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Project 2800 pilot
http://www.pilotodyssey.com/PO/viewtopic.php?f=34&t=9119
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Author:  mudbogger [ Mon Nov 03, 2014 6:19 pm ]
Post subject:  Re: Project 2800 pilot

Oh yeah. In the works as we speak. I have 4 LT pilots and all will have it when all is said and done. It is a game changer for sure. Shoot i am shipping them nj to ca to get it done that's how much i love it!

Author:  Dave-Co [ Mon Nov 03, 2014 6:21 pm ]
Post subject:  Re: Project 2800 pilot

I use Super ATV universal kit on all my pilot. It forsure is not a slap it on type of Mod, it is a lot easier now that I have done 7 or 8. I am sure it could be installed onto a 350 doing it along the same way a pilot is done, I cant imagine driving with out it now that all my pilots have it.. The ps kits were 750.00 then dropped to 650 then to 519 last I checked, they come with funky 17mm splines that couplers do NOT exist for that size, I have been buying 11/16 x 3/4 couplers and modifying them by cutting a slot in them then welding cut pieces of 3/4 x 1/2 tubing on each side of the slot so I can put a bolt in and squeez it onto the splines. The kit comes with 2 U-joints to fit it but there is no way to use them in the tight confines of the pilot. I have modded the splines in the U joint to work on 1 of my pilots but the other way is easier. It comes with a plate to mount it that has to be cut down to fit. You also need some more plate to make it install, I use 1/4 4130 plate myselt and it works well . It is a involved process to do it right where it wont fail and cause you to crash :shock: I modify the steering colom and steering shaft.

Author:  B S [ Mon Nov 03, 2014 9:16 pm ]
Post subject:  Re: Project 2800 pilot

Mudbogger wrote:
had some time this weekend to install all the plastics and shore up this pilot. it needed a little things to be done like extensions for the tachometer and other small items but the plastics were a real pain in the butt. everything had to be custom fitted to fit the electronic power steering and multiple bars for the roll cage and such.
I cannot run stock rims the offset hit the tie rod ends so I installed my OMF rims off of the terrible pilot they work quite well. It still needs some minor modifications to a bracket or 2, and then it is time to ride

here are some finished pictures.


looks like the fronts are on backwards lol :-)

Author:  fully [ Mon Nov 03, 2014 10:54 pm ]
Post subject:  Re: Project 2800 pilot

mud you will have a wicked fleet of pilots when there all done..

dave-co. that does sound like a lot of work. but sounds like it well worth it in the end. it i might have look into it someday...not sure if your will to share some pic of how you installed it, but it sure would help a guy figure it out..

Author:  rmesser [ Tue Nov 04, 2014 10:08 am ]
Post subject:  Re: Project 2800 pilot

I second the picture request. I would even pay for some plans or sketches. I was looking under my pilot last night try to see how in the world the power steering unit will fit. Looks tight to me. Do you even use/need the universal joints? Do you alter the tub in anyway?

Edit / update. After looking closer at Muds pictures I see the power steering electric-motor (( Internal Combustion Engine ? )) is being mounted between the column black plastic cover and the handlebar. I also reread what dave-co posted and I see you do not use the ujoints.

It is not clear to me if you alter the tub or column plastic.

http://www.superatv.com/Universal-Power ... C1039.aspx

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Author:  rmesser [ Tue Nov 04, 2014 11:34 am ]
Post subject:  Re: Project 2800 pilot

Just tried to order a 220W universal kit and the website says they are out of stock.

Edit update - called them and they should have stock sometime in December.

Author:  rmesser [ Tue Nov 04, 2014 12:38 pm ]
Post subject:  Re: Project 2800 pilot

I was looking around on their site and the Honda Rancher 420 Kit includes these brackets. Since the Pilot install is a in-line installation these brackets look like what is needed. Universal joints are not needed. I wonder I the length of the Rancher steering shaft and the pilot are the same or close. Perhaps a guy could get these brackets to work on his pilot or odyssey.

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Author:  rmesser [ Tue Nov 04, 2014 12:55 pm ]
Post subject:  Re: Project 2800 pilot

Mudbogger wrote:
Thanks Dave for all the hard work, and I forgot 1 picture, but I saved the best for last!! My pride and joy that's makes riding so much funner!!!


Hey mud - are the cut outs in the tub for the steering mod or for the long travel/suspension?

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Author:  rmesser [ Tue Nov 04, 2014 1:01 pm ]
Post subject:  Re: Project 2800 pilot

Mud - could you post a picture of the power steering unit like you were sitting in the pilot. I would like to see if the tub has been cut. A photo from the feet view would be nice.

Author:  nitrosport_5 [ Tue Nov 04, 2014 1:39 pm ]
Post subject:  Re: Project 2800 pilot

rmesser wrote:
Mud - could you post a picture of the power steering unit like you were sitting in the pilot. I would like to see if the tub has been cut. A photo from the feet view would be nice.


No cuts. You need to cut the glove box plastic at the top right above the choke/key but that's it. The cuts in the tub on the bottom are for the bump steer kit.

