A King of Hammers inspired garage build [Archive] - UTVUnderground.Com

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cuflipn

06-22-2010, 03:01 PM

This is my first post on what I think is the BEST forum out there and I am happy to be here thanks JoeyD!!
<o>:p> </o>:p>
I will start by saying that this build was inspired by JonÃ¢â‚¬â„¢s (Crowdog) KOH build that is one sick machine!!! A little about me; I am a mechanical design engineer with a background in heavy equipment design and manufacturing but more resent (last 8 years) I have found myself in the medical field designing micro mechanical devices for surgical procedures to drug delivery. So with that said I have some knowledge and skill but by no means am I as skilled as some of you on here (wow).
<o>:p> </o>:p>
Build outline, this isn't a track racer (although that looks like a blast) its really more a rock crawler trail rig. So the chassis will be boated and dove tailed for that all important ground clearance. I am planning on widening it to get my seats as low as I can and stretch my suspension out (6inch long arm with a 3inch forward and back sweep). I will be doing all the work myself in my 2 car garage all basic hand tools but with one secret weapon, Solid Works. LOL
<o>:p> </o>:p>
Here are a few pictures of the tear down. I have been working on this for a few weeks already so some of this is historyÃ¢â‚¬Â¦
<o>:p> </o>:p>
I hope you all enjoy I know I am!
<o>:p> </o>:p>
Cheers,
Brett

Rusty5150

06-22-2010, 06:46 PM

Check out my build thread. It was inspired by the Crowley Teryx.

http://www.utvunderground.com/f56/my-garage-build-2113.html

JoeyD23

06-22-2010, 07:39 PM

Crowdog

06-22-2010, 07:53 PM

Brett,

Best of luck with your build. Should be fun.

Maybe we can hook up in Moab again to test it out when you are done? Or just bring it down to the Rubicon!

Jon

cuflipn

06-23-2010, 10:30 AM

Check out my build thread. It was inspired by the Crowley Teryx.

http://www.utvunderground.com/f56/my-garage-build-2113.html

Rusty, I have read through your build a couple of times! Great job and I got some great info from your post thank you!!

Awesome Brett! Thanks for posting! We cant wait to see you Kawi evolve!!! Keep the pics coming and keep an eye out in the upcoming issue of UTV Off Road Magazine for a special article I did on Jon Crowley's awesome Muzzys/Monster Kawi Teryx!

Thank you Joey! I am very excited about this build I will be posted pic's as often as I can... I can't tell you enough what a great forum you have here!!

Brett,

Best of luck with your build. Should be fun.

Maybe we can hook up in Moab again to test it out when you are done? Or just bring it down to the Rubicon!

Jon

Jon, I would like that! I have never been on the Rubicon that sounds like a trip that needs to happen!!

Moab is a for sure thing! I also hope to see you at KOH next year.

Brett

RZRS EDGE RACING

06-23-2010, 10:40 AM

Brett keep the pics coming we will see ya at KOH with our new RZR4 race rig

cuflipn

06-23-2010, 10:51 AM

Update:

With my tear down complete the design starts...

First recreate the base chassis in Solid Works:
Then consider wheel base and tire size 6 inch long arm with 3 forward sweep and 3 back 32 x 11.50 R 15 Super Swamper TSL SX

Finally the cage design.

You guys should know that I have been working on this so I am just catching you all up LOL I'm doing my best to not drag this out haha

KJSmith84

06-23-2010, 11:00 AM

cuflipn

06-23-2010, 11:08 AM

Nice.

you also might looking into triming that front part of the frame- will get you some more clearance when droping into stuff.

heres an example on how magnum did theirs - but this is a short course bumper.

http://i207.photobucket.com/albums/bb97/ulsjoeyd/MAGNUM/DSC_5664.jpg
KJSmith84,

You are so right!! I also really like that front end. I still have some work to do on how much of the original tower I will maintain and how much will be replaced but hey thats the fun part!

Thank you for your input it is appreciated!

Magnum ROCKS!!!!!

