Rootar's rzr build.

Rootar · Jun 1, 2014

I thought some of you guys might like this and have input on it. Im not a SXS guy, i think they are too expensive and not built worth a damn. Yet some how i this end up in my lap for a deal i couldn't pass up. So i put off building a 4.0 powered promod style buggy to see what i could do with this thing.

This is my take on what i want out of a sxs.

Specs:
-1.75x.120 wall dom chassis with some 1.5 and 1" mixed in
- 94" wb, 52" wide overall (chassis), 5'6" - 5'8" overall height with 16-18" of belly clearance and should be 66-68" wide overall
- 900xp motor
- 1000xp front diff with gilbert designs front skid
- 900xp trans and rear end. (aftermarket clutch and secondary)
- 900xp high lifter max gc trailing and radius arms out back with fox shocks
- 900xp max gc front end +2" forward arms with fox shocks
- rhino axles all around
-corbeau baja seats with pro armor harnesses
-30" roctanes on sti beadlocks
- full size HS winch and size 34 battery.
- led lights,uhmw skids, and all that junk.

this all started with a rzr 900xp i got with a trashed motor.

new bender.

plenty of head room im 6'

rough drawing

here is what i decided on for the nose

steering rack mounts and braces and front suspension.

B hoop

https://scontent-b-sjc.xx.fbcdn.net/hphotos-xpf1/t1.0-9/10425120_10202909074461057_4219166233839075676_n.jpg/img]

rear suspension plate

[img]https://scontent-b-sjc.xx.fbcdn.net/hphotos-xfp1/t1.0-9/10402989_10202909074181050_919103168370859174_n.jpg

rear hoop

exhaust will using factory style mounts so any aftermarket exhaust will work down the road.

will have removeable bar that wrap around exhaust and tie into rear plate

motor mounts/firewall

gotta cut my plates to weld to the bushing sleeves.

and here is where im at now, getting close to getting it off the table and getting the shock mounts done and ill have a roller. then the real fun beigns

drycreekjeep · Jun 2, 2014

looking good!!!

gasman · Jun 3, 2014

I've been thinking of doing something like this. Will be following this for sure. :dblthumb:

Rootar · Jun 3, 2014

Well i should have ordered tires a month ago, roctanes are out of stock everywhere so ill have to borrow some stock 1k tires from a friend to use for rollers until the roctanes are available again.

Wheels and new bearings will be here thursday.

Finally broke down and bought a plasma cutter, hypertherm powermax 45 should be here thursday or friday.

So no point in wasting anymore time cutting brackets and mounts until it arrives. So ill be working on templates and last bits of tube work and getting parts cleaned up and ready to go for the next few days.

I also have to decide on final measurements for my fuel tank so i can get it built, was told it would 3-4 days for him to get it done in his spare time. So do you guys think i would be ok with 5 gallons or do i need closer to 7-8 gallons for a days riding? i know these things drink fuel.

gasman · Jun 3, 2014

My wife's 900 drinks the gas. We rode Sunday and it used over a half a tank of gas and my rail buggy with a 2387 built dual 48 carbs and running 112 octane only used 2 gal. Now that's sad fuel mileage. And I know I ran mine harder also.

blacksheep10 · Jun 3, 2014

I'd cut the upper arms and do short bolts. the one long bolt does nothing but break. Seriously, save a headache.

Bumpers · Jun 3, 2014

Re: Re: Re: Rootar's rzr build.

blacksheep10 said:
I'd cut the upper arms and do short bolts. the one long bolt does nothing but break. Seriously, save a headache.

Yep I agree wasn't the best design by popo

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Rootar · Jun 3, 2014

I considered doing that to the arms but the main idea was to keep everything like that bolt on. The diff, axles, steering, front arms, trailing arms, radius arms, shocks, and exhaust should all be bolt on and easily replaceable for somone should i end up selling it down the road. I didn't want to go over board with custom parts in areas that can get damaged.

So yes 4 heims with bungs, 4 more tabs, and 4 new bolts for the uppers and that would fix that. It would only be a couple hour project to do this later on when im closer to done.

but yes its a good idea

Rootar · Jun 3, 2014

Actually scratch the Heims, just get 4 lower arm bolts and then cut the a-arm tube the bushings and sleeve down to match the lowers. Then even if it needed replace you could take an off the self part and modify it to fit the double bolt mount with two cuts.

wont work · Jun 3, 2014

Keep us updated on this project

blacksheep10 · Jun 4, 2014

Rootar said:
Actually scratch the Heims, just get 4 lower arm bolts and then cut the a-arm tube the bushings and sleeve down to match the lowers. Then even if it needed replace you could take an off the self part and modify it to fit the double bolt mount with two cuts.

You typed what I was about to. Make the uppers the same as the lowers, just cut the cross tube, add 2 tabs per side and recrosstube the arm farther out. The next 900 that comes in missing an arm I'm just going to cut and double tab. I"m tired of that fawking bolt and it totally ****ed us at KOH this year. Plus you have to pull the front body work and bumper to get it in/out on a stocker after it breaks. shorter is better here.

Rootar · Jun 4, 2014

blacksheep, more bolts and extra lower bushings are on the way.

Well i got the steering rack mounted and was mocking up for pedals and steering wheel mounts.

Here are a couple pics for size reference, i have really long legs so unless your 6'5 or taller you should be plenty comfy in this thing. Trying to leave as much room for fuel tank as possible. Plenty of head room.

Craig · Jun 4, 2014

Man this is awesome. I have a couple projects to get done and I am planning something similar but using a sport bike motor and Toyota axles. I think you will start seeing more and more buggies being built as people really start trashing their sxs' s.

Rootar · Jun 5, 2014

got these in today.

i got the stock frame, cage, plastic and etc all loaded up ready to head to the new owner who wrecked their rzr in a head on collision a few weeks ago. Plus I'll be picking up the loaner tires on the way back tomorrow.

wannabe · Jun 5, 2014

You think it will be lighter than the factoryish xp?

gasman · Jun 11, 2014

Rootar · Jun 14, 2014

Yes i think it will be lighter than an equally equipped factory based setup.

im not doing this build for weight and clearance im doing it because im hard on stuff and i dont want to end up with this issue. plus rzr are a PITA to wrench on. the guys were who bought my frame were nice enough to give me their trashed frame so i can cut some of the brackets off for reuse on mine. (gas/ brake/ master cylinder mount, shifter mount, steering wheel mount, exhaust hangers)

got the motor and trans ready to go back in where i can finish the mounts

rear suspension mounts are on and it cycles smooth as can be with the laid over trailing arm mounts. did i mention i like my plasma cutter?

rear at full bump

just test fitting making sure there is plenty of room for everything.