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 Post subject: Akpilots Wildcat build
PostPosted: Mon Apr 15, 2013 8:44 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Purchased a Wildcat in Feb of 2012, number #35. Picked up in March and knew it would not stay stock long just loading it up in the parking lot. I decited to ship off clutches before I even rode the thing. So while waiting on clutches I build these:

Ak


Attachments:
File comment: The front bumper needed somthing?
010.JPG
010.JPG [ 68.92 KiB | Viewed 7953 times ]
File comment: So I added Bling......just cus
DSC02951 (2).jpg
DSC02951 (2).jpg [ 60.69 KiB | Viewed 7953 times ]
File comment: Made a rear bumper
046.JPG
046.JPG [ 74.2 KiB | Viewed 7953 times ]
File comment: Then took a '99 GSXR pipe from the 1/2 off bin, cut front off and welded to fit Wildcat.
005.JPG
005.JPG [ 79.92 KiB | Viewed 7953 times ]
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PostPosted: Mon Apr 15, 2013 8:54 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Second or third ride my daughter's friend decited the Wildcat was too slow after the Nytro Pilot so he decited to go out of view and wring her out......well he rolled it doing 6500 dollars damage. In Alaska if you loan out your car, trailer, wildcat or what ever you also loan out your insurance....So yea my insurance took a hit. I ended up cutting and welding original bottom frame and built my own upper cage. Puchased new doors, fenders ect.

Ak


Attachments:
File comment: Building the new cage
005.JPG
005.JPG [ 101.5 KiB | Viewed 7950 times ]
File comment: A ride out at big lake just before Tyler and I decited to put in the Apex
DSC03035 (2).jpg
DSC03035 (2).jpg [ 114.49 KiB | Viewed 7950 times ]
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PostPosted: Mon Apr 15, 2013 9:07 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Since the Wildcat Engine and trans are one unit I needed a transmission. I'm going with a Polaris 900 XP trans. Looked on RZR sites and they have good track record of Apex's in both RZR S' s and 900's so that's what I'm doing.


Attachments:
File comment: Cut frame just behind the seats and just below the hip rail. Made a jig table holding original subframe
SDC12308 (2).jpg
SDC12308 (2).jpg [ 71.09 KiB | Viewed 7947 times ]
File comment: XP 900 Trans is wider so I'm making the suspension mounts wider - 3/4" on each side
SDC12307 (2).jpg
SDC12307 (2).jpg [ 66.98 KiB | Viewed 7947 times ]
File comment: Bottom of new subframe with new lower mounts
SDC12313 (2).jpg
SDC12313 (2).jpg [ 74.29 KiB | Viewed 7947 times ]
File comment: XP trans with upper suspension mounts.
SDC12318 (2).jpg
SDC12318 (2).jpg [ 72.12 KiB | Viewed 7947 times ]
File comment: Setting in the motor (( Internal Combustion Engine ? )). I originally purchased this Apex before the Nytro Pilot build, but the motor (( Internal Combustion Engine ? )) was too wide for that frame so I made it into a sled and rode it for the past 4 to 5 seasons.....LOVE this motor (( Internal Combustion Engine ? )) but it was always destin for a buggy.
SDC12320 (2).jpg
SDC12320 (2).jpg [ 77.98 KiB | Viewed 7947 times ]
File comment: All wedged in.
SDC12325 (2).jpg
SDC12325 (2).jpg [ 92.36 KiB | Viewed 7947 times ]
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PostPosted: Mon Apr 15, 2013 9:16 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
continuing on.......


Attachments:
File comment: Header will be FUN!!! Yea that is 1.5" from #1 cylinder to trans.
SDC12322 (2).jpg
SDC12322 (2).jpg [ 84.97 KiB | Viewed 7945 times ]
File comment: Making rear mounts
SDC12333 (2).jpg
SDC12333 (2).jpg [ 75.72 KiB | Viewed 7945 times ]
File comment: Front mounts, which I changed....
SDC12337 (2).jpg
SDC12337 (2).jpg [ 86.28 KiB | Viewed 7945 times ]
File comment: Basic sub frame
SDC12336 (2).jpg
SDC12336 (2).jpg [ 74.54 KiB | Viewed 7945 times ]
File comment: Test fitting to see if she fits, front lower mounts
SDC12340 (2).jpg
SDC12340 (2).jpg [ 86.77 KiB | Viewed 7945 times ]
File comment: This is how the rear mounts up to the hip rail
SDC12341 (2).jpg
SDC12341 (2).jpg [ 94.15 KiB | Viewed 7945 times ]
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PostPosted: Mon Apr 15, 2013 9:26 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
More