Cheers,
Brett

Rusty5150

06-23-2010, 01:19 PM

cuflipn

06-24-2010, 10:47 AM

Update:

Boat sides on and getting the double hoop mocked up. Sorry if the cell phone pictures aren't clear!

JoeyD23

06-24-2010, 11:29 AM

looks great! Thansk for the pics. I think the double hoop will look cool. Whats your plans for the suspension?

cuflipn

06-24-2010, 11:34 AM

looks great! Thansk for the pics. I think the double hoop will look cool. Whats your plans for the suspension?

Thanks Joey!

My plan is to design and build my own A-arms... This is driven mostly by cash flow as well as I want to do a 3 inch forward sweep and a 3 inch rear sweep. I haven't seen a kit out there that offers this... the most I have found was 2 inch.

Oh and I am planning on running the Fox air-shock 2.0 with 14 inch travel.

Darryl89

06-24-2010, 11:43 AM

Thanks Joey!

My plan is to design and build my own A-arms... This is driven mostly by cash flow as well as I want to do a 3 inch forward sweep and a 3 inch rear sweep. I haven't seen a kit out there that offers this... the most I have found was 2 inch.

Oh and I am planning on running the Fox air-shock 2.0 with 14 inch travel.

Looking good, I'm looking forward to seeing the finished project. I think that the magazines should do more articles on buildups like yours, as the majority of the sport segment can't afford high dollar buildups, but garage builds are becoming the popular thing.

Keep the pics coming and let us know how the A-arm project turns out. My Prowler build uses arms I built myself, but prior to building, I did much experimenting with different sweeps. I found that some sweeps work while others don't.
Good project...

cuflipn

06-24-2010, 12:21 PM

Looking good, I'm looking forward to seeing the finished project. I think that the magazines should do more articles on buildups like yours, as the majority of the sport segment can't afford high dollar buildups, but garage builds are becoming the popular thing.

Keep the pics coming and let us know how the A-arm project turns out. My Prowler build uses arms I built myself, but prior to building, I did much experimenting with different sweeps. I found that some sweeps work while others don't.
Good project...

<meta http-equiv="Content-Type" content="text/html; charset=utf-8"><meta name="ProgId" content="Word.Document"><meta name="Generator" content="Microsoft Word 11"><meta name="Originator" content="Microsoft Word 11"><link rel="File-List" href="file:///C:%5CDOCUME%7E1%5CBCARTE%7E1.CAL%5CLOCALS%7E1%5CTe mp%5Cmsohtml1%5C01%5Cclip_filelist.xml"><link rel="Edit-Time-Data" href="file:///C:%5CDOCUME%7E1%5CBCARTE%7E1.CAL%5CLOCALS%7E1%5CTe mp%5Cmsohtml1%5C01%5Cclip_editdata.mso"><style>  </style> Thank you Darryl, I agree with you on the garage build and mag comment... I really envy those guys who can do the BIG buck builds but at the same time it sure is cool to say that 'I built it' it really makes it original and yours.

I would like to hear about your finding on the sweeps if you care to share? I have a ton of learning to do and I'm not afraid to ask :D for help.

Darryl89

06-24-2010, 12:42 PM

<META name=ProgId content=Word.Document><META name=Generator content="Microsoft Word 11"><META name=Originator content="Microsoft Word 11"><LINK rel=File-List href="file:///C:%5CDOCUME%7E1%5CBCARTE%7E1.CAL%5CLOCALS%7E1%5CTe mp%5Cmsohtml1%5C01%5Cclip_filelist.xml"><LINK rel=Edit-Time-Data href="file:///C:%5CDOCUME%7E1%5CBCARTE%7E1.CAL%5CLOCALS%7E1%5CTe mp%5Cmsohtml1%5C01%5Cclip_editdata.mso"> <STYLE> v\:* {behavior:url(#default#VML);} o\:* {behavior:url(#default#VML);} w\:* {behavior:url(#default#VML);} .shape {behavior:url(#default#VML);} </STYLE><STYLE>  </STYLE>Thank you Darryl, I agree with you on the garage build and mag comment... I really envy those guys who can do the BIG buck builds but at the same time it sure is cool to say that 'I built it' it really makes it original and yours.