Author:  rmesser [ Tue Nov 04, 2014 5:07 pm ]
Post subject:  Re: Project 2800 pilot

Ok so this pilot has a bump steer kit also. Are the steering improvements better with the bump steer kit or are they the same with only the power steering unit? I'm interested in putting the power steering unit on my stock pilot.

Author:  rmesser [ Tue Nov 04, 2014 5:19 pm ]
Post subject:  Re: Project 2800 pilot

Another option for adapting the 17mm 36 spline to the steering shaft.

http://www.pacificcustoms.com/ac498705.html

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Author:  rmesser [ Tue Nov 04, 2014 5:22 pm ]
Post subject:  Re: Project 2800 pilot

Unit is smaller than I thought. Wish it was smaller. :-)

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Author:  nitrosport_5 [ Tue Nov 04, 2014 5:24 pm ]
Post subject:  Re: Project 2800 pilot

rmesser wrote:
Ok so this pilot has a bump steer kit also. Are the steering improvements better with the bump steer kit or are they the same with only the power steering unit? I'm interested in putting the power steering unit on my stock pilot.


Improvements should be the same. Basicly this is just eliminating most of the feedback through the wheel. Only reason mud has a bump steer kit is for the long travel.

I installed this unit on mine. I cut the ujoints up and used them to weld to the shaft. Was not bad but Dave is the man for figuring this out. That coupler would have made things a bit cleaner for me. Looks like pacific customs offers the same steering unit just not super ATV branded.

Author:  rmesser [ Tue Nov 04, 2014 5:26 pm ]
Post subject:  Re: Project 2800 pilot

Nice fault code diagram here. Super ATV just wants you to call them when there is a fault code. Looks like there are plenty of these units out there, not just Super ATV.

If you red LED light ever flashed a code look here.

http://www.pacificcustoms.com/mm5/graph ... -codes.pdf

Author:  rmesser [ Tue Nov 04, 2014 5:28 pm ]
Post subject:  Re: Project 2800 pilot

You guys have inspired me - gotta give it a try now. Mud sorry if I crashed your thread. Maybe this should be moved to a separate thread????

Author:  mudbogger [ Tue Nov 04, 2014 9:00 pm ]
Post subject:  Re: Project 2800 pilot

No worries. I like the thread as it is. This kit and the fabrication is great for the hobby, the group and the long term.

Author:  Dave-Co [ Tue Nov 04, 2014 11:48 pm ]
Post subject:  Re: Project 2800 pilot

The 17mm couplers are a new piece, I have spent countless hours and phone calls trying to find such a thing with no luck what so ever. Price is kinda redicules but at least they make them now. The pilot steering shaft is smaller than the 3/4 smooth bore in the coupler, have fun getting it straight when trying to weld it in!!! ON BOTH ENDS!!!

Author:  John l [ Wed Nov 05, 2014 6:59 am ]
Post subject:  Re: Project 2800 pilot

Rmesser _ That coupler could be a game changer for installation in a wide variety of vehicles.. thanks for that Post!

Author:  B S [ Wed Nov 05, 2014 7:19 am ]
Post subject:  Re: Project 2800 pilot

Dave-Co wrote:
The 17mm couplers are a new piece, I have spent countless hours and phone calls trying to find such a thing with no luck what so ever. Price is kinda redicules but at least they make them now. The pilot steering shaft is smaller than the 3/4 smooth bore in the coupler, have fun getting it straight when trying to weld it in!!! ON BOTH ENDS!!!

You could make it work with a lathe

Just make a couple of welds across the shaft to built it up then machine it down in the lathe

Or if you don't have access to a lathe you could wrap the shaft with tape then weld it tougher

It doesn't rotate a full turn so it doesn't have to be perfect

Author:  rmesser [ Wed Nov 05, 2014 10:32 am ]
Post subject:  Re: Project 2800 pilot

I'm not crazy about that style of coupler as it uses a set screw to lock down on the splines, which could damage the splines. I prefer the clamp style, but have not located one yet.


Edit - I take it back - The set screw would not hit the splines. It is designed to engage the shaft of the electric steering box at the groove - so the splines would not be damaged.

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Author:  rmesser [ Wed Nov 05, 2014 1:22 pm ]
Post subject:  Re: Project 2800 pilot

rmesser wrote:
Mud - could you post a picture of the power steering unit like you were sitting in the pilot. I would like to see if the tub has been cut. A photo from the feet view would be nice.



Mud would you be nice enough to post some pictures?

Author:  rmesser [ Fri Nov 07, 2014 10:02 am ]
Post subject:  Re: Project 2800 pilot

Looks like no detailed pictures on this mod - this must be in the category of top secret squirrel stuff. Thanks for what you guys have shared.

Author:  mudbogger [ Fri Nov 07, 2014 6:53 pm ]
Post subject:  Re: Project 2800 pilot

Guys i am sorry i have been swamped at work no secrets here. I should be by there tomorrow for pictures. Again sorry.

Author:  bugeye59 [ Fri Nov 07, 2014 11:30 pm ]
Post subject:  Re: Project 2800 pilot

Sorry?.......SORRY???..............You will be if it happens again! :-)

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