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Fl400 for fun build
http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=16312
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Author:  afastcar [ Mon Jan 18, 2016 11:48 am ]
Post subject:  Re: Fl400 for fun build

hoser wrote:
rmesser wrote:
Was it able to be welded with the tranny together, or did you have to take it a part because of the heat?



Mine was done when it was apart but I wanted to inspect the internals anyways. viewtopic.php?f=118&t=14230



Looks like yours had a big chunk missing so it probably took a lot more heat to weld, his and mine was more of a clean break taking less heat to weld. Maybe that matters maybe it doesn't?

Author:  hoser [ Mon Jan 18, 2016 11:55 pm ]
Post subject:  Re: Fl400 for fun build

afastcar wrote:
hoser wrote:
rmesser wrote:
Was it able to be welded with the tranny together, or did you have to take it a part because of the heat?



Mine was done when it was apart but I wanted to inspect the internals anyways. viewtopic.php?f=118&t=14230



Looks like yours had a big chunk missing so it probably took a lot more heat to weld, his and mine was more of a clean break taking less heat to weld. Maybe that matters maybe it doesn't?



I am not really sure I had my son weld it (my eyes are going) so not really sure on the heat issues, I took my trans apart to do an inspection while it was out and for the welding, I wanted to see the internals since it was pretty much a unknown trans, same with the Engine I tore it down installed new bearings, seals, inspected everything so I know what I have..

Author:  btroxl [ Sun Mar 06, 2016 9:46 pm ]
Post subject:  Re: Fl400 for fun build

Progress is slow right now as work has been crazy lately... After letting the axle cup soak for 4 weeks it still wouldn't budge so I put the entire trans on the milling machine and drilled the end off the spline shaft to release the c-clip. Ill let the pictures explain this further. I need to cut a new c-clip groove and splines on the end of the shaft and it will be good as new. Also welded the trans and the motor (( Internal Combustion Engine ? )) cleaned up a little. Ill try and rip the trans down this week to replace the bearings and seals.

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Author:  btroxl [ Sun Mar 06, 2016 9:49 pm ]
Post subject:  Re: Fl400 for fun build

more pictures

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Author:  mudbogger [ Wed Mar 09, 2016 7:26 pm ]
Post subject:  Re: Fl400 for fun build

Good to see the project going very happy for you!

Author:  btroxl [ Sat Mar 12, 2016 11:25 pm ]
Post subject:  Re: Fl400 for fun build

Mudbogger wrote:
Good to see the project going very happy for you!


Thanks mud. Hope to have it up and running in the next few weeks.

Got tha axle stub all fixed up and it works as it should. Also replaced the to axle bearings in the trans and added new seals. The trans looked like new inside. Bead blasted and painted the exhaust too.

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Author:  btroxl [ Sat Mar 12, 2016 11:27 pm ]
Post subject:  Re: Fl400 for fun build

more pics

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Author:  mudbogger [ Sun Mar 13, 2016 7:58 pm ]
Post subject:  Re: Fl400 for fun build

Cannot wait, nice machine work Brian!

Author:  btroxl [ Sun Mar 13, 2016 9:42 pm ]
Post subject:  Re: Fl400 for fun build

regreased the axles ad installed new boots today

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Author:  rmesser [ Mon Mar 14, 2016 2:13 pm ]
Post subject:  Re: Fl400 for fun build

Great work - I have really enjoyed seeing your work. Why spin the axle in the lathe? Are you prepping the axle for paint?

Author:  btroxl [ Mon Mar 14, 2016 9:28 pm ]
Post subject:  Re: Fl400 for fun build

rmesser wrote:
Great work - I have really enjoyed seeing your work. Why spin the axle in the lathe? Are you prepping the axle for paint?


Thanks,
yes I spun it in the lathe to sand the rust off before painting.

Author:  rmesser [ Tue Mar 15, 2016 9:53 am ]
Post subject:  Re: Fl400 for fun build

How did you cut the new splines. I see the picture, but can't get it straight in my mind. Does the machine stroke horizontally, like a shaper? Sorry if its a dumb question, but its buggin me that I can't figure it out. Looking at the picture again I see the tailstock. Looks like it is just chucked in the lath. Did you grind a tool bit to match the existing spline and just manually move the crosslide? or maybe you engaged and then disengaged the lead screw to get the horizontal cut.