Attachments:
File comment: She fits, I will be pushing out the trailing arms to the outside of OEM mounts and make new outer mount
SDC12346 (2).jpg
SDC12346 (2).jpg [ 88.29 KiB | Viewed 7942 times ]
File comment: OEM radiator fits, so does the rear bed.
SDC12347 (2).jpg
SDC12347 (2).jpg [ 85.78 KiB | Viewed 7942 times ]
File comment: Only the right rear radiator mounts need to be relocated.
SDC12348 (2).jpg
SDC12348 (2).jpg [ 96.15 KiB | Viewed 7942 times ]
File comment: Start of the header, 4 each 1.5" stainless tubes on the notcher
SDC12350 (2).jpg
SDC12350 (2).jpg [ 91.64 KiB | Viewed 7942 times ]
File comment: Each tube gets two cuts
SDC12351 (2).jpg
SDC12351 (2).jpg [ 67.57 KiB | Viewed 7942 times ]
File comment: 4 tubes to make up collector
SDC12353 (2).jpg
SDC12353 (2).jpg [ 64.47 KiB | Viewed 7942 times ]
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PostPosted: Mon Apr 15, 2013 9:48 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Again more.....

The exhaust has expansion/vibration joints but I also want the header to be rubber mounted that's why I'm looking for the Pilot Engine/trans mounts they work great.

Ak


Attachments:
File comment: Start with furthest away, made this tube the same length as the stock header. As you can see I used header donuts to move #1 & #2 cylinders up above the trans.
SDC12354 (2).jpg
SDC12354 (2).jpg [ 93.31 KiB | Viewed 7938 times ]
File comment: #3 cylinder, I'm using masking tape to hold together as I build.
SDC12355 (2).jpg
SDC12355 (2).jpg [ 88.84 KiB | Viewed 7938 times ]
SDC12356 (2).jpg
SDC12356 (2).jpg [ 91.22 KiB | Viewed 7938 times ]
File comment: Now the fun one.
SDC12358 (2).jpg
SDC12358 (2).jpg [ 88.34 KiB | Viewed 7938 times ]
File comment: Another shot of #1
SDC12360 (2).jpg
SDC12360 (2).jpg [ 81.04 KiB | Viewed 7938 times ]
File comment: Finally #2 cylinder. The tubes are within 3/8" of each other which was tough enough for me! But so far this has been the best part of the build thus far, the hardest usually is.
SDC12361 (2).jpg
SDC12361 (2).jpg [ 83.82 KiB | Viewed 7938 times ]
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PostPosted: Mon Apr 15, 2013 10:05 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
My NEMESIS the Gas/Oil tank combo.


Attachments:
File comment: Start of the Sump
002.JPG
002.JPG [ 78.15 KiB | Viewed 7934 times ]
File comment: OEM fuel pump in sump
005.JPG
005.JPG [ 52.09 KiB | Viewed 7934 times ]
File comment: The sump is large because the pump on the right side and the 4X4 shaft on the left side
003.JPG
003.JPG [ 71.29 KiB | Viewed 7934 times ]
File comment: Main tank taking shape
m003.JPG
m003.JPG [ 66.33 KiB | Viewed 7934 times ]
File comment: Filling in the little voids to get as large of a tank as I could. When I started I was thinking I had plenty of room but it's going quick
MG001.JPG
MG001.JPG [ 45.6 KiB | Viewed 7934 times ]
File comment: Basic upper tank, hugging the plastics as best I could. Oil resivior will be on the left.
MG006.JPG
MG006.JPG [ 67.73 KiB | Viewed 7934 times ]
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PostPosted: Mon Apr 15, 2013 10:15 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
More tank