I would like to hear about your finding on the sweeps if you care to share? I have a ton of learning to do and I'm not afraid to ask <?xml:namespace prefix = o /><o:lock aspectratio="t" v:ext="edit"></o:lock><?xml:namespace prefix = v /><v:shape style="WIDTH: 12pt; HEIGHT: 12pt" id=_x0000_i1025 coordsize = "21600,21600" alt = ""><v:imagedata src = "file:///C:\DOCUME~1\BCARTE~1.CAL\LOCALS~1\Temp\msohtml1\01 \clip_image001.gif" o:href = "http://www.utvunderground.com/images/smilies/biggrin.gif"></v:imagedata></v:shape> :D for help.

What I found on mine (Arctic Cat Prowler), that cycling the suspension through all the range (shock removed, on jackstands) with the axle removed from the hub, but still in place on the diff, I could move the axle to the setbacks and forward sweeps and see what interferences there were. I found that my rear axles could only have an inch to 1.5 inches rear sweep (at +4 inches wider per arm) before the axle would contact the lower A-arm mount, which could cause damage to both the axle and rear diff. Same with the front, going past a couple inches forward sweep (+4 inch wider per arm), I had contact both on the upper and lower A-arm mounts at full extension and compression. I ended up changing the position of the rear diff backwards by 5 inches and building J-arms for the rear suspension, which allowed me to move the wheelbase length out 5 inches while moving the center of balance on the machine to a more neutral position overall.
It's still being built, so I'm not ready to post pics. I want it fully finished and tested before I go bragging about it... :D, I've already found several weak areas on the OEM machine that have required re working (ie: ball joint spindles pulling out of hubs, etc.)

I ended up going through several design changes on the overall machine, trying to come up with an ultimate setup. But it's all worth it in the end. I can see why Dragon Fire Racing built much of their machines from scratch.

Joey, hint hint, UTV Off-Road Magazine needs more garage builds...with the current economy, I can't afford the big-buck builds either.

Crowdog

06-24-2010, 05:55 PM

Looking good Brett. Those tires are HUGE! Got to think about axles/CVs with that much meat. Keep the pics coming.

fundad

06-24-2010, 10:22 PM

Looks good Brett. I'm interested to find out how it turns out as well and will be watching. Plus 3 on both ends ought to be interesting. Keep the pics coming!

cuflipn

06-25-2010, 08:43 AM

What I found on mine (Arctic Cat Prowler), that cycling the suspension through all the range (shock removed, on jackstands) with the axle removed from the hub, but still in place on the diff, I could move the axle to the setbacks and forward sweeps and see what interferences there were. I found that my rear axles could only have an inch to 1.5 inches rear sweep (at +4 inches wider per arm) before the axle would contact the lower A-arm mount, which could cause damage to both the axle and rear diff. Same with the front, going past a couple inches forward sweep (+4 inch wider per arm), I had contact both on the upper and lower A-arm mounts at full extension and compression. I ended up changing the position of the rear diff backwards by 5 inches and building J-arms for the rear suspension, which allowed me to move the wheelbase length out 5 inches while moving the center of balance on the machine to a more neutral position overall.
It's still being built, so I'm not ready to post pics. I want it fully finished and tested before I go bragging about it... :D, I've already found several weak areas on the OEM machine that have required re working (ie: ball joint spindles pulling out of hubs, etc.)

I ended up going through several design changes on the overall machine, trying to come up with an ultimate setup. But it's all worth it in the end. I can see why Dragon Fire Racing built much of their machines from scratch.

Joey, hint hint, UTV Off-Road Magazine needs more garage builds...with the current economy, I can't afford the big-buck builds either.

Darryl89, Thank you for sharing your experience with A-arms I will keep this in mind.

Looking good Brett. Those tires are HUGE! Got to think about axles/CVs with that much meat. Keep the pics coming.