Author:  btroxl [ Tue Mar 15, 2016 9:06 pm ]
Post subject:  Re: Fl400 for fun build

rmesser wrote:
How did you cut the new splines. I see the picture, but can't get it straight in my mind. Does the machine stroke horizontally, like a shaper? Sorry if its a dumb question, but its buggin me that I can't figure it out. Looking at the picture again I see the tailstock. Looks like it is just chucked in the lath. Did you grind a tool bit to match the existing spline and just manually move the crosslide? or maybe you engaged and then disengaged the lead screw to get the horizontal cut.


I hand ground a tool to match the spline shape of the axle the mounted everything up in the lathe, used the tail stock for support. Picked up each spline by hand then put the lathe in back gear to lock the chuck in place, then "scraped" the splines in by hand .oo5 of depth at a time. this was all done with the lathe turned OFF. it was time consuming and i still needed to do a bit of hand filing but overall im happy with the results.

Author:  btroxl [ Sat Mar 19, 2016 10:32 pm ]
Post subject:  Re: Fl400 for fun build

amazing what a little cleaning and paint can do. also copied hoser's diy axe seal. Not done yet but m getting there.

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Author:  btroxl [ Sat Mar 19, 2016 10:33 pm ]
Post subject:  Re: Fl400 for fun build

one more pic

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Author:  mudbogger [ Sun Mar 20, 2016 3:09 pm ]
Post subject:  Re: Fl400 for fun build

Holy crap WOW- that's crazy how nice it looks, the old frame is toast right? Great work my friend, good to see that Pilot is going to be a sweet ride and used not parted up congrats on a fine job!

Author:  btroxl [ Sun Mar 20, 2016 9:05 pm ]
Post subject:  Re: Fl400 for fun build

not sure if the other frame is scrap or not yet, I've put it aside an will come back to it at a later date.

I did score some sweet parts from mud today! Thanks again mud!!

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Author:  mudbogger [ Mon Mar 21, 2016 9:25 pm ]
Post subject:  Re: Fl400 for fun build

My Pleasure sir, glad they are being used for sure! Sorry I missed you, but we will met again soon!

Author:  stix [ Mon Mar 21, 2016 10:39 pm ]
Post subject:  Re: Fl400 for fun build

Shes lookin good. i noticed you had the ATV Racing body skid plate, notice how the plate extends below the frame a couple inches under the seat. So much for ground clearance. The only reason I can think of that they designed that way was to allow for their retrofitted seat to fit. If you have the original seat take a look at this post. viewtopic.php?f=111&t=14711

Author:  btroxl [ Mon Mar 21, 2016 11:02 pm ]
Post subject:  Re: Fl400 for fun build

stix wrote:
Shes lookin good. i noticed you had the ATV Racing body skid plate, notice how the plate extends below the frame a couple inches under the seat. So much for ground clearance. The only reason I can think of that they designed that way was to allow for their retrofitted seat to fit. If you have the original seat take a look at this post. viewtopic.php?f=111&t=14711


thanks for the heads up and the link, I have now put this on my todo list.

Author:  mimi [ Sun Mar 27, 2016 6:55 am ]
Post subject:  Re: Fl400 for fun build

Hello,

Congratulations for this great work.
I live in France and have the chance to own a Pilot rare here.
Right now, I no longer workshop and am limited to work on.
I see you have changed the seat.
Would you seller of the original model?
or What brand and reference is the new one you bought?

Thanks
Michel

Author:  btroxl [ Sun Mar 27, 2016 11:35 am ]
Post subject:  Re: Fl400 for fun build

mimi wrote:
Hello,

Congratulations for this great work.
I live in France and have the chance to own a Pilot rare here.
Right now, I no longer workshop and am limited to work on.
I see you have changed the seat.
Would you seller of the original model?
or What brand and reference is the new one you bought?

Thanks
Michel


I think the aftermarket seat is from atv racing? as for the stock parts i ave, Im gong to hold onto them for now. I have seen some stock seats on ebay...

Author:  mimi [ Sun Mar 27, 2016 1:07 pm ]
Post subject:  Re: Fl400 for fun build

ok,

I'll look on ebay, there is no emergency.
thanks anyway.


Michel

Author:  btroxl [ Sun Apr 03, 2016 8:43 pm ]
Post subject:  Re: Fl400 for fun build

decided to do a trx450 hub/spindle conversion while im at it. Not sure I like the way i fit with the aftermarket seat in this thing, I may go back to stock. Ill let the pictures do the talking.

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Author:  mudbogger [ Tue Apr 05, 2016 5:35 pm ]
Post subject:  Re: Fl400 for fun build

Hard to believe how good that thing looks. Amazing transformation great job indeed!

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