Starting a new project,a FL350 with some Pilot mods as SCPILOT did on his son's ride:

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Started with a FL350 FRAME, WITH A STRAIGHT front clip and I purchased a KAWONDA LT front end kit for it:

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I purchased off a private seller a complete Pilot steering wheel used but in great shape,a Pilot wire harness,Pilot electronics,Pilot rear brake light,and a Pilot complete Radiator with switches and fans all to be installed on this.The frame is currently at my fab guy getting the KAWONDA LT FRONT end kit welded up-theres a brief write up on it in this thread:

viewtopic.php?t=6375

As I progress on this I will post pictures and document all the mods.I am copying almost everything Steve has done.The harness has to be custom wired to accept the Pilot electronics first of all, which Steve has documented in his thread.I will be sending a motor (( Internal Combustion Engine ? )) out in the coming months for a complete rebuild, but I am waiting for SPEEDCHASER to make some 350 water cooled heads for it (come on SPEED!!)and I still have the Tecate project and the ODYKID Pilot as well needs to be buttoned up as well.

I'll stay tuned for sure. Great project!

Brief write up on the front application process of the KAWONDA front LT kit:

viewtopic.php?t=6375

last page please refer too.

ok, progress on this.
Got the KAWONDA KIT ALL WELDED up-we boxed in the top section of the kit-it IMO it will just plug up with dirt.I'll picture the items I am discussing as soon as I get back to my fab guy.He redid all of the brackets on both sides to make the clearances closer, it was not in anyway poorly done, I am just anal and wanted it perfect.I purchased a Pilot wheel with OEM BRAKE LINES,and complete Radiator assembly(fan,sensors,complete) off Ebay, as well as a complete steering column too.These will be brought down to the fab shop for the new brackets to be welded on for the Pilot brake lines, as well as the steel connections for the Pilot wheel to the stock OEM 350 lines.The harness is in the final stages of completion, and I have a battery box which needs to be fabbed to accept the Pilot relays, etc.Powder coating is going to be done by SDL POWDERCOATERS of Toms Rivers,NJ WITH A FAMILIAR COLOR everybody seems to love-that's gonna be a secret for now.I also have purchased a Pilot rear brake light which will need brackets welded on the top cage as well.I have many motors here, that's the last thing on my agenda as Hoser has tons to do and I do not need the motor (( Internal Combustion Engine ? )) till the very last moment. I am hopeful he can build me another motor (( Internal Combustion Engine ? ))!!
I will be having the frame with Kawonda kit media blasted the same color, and the arms, etc will have to be painted as the ends can't be powder coated.I have many other brackets etc left over from a previous project that are powdercoated and ready for installation.

Got down to the fab shop today and got some good time in on the project.First, I had my friend box in the front tubes on the kit as shown in the first picture, It comes open from Kawonda and I felt it helps with strength and mostly keeps dirt out.I had him do top and bottom.I had all the tabs for the arms remounted closer to the tubes and welded,I also had the rear mount for the kit welded to the frame, it comes with a clamp which is fine, but I preferred to weld mine right to frame to minimize any potential for the clamp to loosed or break off the frame rail,Picture 2.
I did some dry fitting of the stock floor tub with the kit mounted, it does fit and you can use the provided clamps for the rear mounts with it, it clears fine.The stock fenders will not fit without some good cutting to allow the upper shock mounts to clear, and I need to install a piece of tubing from the upper mount to the frame rail as provided with the kit still, so you'll have to hack them up pretty good for them to work.The stock OEM bumper plates need to be installed with the kit as well,that's has been asked by some here-they fit perfectly on.
I mounted a SPEEDCHASER 350 bumper on the front end with the stock end plates, they matched up perfectly to the sub frames on each side without any use of the stock dust seals or caps, there not needed in the kit.
I dry fitted the steering rods and tie rod ends on the spindle's,after reading the provided and detailed instructions it was pretty easy-and after drilling out the stock end off the column everything is easy fitting and well described in the instructions.
I mounted a Pilot wheel on the 350 steering column, and I will have my fab guy weld the bracket for the stock OEM brake lines.The kit provides steel braided lines for the front, with a line going directly to the old 350 masters, which are omitted with the conversion to the Pilot wheel, so I do not need to make a section of new brake line as I will for the rear brake.
I have pictured some photos of the frame and dry fitting of the a-arms and such for the guys that purchased the kit,hope they help.

I wanted to mention the kit is being dry fitted, final welding is still needed on surfaces, we are going to dry fit everything prior to final welding to make sure everything is perfect.I have pictured here something I mentioned in the earlier posting-the steering arm where the tie rod ends connect comes close to the sub frame, I have not had the chance to mount the shocks and tires/rims to make the steering complete, so it may not be a issue as we progress, but I will picture it here and we can see what the final results come too after alignment/tightening of the complete front end.
The arms and spindles fit well, the only thing I can I guess complain about is the boots on all the arms are cut, and sliced they need to be replaced, but they are used arms and I can bet Kawonda got them that way-I really can't say anything about this and it does not bother me personally, but to be fair I will report it.In the pictures of the upper shock mounts, there's still a piece missing on that between the mount and the main frame rail, that is to be installed in the coming week.More pictures:

more pictures:

The PA rocks will be a good test for this setup.
Looks good.
If your not worried about welding on the frame, why not just weld the tabs(a-arm tabs)directly to the frame and skip all the extra tubing?

wow that bumper looks good on that

Don't for get you might add some tab to it for a skid plate
or use the the extra holes in the bumper bracket by making little U shape brackets that bolt on

let me know i can whip one up to show up what i mean

thank speed

keep up the good work mud

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I guess you could, do this, but then the arms would be closer in, the tie rods wouldn't fit, the geometrics on the front end would be a mess for this kit and I honestly have no fabbing skills LOL.I am going to weld the upper tube that goes between the upper shock mount and the main frame rail, Kawonda designed it with a clamp style to remove it when needed,but it is going to be on my ride so it is getting welded on,if you look on Kawonda's home page you'll see what I am referring too:(right above the top of the shock is what I am speaking of here)

http://www.odysseyconversions.com/index.html

Need to purchase some shocks either from him, or Ebay today.I also need to find the bolt pattern for the TRX450R spindles,anybody have a clue?

