the all of the pyramidal supports and and a few other items. Tomorrow, I need to drill out all the rivets and get the plastic off of it, then off the Cool Concepts.

OK. I got some pictures done up today of the progress.

I got the bulkhead removed from the tunnel today and the A-Arms tabs finished up.

Here are the pictures of the bulkhead with all the stuff removed so I can start installing the Matt Santwire bracing. I have the front of the NUN removed and the MAG side bulkhead brace removed in these pictures.

                                       

Here is the body work I did on the area under the chaincase. I didn't take any before pictures (sorry, I forgot) but you can see the "message" marks from hammering it out.

Here are the parts that were removed.

I removed the pyramidal support brackets and seat brackets.

I removed the steel footwell supports so I could cut out the bulkhead. The new bulkhead will over lay in that area.

Here is the bulkhead removed from the tunnel. I left a tab for each area around where the A-Arms mount. The new tunnel will tuck up under the factory locations in front, but my own area on the rest.

These are the rought cuts. The tabs will be filed down so they are straight, and the old rivet holes will be tigged up and then DA'd to smooth out before the powder coater takes over.

                                       

Got back from Eagle River last night, I had today off work, so I got some custom sled time.

Today I got the bulkhead finished up and ready to be sent to the welder. I am having all the old rivet holes welded back so there are no 'extra' holes in the bulkhead.

I also cut fillets in the tabs for the front arm mount. I wanted that to be double walled. I also will reinsforcement on the sides. I cut the size down on the sides.

l also got the tunnel mocked up in cardboard. Here is what is similar to what will be on the sled.

I have the VanAmburg running board edges, they will need to be cut to length and the end plate welded. The back of the running I am going to leave open for two reasons. There isn't anything to attach the piece to, and my High Jacker will fit through it then.

I took the afternoon off work today and worked on the bulkhead. I got the old holes welded up, and one side finished and ready to go.

Here is a picture of the holes welded on the one side. I had a little warpage, but not bad. The finished side is shrunk, and hammered back into place.

Here is the other side completed: (I am not sure how well the shots come out, so I had two different lightings)

Well.  The bells quit ringing (I have been off all week with a concussion) so I decided to work on the sled today.  I got the tunnel bent up and all the test fitting done.

I can now get the rear cooler cut down, the elbows cut out and the whole thing welded up.

I got the footwells where I want them so I can order the set of Snow Eliminators tomorrow.

Here is all the tunnel parts test fit and tweaked.  I have to make the side supports for where the VanAmburg edges will bolt to the side of the tunnel.

That should make them extremely sturdy.  It will have the edges welded to plates and those will bolt to the side.  It will have the rear drop brackets for more rear support, the Snow Eliminators in the center, and the front metal footwell fittings as well as the front footwell sides and braces.

Well. I got off work today and hit the shop. I got some guys from Illinois coming tomorrow to have their shocks done up.

Today, I got the VanAmburg rails fitted to the footwell and tunnel. The plates on the back will be TIG'd to the board for support and then bolted with a backing plate to the tunnel. I got the measurements to Terry at Snow Eliminators last night so I should have them next week.

I got the cooler cut to length, tomorrow after I get the shocks done up and then go bowl for Big Brothers and Big Sisters I need to get the elbows cut off so I can get them TIG'd up this week.

I am sending the cooler to Liberty Anodizing in West Liberty, IA. They are going to anodize the cooler black so I don't lose any cooler capacity. Once the tunnel is done up I can TIG the brace on the bottom and then ship it off to be powder coated. Hopefully, I can that finished up this week, too.

Anyway, you can see how much wider I made the running boards for this sled. That leaves a lot of room to move around for boonedocking. I also included some shots of the rear drop brackets I use. These are from the older summits. The give excellent support for the running boards.

           

I got a lot of work done on the sled in the last few days. Tonight I got the welds done up for the MS bracing, the VanAmburg running board edges and the cooler done up.

Unfortunately, I forgot to take pictures of the cooler before I got it packed to be shipped to Liberty Anodizing to be anodized black. I will get shots of that when it gets back.

Here is a shot of the brace welded in place:

Here are a couple of shots of the VanAmburg running boards edges welded up and ready for final fitment. Once fitted, I can get them to the powder coater.

              

I also got the rest of the titanium springs for the skid. I got rear torsion springs from GLHPerformance here on Dootalk (thanks, BTW) and the center dual spring set up from Renton Coil Springs.

Here are the rear torsion springs:

Here is the dual-rate set-up:

The shock business is kind of winding down for the season. I got to work on the sled all weekend.

I got the extensions fitted up, the rear skid torn down for powder coating, and some other pieces ready for the powder coater. I still have many other items to go to powder coaters, but need to wait until I get the items test fitted with the new powder coating.

Here is the extension for the 154 to 163" with the 9" 2-wheel offset axle.

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