Jon, thanks! You are so right they are some BIG old meat hooks!! LOL I have given it some thought I have upgraded to Gorilla axles and I am planning on doing a gear reduction (although the gear reduction doesnt off load the axle it will with gas peddle) ... with that said I will still need to be careful.

Looks good Brett. I'm interested to find out how it turns out as well and will be watching. Plus 3 on both ends ought to be interesting. Keep the pics coming!

Thanks Aaron, it will be interesting!! I hope to get a lot of my answers with the simulation in Solid Works i.e. axle angle wheel travel shock placement and any pinch points :D

cuflipn

06-25-2010, 08:56 AM

Update:

Double hoop taking shape, man getting them to match was not easy!! LOL Harness bar is in and front dash tube... I am very pleased with the seat placement 6 inches lower then stock about 5 off the stock chassis :D the double hoops are 49 inch off the top side of the main chassis that will give me about 4 inch clearance from the top of my helmet. Leg room is better then I had hoped for! Having a blast!!!

Next the rear hoop and down tubes.

JoeyD23

06-25-2010, 09:11 AM

this build just moved up the rankings in my book....I love that double hoop look. Your UTV is gonna look like a mini Toyota rockcrawler!!! Keep the pics coming!!! REP POINTS BRETT!

MAGNUM OFFROAD

06-25-2010, 09:12 AM

BEST "crawler" inspired design I've seen yet! Look's like a little Yota bobber buggy. The double hoop came out great!

Great work Brett!!!

Looking forward to seeing this build unfold!

MAGNUM OFFROAD

06-25-2010, 09:19 AM

Forgot to mention that I am a Jessie Jane fan myself!

cuflipn

06-25-2010, 09:25 AM

Thank you guys!!! I am very excited with how its coming together!

Magnum Offroad, you crack me up!! You must really be a fan most of that autographed ;) posted is covered by the table in that picture... That's some funny sh#t LMAO!

More pictures coming!

Team Green

06-25-2010, 11:37 AM

Get that thing done and come back to Moab next year and show it off!

KJSmith84

06-25-2010, 01:20 PM

looks good.

Rusty5150

06-25-2010, 01:27 PM

cuflipn

06-25-2010, 01:33 PM

Looks good. Are you using 1.75" tube.

Yea I am using 1.75 x .095 tube...

Thanks for all the compliments and support!

Darryl89

06-25-2010, 02:01 PM

Brett,
I was just looking at your photos and noticed you have the same seats it looks like that I have. Beard Super TZs. If so, I found the running the front of the seats about 1 inch higher mountwise than the rear, provides a lot more thigh support and keeps the legs from being bounced around so much. You might try to block the fronts up and just see if it feels any better and allows your legs to rest more naturally where the pedal well would be.

cuflipn

06-25-2010, 07:55 PM

cuflipn

06-25-2010, 08:04 PM

Update:

Rear hoop and down tubes in also some of the small cross tubes on the double hoop. I must say that when I got the pieces in to tie the double hoop into the dash bar it really brings its together :D I'm digging it! Amazing how much you can get done by calling in sick haha :rolleyes:

JoeyD23

06-25-2010, 09:35 PM

wow its really coming together nice!! Why not use smaller tubing for the lacing in between the main hoops and bars to cut down on weight?

Rusty5150

06-25-2010, 09:56 PM

Your build is coming together good. Keep up the hard work.

Crowdog

06-26-2010, 06:55 AM

Looking really good Brett. You are making awesome progress.

You should think seriously about adding power steering too. I love it in mine.

Keep the pics coming.

cuflipn

06-26-2010, 09:15 AM

wow its really coming together nice!! Why not use smaller tubing for the lacing in between the main hoops and bars to cut down on weight?

Joey, to be honest I didn't think about that... structurally the same size is better for transferring load but I agree that you could go smaller with out effecting that to much and gain the weight savings. I will remember that for future projects thanks!

Your build is coming together good. Keep up the hard work.