Attachments:
File comment: Fuel sending unit mount
gas tank 017 (3).jpg
gas tank 017 (3).jpg [ 57.56 KiB | Viewed 7931 times ]
File comment: Fuel pump mount
m001.JPG
m001.JPG [ 30.52 KiB | Viewed 7931 times ]
File comment: 1/4" tabs weld to gas tank and oil tank, then a weld to hold the oil tank onto the gas tank. In the 1/2" void will be fiberglass heat sheild just like I did on the Nytro Pilot.
MH001.JPG
MH001.JPG [ 31.93 KiB | Viewed 7931 times ]
File comment: Oil tank taking shape
MH003.JPG
MH003.JPG [ 31.8 KiB | Viewed 7931 times ]
File comment: Oil tank sump
MI002.JPG
MI002.JPG [ 36.4 KiB | Viewed 7931 times ]
File comment: Inner baffeling for oil tank. The tube is the return air to the crank case. This will be MUCH easier than the Nytro as the Apex case is vented not by this tube, so if oil does make it back to the case no big deal. On the Nytro this tube goes to the air box, and yea I fought it!
MI011.JPG
MI011.JPG [ 62.8 KiB | Viewed 7931 times ]
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PostPosted: Mon Apr 15, 2013 10:28 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
This is where I'm at now, man wish the build took as long as this posting...... I'll update this with my thread on Wildcat.net, this is a bit condensed but probably better for viewing.
Still need to weld the top of the oil tank and it is done, build the back and top of the gas tank, but probably going to start wiring as the tank will mount most of the electronics, so I need to know where they go. Its definately nice to have a removable subframe! no bending over and climbing around a Pilot frame :-) . Can't take credit for the subframe that goes to Proto die, always liked how everything goes in and out easily. The only thing I'll need to disconnect is the coolant along with the wiring.

Ak


Attachments:
File comment: Dipstick! No not me the oil dipstick
MI004.JPG
MI004.JPG [ 70.52 KiB | Viewed 7929 times ]
File comment: Gas filler taking shape. This tank is going quick compaired to my other builds. No foam 3d model like the Nytro. I'm just wingin' it with lots of construction paper.
MI014.JPG
MI014.JPG [ 67.4 KiB | Viewed 7929 times ]
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PostPosted: Mon Apr 15, 2013 10:50 pm 
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Joined: Mon Jul 19, 2010 3:20 pm
Posts: 1718
Location: saskatoon, sk, canada
you got some mad fab skill..keep up the good work


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PostPosted: Mon Apr 15, 2013 11:49 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 7698
Location: Hope, B.C Canada
Nice work. You are obviously skilled at fabin.


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PostPosted: Mon Apr 15, 2013 11:51 pm 
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Joined: Tue Jan 17, 2012 3:19 am
Posts: 7698
Location: Hope, B.C Canada
I do have a question though. Why would you use a holesaw and not a milling bit to cope pipes??
Milling bit would last longer wouldn't it?


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PostPosted: Tue Apr 16, 2013 2:29 am 
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Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA
when that 150 hp ain't enough you can turbo it :-)


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PostPosted: Tue Apr 16, 2013 5:10 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
XP trans has a chain drive for reverse and they are breaking :shock:

Project looks good cant wait to see it finished looks like a lot of work, should be a really fun machine.


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PostPosted: Tue Apr 16, 2013 9:26 am 
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Joined: Thu Jan 12, 2012 11:35 am
Posts: 2010
Location: Ottawa, IL
Nice job on the fuel tank! I was wondering where the AKpilot got that fancy tank. Great work.


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PostPosted: Tue Apr 16, 2013 10:22 am 
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Joined: Wed Jan 21, 2009 10:11 pm
Posts: 3496
Location: houston
Youve got some skills,great job
Daughters friend sounds like a douche


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PostPosted: Tue Apr 16, 2013 1:31 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Thanks guys, Yea my wife still does not know why I do this but to me it is relaxin', I like building more than riding :shock: Mostly because here in Alaska we don't have dunes, only snow and mud. Hence why I got a 4X4 buggy.

