Lets see Updates, been a slacker here for sure. It's about time I bring this thread up from the ashes - even supprised me how long I let it go....

Well the gas tank/oil tank is finally done - seems like on the FL800 it was my stumbling block as well. Maybe I should not make such elaborate tanks in the future and I can stay on task.

Wiring harness - another thing I was not looking forward to. Wanted to use all of the Yamaha harness and none of the Pilot harness - unlike the FL800 which has both. On the FL800 the Polaris motor (( Internal Combustion Engine ? )) is self sufficent and only has a rectifier that goes to the battery and the Honda harness just works off the battery. However I did get the kill switch and starter to go to the pilot motor (( Internal Combustion Engine ? )). With the Nytro motor (( Internal Combustion Engine ? )) the key will also start the motor (( Internal Combustion Engine ? )) so as of now the lights, starter, all steering idiot lights won't work. I could have ran the lights through the honda switches but was afraid of the voltage running through them - maybe a relay but decited to mount the light switch and thumb/hand warmers next to the gauge. Also the Yamaha system is sensitive to amperage - found this out when changing to aftermarket hand grips. They were not the same resistance so it threw codes.

Wayne

Looks great Diablo,bout time too!!!

When can I expect the vids?

I'll be 52 in a few months...remember you promised to finish it by then? Reckon' you'll finish it BY THEN????

Would make an awesome present what? Your best Downunder MATE.

Well I purchased used ATV-R front suspension and since it did not have mounting tabs I decied to make my own as I have my FL800 to copy form. I've never liked the messy anti-bump steer tub cut outs so I've decited to try and make it work with out hacking the tub. Not sure what affect this will have, I suspect it will only play a part in when the Ackerman is introduced in the corner (I think it will lessen the ackerman throughout). If it does not handle compaired to the FL800, I'll cut it out and place in the correct ATV-R intended place. Basically I just moved out the pivot point outward the tie rods have no change at all from what I recieved from the previous owner. Thoughts?

Wayne

Bazz,

I would say your up way late, but being on the other side of the planet your half way though Sunday by now.


VIDEO?????? you want video?

Well Bazz........"ask and ye shall recieve" - a fitting Sunday theme for you Bazz

http://www.youtube.com/user/Akpilot1?fe ... -P7uXRlQ-U" ."..

Wayne

Thanks for the vid Wayne.
Damn near wet my pants with excitement........or is it just the onset of incontinence?

It's Sun arvo 3pm here,your the one who's up late Mate! Time you should be finishing off my,er your Pilot.

I might have to give ya another surprise

You still talk funny Bloke!

Well I'm in that perverbial last 10% of the project that takes 90% of the time to complete. I just finished up welding in the motor (( Internal Combustion Engine ? )), had it running and allowed the secondary clutch to self align, shimmed to motor (( Internal Combustion Engine ? )) to the mag side about 3/8" to get the secondary just at the poing of the support bearing.
I finished up the rear suspension and on Monday I'll ship off to powder coat to match the front color. Next is to finish up electrical holding tabs (origional Honda cut and remounted to hold Nytro harness) After that make the motor (( Internal Combustion Engine ? ))/frame bracing which will take a bit - I want to make a motor (( Internal Combustion Engine ? )) mount for the front that will take the side to side movement out of the removable motor (( Internal Combustion Engine ? )) mounts (it will become clear as I make it). Then strip it down to the frame finish welding it all up and either paint it or powder coat. Leaning towards powder coat but wish it was not winter here to at least ride it to make any changes before paint. Oh well.

Wayne

Very nice job. Thank you for sharing

Well I've been working on the motor (( Internal Combustion Engine ? )) mount idea, changed shape a couple times but the theory remained the same. My objective is to take the side to side movement the front motor (( Internal Combustion Engine ? )) mounts might have, also I can control the twisting motion of the motor (( Internal Combustion Engine ? )) better as well. By holding the mag side solid to the chassie it stops it from pushing forward under hard acceleration (pivoting around the motor (( Internal Combustion Engine ? )) brace, BTDT with mod sleds). It also allows me to align the front of the motor (( Internal Combustion Engine ? )) by pushing or pulling with the bolt. The plan is to get a castle nut and drill for a cotter pin, then tighten the carriage bolt to proper torque and lock in cotter pin, then push or pull with side bolt.
It started out as a lock nut welded to a peice of pipe, then welded to a rectangle 1/8" tube then mounted to the bracing tubes and finally hole drilled for dranage of what ever, sand, water ect.

Pics

Wayne

Well I've benifited from the Ackerman tread - thanks all - and so I decited to update my project build. I have definately decited to keep the "no cut tub" Idler arm placement and will look into doing the Big Tom ackerman corection but after I run what I have. That can be done after powder coat. Probably will look into picking up a spare steering shaft to do the modification if it's not to expensive. If it is i'll just redrill/drill the welded holes if I don't like, but I would like to try it one way then slip in the second shaft to see which I like on the same day for better feedback.

Finished up making the outer bumpstops.

Akpilot.

Nice work Diablo...but are'nt you meant to be resting that greek tendon????

where is this big tom ackerman fix+??

Nice easy stops... I wish I would have seen this before I did mine...

where is this big tom ackerman fix+??

Nice easy stops... I wish I would have seen this before I did mine...

Turbotexas

http://www.dirtcheapracing.com/steering/" .".." ."..

Big Tom welded up the two holes in the steering flag and drilled on hole in the center. Then lengthened the short tierods, one on top and one on bottom. Stacked kindof like the Odyssey is. Its been stated that it would be best to bring metal up and down to double shear the tierods.

Akpilot

OH ok... But I always thought toe out on turn was a good thing in off road??? Just like the quads do....

Amazing build, thank you for posting it.

Thanks Rarerat,

Well, I started on the bumpers and just pretty much copied what was on my Fl800, I'm using 1" Sch40 aluminum pipe for bumpers/nerfs. Going to start on the Nerf Bars next, after bars then roof and skid plate.

Akpilot

Well I've havent had much to post, but I have been working on it. I figured I'd post on my tread the nerf.
Now I'm making gussets, it seems once I started I'm finding all kinds of things to gusset, here are a few.

Akpilot

Very nice trans... I wish I had one...
I like what you did with the frame... that will hold all you can throw at it!

I too hope it holds up go oddy, but I'm about tired of making gussets NOW!!! I've decited to just rattle can the frame for this summer then I can make changes easily with out worring about powercoat, I would think it would be crazy to think I have the frame just perfect and not need to make changes dispite what Bazz thinks I can do . After this summer I'll definately get it sand blasted and powdercoated.

Akpilot

hi akpilot,very impresive,it looks it was made in nasa!!!it will be bad a....pilot!
step on in,the faster you finish,the more time you have to enjoy it!!!
tal

I had a chance to meet up with the master fabricator ak Pilot and can't say enough good things.
His Pilot is insane!!!!!! More to come

and theeeeeeennnn?
C'mon Rick,all those miles travelled,and 2 pics?...AAaarrgghhh!!!