Rusty, thank you for following my build the encouragement is appreciated!

Looking really good Brett. You are making awesome progress.

You should think seriously about adding power steering too. I love it in mine.

Keep the pics coming.

Jon, funny you should bring that up (power steering). I am planning on it but not just any old power steering... I am going to hold off saying what my plan is until I have reached that part of the build but I think you guys will like it. :D

Cheers,

Brett

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JoeyD23

06-26-2010, 10:37 AM

Bretts build is blowing up!!! UTV Guide Blog: Awesome Kawasaki Teryx Rock Crawler Garage Build (http://blog.utvguide.net/2010/06/awesome-kawasaki-teryx-rock-crawler.html)

Darryl89

06-26-2010, 02:38 PM

Bretts build is blowing up!!! UTV Guide Blog: Awesome Kawasaki Teryx Rock Crawler Garage Build (http://blog.utvguide.net/2010/06/awesome-kawasaki-teryx-rock-crawler.html)

Awesome, thanks and props to Jon and Joey for bringing this machine project to the forefront.
We want more.....

MAGNUM OFFROAD

06-26-2010, 04:36 PM

Coming along great Brett!

Crowdog

06-26-2010, 08:11 PM

Jon, funny you should bring that up (power steering). I am planning on it but not just any old power steering... I am going to hold off saying what my plan is until I have reached that part of the build but I think you guys will like it. :D

Cheers,

Brett

I think Reid (Team Green) was going to put a PS unit from a Mule in one if his Teryx.

OFFROADSWAPMEET

06-27-2010, 08:50 AM

Looking good brett. I like the truck look and should be fun climbing the HAMMERS.

Dirtdaddy

06-27-2010, 08:33 PM

Hay Brett are you done with my welder yet ? I would like to get my Rex done. :eek: You guy's it looks even better in person. It is going to be sick on the trail.

cuflipn

06-28-2010, 09:18 AM

I think Reid (Team Green) was going to put a PS unit from a Mule in one if his Teryx.

Jon, I have looked into this and didn't really see any benefit also from what I could tell the cost was higher then the unasteer... Do you know why he is thinking of going this way? Ried???

Coming along great Brett!

Thanks!!

Looking good brett. I like the truck look and should be fun climbing the HAMMERS.

I am looking forward to KOH!!! It will be a blast :D Thanks!

Hay Brett are you done with my welder yet ? I would like to get my Rex done. :eek: You guy's it looks even better in person. It is going to be sick on the trail.

Ed, you can have your welder back when I am done with it! LMAO! JK! Thanks for the props on the build :rolleyes:

cuflipn

06-28-2010, 09:43 AM

Build update:

What a great weekend! I have welded all the main tubes on the chassis next step start making triangles. But first I am turning my attention to the suspension, I have about 80% of it designed and I feel like it is going in the right direction. Couple questions though:

1. I am planning on using Hiem joints on all connecting points except for the upper front arms at the chassis where I will use the stock bearing system. I have read and seen other long travel arms use a 3/4 inch hiem out on the steering yoke. What and where do I find the hardware i.e. OE tapered bushing and with that what kind of bolt? Does the hole need to be reamed out?

2. Does anyone see any problems with using Hiem (I'm thinking 5/8) to connect the arms to the chassis? My thought here is they are doubled up where the steering is a stand alone that why it's 3/4...

I also would like to add the thought behind Hiem at the chassis is also for fine tuning the wheel alignment.

I was able to get the Teryx up on a cart (Thanks Aaron for letting me use one of you jet ski stands!!!!) WOW this makes things so much easier!! LOL with it on the stand I took all the suspension off and cut the front shock tower off :eek: now I need to get the new A-arms under it so I can double check the new shock placement so I will hold off on doing the rear lower hoop and the front shock hoops till then.

Cheers,

Brett

JoeyD23

06-28-2010, 11:19 AM

cuflipn

06-28-2010, 11:30 AM

this thing is looking awesome. I will say I have never seen tubing go from the dash bar to the front bulhead at that angle. I think it may encourage bending on a really hard hit? I am by no means a fabricator mind you so pardon my nonsense...hahahha Keep it up! I am loving this build.