Hoser - yea I heard of the reverse chain issues, don't plan on muddin' this just go out to river beds and old logging roads. A couple of other WC owners want me to go with them but where they go it just destroys them, not my cup of tea.

Canadian Oddy - milling bit would be better, but I only burned up one hole saw bit making the header. I don't use the notcher much, with cromolly I just bandsaw/grind notch, it does however work great on Aluminum. Made a couple of roof cages for the boss' Argo's and it worked great, also the Wildcat bumpers.

BS - Yea, I need to either make a smaller gas tank or it's getting boosted. :-) On the Nytro I put the airbox on top of the tank but this tank would be pretty small, right now I'm looking at a 10+ gallon tank but with airbox....much smaller. A couple of my sled heads buddy's are pushing for it, we'll see. Trany is my big hang up right now.

Ak


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PostPosted: Tue Apr 16, 2013 8:25 pm 
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Joined: Tue Dec 23, 2003 10:31 pm
Posts: 5559
Location: New Jersey
Each and every thread and or project you do I am glued to the thread. You skills are unmatched, your projects are bar none informative, cutting edge and always crafted to perfection with safety, clean lines, superb welds and items fabricated with ungodly craftsmanship.
Very nice, please keep us updated! :-)


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PostPosted: Wed Apr 17, 2013 2:06 am 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Mudbogger,

Your making me blush :-) ....I appreciate it. I too enjoy reading a thread that gets into the How to, and pics, I learn as well. BTW if anyone has questions on how I did something just ask.

Ak


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PostPosted: Wed Apr 17, 2013 6:18 am 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Yeah,I have a question! :shock:
What made you want to be the DastardlyDuneBuggyDiablo huh???Image
How many souls do you own now(notice own/now similarity?),how do you sleep at nights.............................you DO sleep? Image


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PostPosted: Thu Apr 18, 2013 11:37 am 
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Joined: Thu Oct 30, 2008 8:22 pm
Posts: 2641
Location: Rancho Cucamonga, Ca
I gotta wonder, why did you even buy a WC in the first place? With your skills, why didnt you just buy the components you need and build your own UTV?


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PostPosted: Mon Apr 22, 2013 1:23 am 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
Nick

Yea that probably, but this one was not suposed to be modified.....or well that's what I told my wife.


Attachments:
File comment: Setting up the fuel gauge. sending unit just misses baffle. I straightened out float wire and added all I could, would have liked to have float at bottom.
070.JPG
070.JPG [ 64.33 KiB | Viewed 7750 times ]
File comment: bottom sump is just a hair over 1 gallon. I'll have 3 gallons once gauge hits empty. Tank is 12 gallons
076.JPG
076.JPG [ 88.99 KiB | Viewed 7750 times ]
File comment: Start of wiring, stripped and ready to start cutting
088.JPG
088.JPG [ 65.29 KiB | Viewed 7750 times ]
File comment: Been around Pilots too long, mimiking the metal wiring tabs.
089.JPG
089.JPG [ 82.05 KiB | Viewed 7750 times ]
File comment: Mounting all the electrical on the tank. Yea the tank is mounted with Honda Engine mounts. Works great as they are mounted in single shear, that way subframe can move away.
090.JPG
090.JPG [ 83.01 KiB | Viewed 7750 times ]
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PostPosted: Mon Apr 22, 2013 4:03 pm 
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Joined: Thu Apr 29, 2010 12:53 am
Posts: 1430
Location: Norco, CA
Akpilot wrote:
Nick

Yea that probably, but this one was not suposed to be modified.....or well that's what I told my wife.


It's just a slight modification :shock:


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PostPosted: Wed Apr 24, 2013 3:01 am 
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Joined: Sat Mar 03, 2012 11:45 pm
Posts: 3610
Location: CHICO,CA
the apex's are great engines.
there basically an R1 Engine without the trans

the tig welding looks great
what brand/model welder you using ?


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PostPosted: Wed Apr 24, 2013 9:23 pm 
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Joined: Sun Sep 25, 2005 2:03 am
Posts: 185
Location: Anchorage Ak
BS

Started out with a Lincoln 175 Pro but the Fl800 tank was too big, could not get enough heat on it so I purchased a Lincoln 275.

Ak


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