Decided to save another one

I wanted to start a new thread for my pilot build as I have started to make some progress on it. As you may know by now, my projects take awhile to complete, don't expect this one to be any different. I had been wanting to find a FL400 roller (almost impossible to find in the northeast) for awhile now to build/mod. In November last year I stumbled across an add on FB that listed a hondaline front bumper. I inquired on it and he stated that he had a FL400 roller he wanted to sell. Sent me some photos and I agreed to go take a look at it. About a 3hr ride to a little town in Connecticut called Sandy Hook. Below are the photos I received of it, I knew that it was in rough shape, & just what I wanted. I measured out my current pilot to make sure the frame was not tweaked and suspension mounting points were good.







He did not send me any photos of the damage in the front so I was a little upset and called him out on it. I felt like I just wasted a day when he could have been honest upfront about the damage. I went back to the truck to get the measuring tape and got to work checking it all out. To my surprise, the front suspension mounting points were all right where they should be. I measured from the rear frame forward and center to center on all the bolts. The tube was so bashed in that it made it look a lot worse that it was. Still really bad, but repairable. This was a good segue into negotiating the price & he kept the nerfs and front bumper.



When I got it back to the shop it cleaned up really well.

I have purchased an rotax Engine mount for it and have picked up a 1999 SkiDoo MXZ 600 for the power plant.

I almost completed the repair on the front yesterday. No way I could leave it like that. It will now be protected by the front bumper skid plate and a belly pan.

I ordered some gussets for the 90deg like the stock setup. That will complete the repair.

Another saved... and with an upgraded power plant will humble some very expensive machines shall the need arise.
More than 1/2 the fun and interest for me is building and tweaking/tuning..... trying to get that last little bit out of the package without breaking the bank.
Regards

I agree 100%

Way to be thorough on a pre-purchase inspection. Some really quality repair work done there, too.

Thanks!

I have learned my lesson buying machines that I was unfamiliar with. Unfortunately for the owners of FL350 & FL400 sellers, I have come to know these machines very well and will point out anything I notice. It is a bargaining chip to negotiate price. The repair intimidated me a little bit. I took my time cutting/grinding out the old tube. I am happy with the finished product and confirmed all measurements before and after final welding.

scpilot66 was a huge help when I bought my first pilot and gave me the run down of common issues and things to look for pre-purchase. Many thanks!

Sc is the man. Always willing to help.

that's awesome..I think a roller is the way to go..then you can build it the way you want.

I got my eps kit installed today. Huge thanks to methodical for top notch work as always. Fit together perfectly and I was able to make quick work of it. I think I’ll be able to keep the tool box and going to trim the column cover to fit nicely. I’m waiting on a hood from socalgigi and then I will mount the electrical box for the eps. I am also going to make a dash for the snowmobile Engine tachometer.

I have been riding the snowmobile all winter and had it out last weekend. The snow is melting quickly up north. Might get one more weekend out of it in the snow.

I got the gussets welded in today as well to complete the front end repair.

Started to rebuild parts for this project. I went right through the gearbox after struggling to get the axle stubs out. Info on that can be found here: viewtopic.php?f=2&t=19753 I was happily surprised how much simpler they are then the FL350 gearbox. I installed new seals & clutch discs and plates while I had it apart. Rebuilt the front and rear hubs as well. I got on a super chrome powder coat kick and they came out really nice.

WOW you build some really nice stuff.
Show room quality.
CO

where did you purchase the ball joints and what P/N?
powder looks good, do you need to do any clear coat over it or is it all in one?
how is the Engine install coming?

Thanks CO!

Kuma,
I got the ball joints from Lee. He is on this forum and also sells on ebay. Junkboy66 They are the most expensive ball joints ever made, just a FYI

I do clear powder coat over the super chrome using what they call clear vision. Some info can be found here: https://www.prismaticpowders.com/shop/p ... -chrome-ii

The Engine install has not made much progress as is is still in the snowmobile & I am going to use the snowmobile this winter as well. I have been using most of my free time on my odyssey build. Realistically, this won't be assembled until sometime next year. I am hoping to purchase a long travel suspension setup for this project between now and then.

-Curtis

I forgot to mention that Emmanuel has made me the exhaust for this rotax conversion. A huge help to me as I was dreading making the exhaust myself. Thanks again!

What size of nut is that. Same as stock or larger.
Thanks.
Nice something is available.

Nice until you see the price. I believe he is buying a stock ball joint off another bike I can not recall what it fits, and turning them down to fit.

If you look close at the picture you can see the zinc yellow is missing were the diameter is turned down.

Wasn't someone from Tennessee doing this years ago?

It is nice that you can just buy them.

found this...

viewtopic.php?f=4&t=9967&p=149823&hilit=fl400+balljoint#p149823

It is a larger nut. 17mm I believe.

These are a bit different then the OEM ball joint. They are installed in the opposite direction as the OEM. The retaining clip is on the opposite side as well.

While it looks to be machined down (can't see the zinc) it is in fact not. Rather, it has a very thin sleeve over it..... making them very finicky to press in. You have to take your time and press them in perfectly or this thin sleeve will wrinkle/fold and your F cked with a $90 useless ball joint. Not a fan of this sleeve personally & I think they would be better if they were just machined down from a larger joint.

My goodness Curtis, pertty pertty.

My trans. in my LT is shiny to but I think someone polished the heck out of it.

sure putting that powder coater to use. looking good bud

Thank you guys! I thinks it’s going to be pretty awesome when I get it finished.

I have been putting the powder coater to good use and getting better at it as I go. I hope to one day build a larger oven as I am currently limited to smaller parts.

Thanks for the response Curtis
Look forward to the rest of the build

While I am waiting on some parts for my FL350 I decided to get working on this project. I got the Engine removed from the snowmobile and cleaned it up a bit. I made 2 block off plates, one for the oil injection system and the other for the coolant system. I installed new v-force carbon fiber reeds as well. I decided to not use the oem carburetors for it and upgraded to the Lectron carbs. Hoping to get the Engine in the chassis this weekend and to start the wiring.