Joey,

I think your right if it was left like the picture shows it could be bad! there are few tubes that have not yet been placed because I need to check for shock and tire clearance. As soon as I get the A-arms in so I can feel good about all that I will lay in the rest of the structure to the front and rear of the chassis :D.

I have a ton of work yet to do so many details that are still only in my head... LOL

Thank you for the input and supporting my build on the Underground this forum ROCKS!!!!

Brett

Team Green

06-28-2010, 04:18 PM

cuflipn

06-28-2010, 04:48 PM

Brett,

Looks good! While you are going to this extent on your build I have two suggestions for you.
1. Tie your shift tower to the engine and not the chassis and keep the solid shift rod or tie the shift tower to the chassis and use a cable to shift it.
2. Add power steering if you don't already have it.

Ok 3 things!
3. Get rid of the vaccum actuator for the 4wd switch and make it a straight cable actuated action. It'll save room and you'll never need to worry about air (vaccum) leaks.

Thank you Ried for you input!

I have read about this shift tower thing and seen what can happen so thank you for reminding me!! If you have any pictures of how you did it I would like to see...

I agree power steering is a must!! This year in Moab (I did the UTV Rally) I broke my hand on Moab Rim trail when my tire grabbed a pothole and sucked my hand in even though I drive thumbs out!! Not doing that again.

I have some special plans for the power steering so stay tuned... :rolleyes:

The vacuum thing was ditched last year after Moab when we couldn't keep the dang things in four wheel drive LOL. That electric switch over vacuum to mechanical is way over complicated IMO> I love my cable, pull and it in!!!

Thanks again for the input, I hope to finish this thing and chase you and Jon around Moab next year oh and KOH!!

Cheers,

Brett

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cuflipn

07-06-2010, 09:07 AM

Update:

I have the A-arm design done and fixture laid out. All the materials have been ordered (Hiem joints tubing new notcher shocks...) the fixture will be ready by the end of this week.

I will post some new pictures later this afternoon but until then here is a screen shot of some of my changes.

Cheers,

Brett

STETLER

07-06-2010, 07:10 PM

Just found this build thread. Looks good. Lots of hard work ahead of you and already behind you. I'll be following this build. Thanks for sharing !

JoeyD23

07-06-2010, 07:17 PM

this build is sick!

fundad

07-06-2010, 09:57 PM

Wait till you guys see this in person next year at the big rides. It's really amazing. Never seen a UTV built like this. Agressive looks with unbelievable suspension. Wait and see :)
:cool:

cuflipn

07-22-2010, 08:49 AM

Update:

Not a lot to show as far as fabrication goes I have been doing a lot of design work on the A-arms and buying/ building tools...

Here is a pic of the A-arm design in Solid Works I will bend and weld them this weekend. I cant wait to see this thing sitting on its wheels again!

Oh and some pic's of my A-arm fixture I built it out of some aluminum extrusion and a slide so it can be adjusted for sweep and length.

Cheers,
Brett

Darryl89

07-22-2010, 10:15 AM

Brett,
That looks good. nice jig you made there. I'm looking forward to seeing more.

MRPAT920

07-22-2010, 10:35 AM

man this build looks great im even getting motivated to build a KOH rig

OFFROADSWAPMEET

07-22-2010, 11:00 AM

KING OF THE HAMMERS IS GOING TO GET BIGGER AND BETTER!
http://i561.photobucket.com/albums/ss55/fernandezracing45/KOH%202010/DSC_0291.jpg

http://i561.photobucket.com/albums/ss55/fernandezracing45/KOH%202010/DSC_0176.jpg

THIS IS WHAT HAMMER TOWN IS ABOUT!!