Could you please Speed?I love the bumper and a skid would really make the front end!!!! The bumper fit right on all the stock OEM hardware, it was perfectly machined.Do you still have any of these around Speed?I bought 2 lucky for me!!!

Scroll down to honda.

http://www.mud-throwers.com/atv_wheel_chart

Thank you Bullnerd!!!

Contacted a member on the 3 wheeler board that does plating, I will be sending all the bolts and nuts for the project to him for zinc plating,all other pieces are going to my powdercoater, everything will be getting powdered or zinc plated on this project,I will not paint the frame as I did with Odykid's PROJECT PILOT, it just sucks in my opinion.Color to be displayed after media blasting and powder, should be sweet indeed.The motor (( Internal Combustion Engine ? )) and trans are going to be CSI'D in the future-Pilot radiator and resevior tank installation to be pictured in future postings.I also need to have the battery box modified for the Pilot electronic clusters,and a rear brake switch bracket installed as well on the rear of the odyssey for the Pilot warning light.The harness for this project is being made as we speak and should be completed soon.I am following everything per SCPILOT66 thread on his conversion for his son's 350,just wanted everybody to view that thread as it is a great catalyst for any future conversions IMO:

viewtopic.php?t=5598

Rims are 4/144 10x5 bolt pattern for the trx450r arms as per Bullnerds link.

Mud since you are welding your kit to the frame you can weld a brace in for the shock mount from the lower frame rail so you wont have to hack the fenders up as much, it can be 3/4" round tubing it doesnt have to any bigger all your doing is triangulating the bracket.

In the instructions he has a piece going to the upper rails-with the shock towers as high as they are,the upper bracket could in theory with a piece going downward bend, the shock puts so much prsssure on the mount I think it need the bracing on the top,you can see where Kawonda has mounted the piece on his home page-use the link here.I will weld mine,he uses a clamp stlye which I am not using.

Im just trying to save you from hacking the fenders up looks good though keep up the good work. the brace doesnt care if it goes up or down your just bracing it.

not to hijack your thread I just want to show 2 more pics if you run it down it looks to me like it would clear the fender if you run it up it will cause you to cut a big slot in the fender.

I understand the posting and thanks for it-I have a 78 F-150 as pictured with the same shock kit-I will look into it with my fab guy, I would prefer to use the stock fenders and if as you say any bracing is suffice for the upper bracket I'll go the route you have pictured, the fender will need modest modification to fit,but much easier in the form of bracing you speak of.Thanks for the help!!

here a pic of skid plate brackets will ship out this week







updated my post more pic's for you mud

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thanks Speed

are you going to cut off all the old suspension mounts since you are not using them any more?

No, I am going to leave them. In theory you can just cut the welded areas off and remove the kit,if the stock set-up is gone the frame is useless.

Ok, shopping for shocks today for the kit.I am curious as to what measurements I need to provide to say FOX for there FOX AIRS do you need total compressed length on the lower arm to the upper shock mount, or total length extended?How does 1 go about getting the proper correct measurements for a shock?Fox air makes shocks from 5.5 LENGTH to a 18+ length-what determines the length/size/etc.

http://off-roadproducts.com/2_0_air_shock.html

Looking at postings from Kawonda, he has stated this for shocks:

"The works shocks that are used for the stock FL350 front suspension would be too short. The kit is designed to use stock shocks from a quad. Any 400 or 450 size shocks will work, as long as they are 16 3/8" eye to eye."
Travel is the same as the donor quad arms, and quad shocks, which is usually around 8.4".

Adnoh posted this in the thread for the kit:

Since you went with Honda 450 stuff, by the way great choice hoping you go 04 or 05. Depending on set up works make a 12" travle shock for the stock arms and shock mounting points. This depemnding on ground clearence and from what I been reading should be ok. A 50% sag might just be the ticket for this shock witht the kit. Can not wait to see some install pics.

Now using the chart from FOX-I would like to purchase the same shocks as my CO PILOT has, 2.0 SERIES/ 1.25 shaft non coil over air shocks-but do I purchase them at a total length of 16.29 extended length-or a little longer like 18.29 they list?I am confused if the 15 inch shock or 16 inch shock is the right one-I have the 16's on my CO PILOT.The 16 inch has the right travel as specified by Kawonda-but should I measure go by his measurements?
Heres the chart from FOX:

http://www.off-roadproducts.com/FOX08AIR.htm

Any help on this is appreciated-

If you go to works site they list the shock I mentioned. It comes in a varitty of set ups and price. If you go used look for 06 fronts ( better valvling and softer spring rate). If you get 04/05 look at work zero preload triple rate stadium spring kit. This will lower you font ride height provide low speed feel and great bottom out resistance if you like to chanrge stuff at speed. The 04/05 are cheaper plus you can respring them. Just some thoughts. The reason for using 450 shocks are they adjustable in stock trim.