Darryl89

07-22-2010, 11:58 AM

man this build looks great im even getting motivated to build a KOH rig

That would be awesome to see 20-30 UTVs racing KOH in 2011.

cuflipn

07-22-2010, 01:57 PM

Brett,
That looks good. nice jig you made there. I'm looking forward to seeing more.
Thank you Darryl I am ready to see things come together too!! :D

man this build looks great im even getting motivated to build a KOH rig
I know what you mean it was Jon's (crowdog) build that did it for me!

KING OF THE HAMMERS IS GOING TO GET BIGGER AND BETTER!
http://i561.photobucket.com/albums/ss55/fernandezracing45/KOH%202010/DSC_0291.jpg

http://i561.photobucket.com/albums/ss55/fernandezracing45/KOH%202010/DSC_0176.jpg

THIS IS WHAT HAMMER TOWN IS ABOUT!!

I cant wait to experience this awesome event!! Just to run in the KOH is going to be amazing.

cuflipn

07-22-2010, 02:01 PM

Here are some fun screen captures... I need to weld something LOL

fundad

07-22-2010, 02:54 PM

OK those solid works pics are way to much fun. I highly recomend clicking through them fast. It's like an old fashion cartoon. You can really see how much travel this Mean Machine has!

Lets start bending and welding tonight!

Jonas - you home yet?

JoeyD23

07-22-2010, 03:02 PM

looks so sick!!!

roadiestar

07-25-2010, 03:58 PM

Looks great i'm jealous I wish I had your talent.

Crowdog

07-25-2010, 08:58 PM

I know what you mean it was Jon's (crowdog) build that did it for me!

:D

I cant wait to experience this awesome event!! Just to run in the KOH is going to be amazing.

Everyone that wants to see a King of the Hammers UTV race for 2011 better start letting Jeff and Dave of KOH know that they are planning on it. Not sure how hip there were on the UTV race in 2010. I think they were hoping for a much larger turnout.

cuflipn

07-26-2010, 08:24 AM

Looks great i'm jealous I wish I had your talent.

Thanks roadiestar!

Everyone that wants to see a King of the Hammers UTV race for 2011 better start letting Jeff and Dave of KOH know that they are planning on it. Not sure how hip there were on the UTV race in 2010. I think they were hoping for a much larger turnout.

Jon, do you have contact info or is it whats on their website?

OFFROADSWAPMEET

07-26-2010, 08:47 AM

cuflipn

07-26-2010, 08:58 AM

Update:

Well I finally got away from the computer and welded something LOL

Saturday morning I finished bending all the a-arm tubes and cutting them to length... the moment of truth was here, will the fixture work as designed?? :confused:

I am happy to say, yes it works perfectly :D! I was only able to get my front lower and upper arms built but I am very happy with how they turned out. Also if you are in the market for a tube notcher, I highly recommend the 'Notch Master' from JD Squared Inc it is worth every penny of the $270.00 dollars!!

Cheers,
Brett

Darryl89

07-26-2010, 08:59 AM

Emails / messages sent to both Dave and Jeff....

I'm building a car that I hope to run in KOH also...

http://i294.photobucket.com/albums/mm91/DarrylD89/PROWLER%20PROJECTS/IMG_3289.jpg

cuflipn

07-26-2010, 09:02 AM

Emails / messages sent to both Dave and Jeff....

I'm building a car that I hope to run in KOH also...

http://i294.photobucket.com/albums/mm91/DarrylD89/PROWLER%20PROJECTS/IMG_3289.jpg

Darryl,
That is looking sweet!! Great lines on the cage I really like that! Are you doing a build thread? If so what is it called I would like to check it out...

Brett

cuflipn

07-26-2010, 09:25 AM

Everyone that wants to see a King of the Hammers UTV race for 2011 better start letting Jeff and Dave of KOH know that they are planning on it. Not sure how hip there were on the UTV race in 2010. I think they were hoping for a much larger turnout.

Everybody thats wanting to race needs to contact these guys ASAP!!! We cant afford to lose the KOH SXS RACE. Spectators should contact them aswell.
King of the Hammers (http://www.kingofthehammers.com/)
KOH 2011

I just heard back from Jeff (KOH) he said that they will be giving it one more shot this next year to see if they can get better numbers...

So if we want this to be something we can look forward to each year we need everyone out there please!

Brett

Darryl89

07-26-2010, 09:26 AM

Darryl,
That is looking sweet!! Great lines on the cage I really like that! Are you doing a build thread? If so what is it called I would like to check it out...

Brett

No build thread yet, I'm waiting on getting it a bit more done. It still needs to go to the welding shop, it's just tacked together for fit checking.
But I'm planning on doing a full build thread soon. It stands 65 inches tall with 13 inches GC, the new A-arms will move the rear wheels back 3 inches andthe front wheels forward 1. It'll be a +5 inch setup with expected 15 inches of travel. The fuel cell will be 10 inches lower than in the photos.
Lots of engine and transmission work going into it also.
The cage consists of 216ft of 1.75X.095 4130 Chromemoly and some DOM.
I'll keep you posted, sorry for the hi-jack, now back to your awesome build, I'm looking forward to more of yours...

JoeyD23

07-26-2010, 09:26 AM

I love this thread!!!!!!!!

cuflipn

07-26-2010, 09:50 AM

No build thread yet, I'm waiting on getting it a bit more done. It still needs to go to the welding shop, it's just tacked together for fit checking.
But I'm planning on doing a full build thread soon. It stands 65 inches tall with 13 inches GC, the new A-arms will move the rear wheels back 3 inches andthe front wheels forward 1. It'll be a +5 inch setup with expected 15 inches of travel. The fuel cell will be 10 inches lower than in the photos.
Lots of engine and transmission work going into it also.
The cage consists of 216ft of 1.75X.095 4130 Chromemoly and some DOM.
I'll keep you posted, sorry for the hi-jack, now back to your awesome build, I'm looking forward to more of yours...

It's all good Darryl :D! That all sounds awesome it will make for a good read cant wait!

I love this thread!!!!!!!!

Thanks Joey! This week I am in California for work so I wont have to much to update on but this weekend I plan on finishing the A-arms and chassis (oh I took those silly bent tubes off the front LOL I think you will like the new stuff better)... I also need to send out my gusset / shock mount designs for laser quote. So much to do and so little time!

Cheers,

Brett

Team Green

07-26-2010, 10:05 AM

cuflipn

07-26-2010, 10:13 AM

Nice touch Brett, your making it a front steer I see.

Thanks Reid,

You have a great eye for detail LOL yes I am planning on a front steer configuration.

Question for you: Who do I need to talk to about getting some BIG monster decals for this thing? I have a lot yet to do but I am going with green and black and want to fly the Kawi Monster big and proud! Please let me know if you can point me in the right direction.

Cheers,

Brett

Team Green

07-26-2010, 10:22 AM

I think I know a guy that might be able to help. When you're ready give me some approx sizes and I'll see what can be done.

cuflipn

07-26-2010, 10:26 AM

Thank you Reid, you the man! :D

fundad

08-02-2010, 11:06 PM

WOW!!!
Great Progress is being made on this build.
Just got back from Bretts and he's got 3 of the 4 sets of A Arms done. This is beyond garage built. He's got mad skills!!!
Rock clearance, Huge functional travel and.....just wait.

Come on Brett post some pics. You have to share, it's just to cool!

cuflipn

08-03-2010, 11:29 AM

cuflipn

08-03-2010, 11:41 AM

Update,

Ok we it may not look like much as been done sense my last update but I will assure you that I have been working my butt off! :D

My first swing at the A-arms fell short of what I wanted to see in the wheel travel. I really should have verified the working angel of the high miss alignment spacers on the hiem joints (this is what happens when you ASSUME!!!). The affective angel is only about 30 deg each way and I didn't have any bend in the A-arms to consider the starting point of this angel sooooo in short I redesigned my A-arms and ordered more tube and rebuild the front upper and lower. The results of which I am very pleased with!!!

Now with A-arms behind me on to finishing the chassis! I hope to have some good progress this week and weekend. I will be sure to post the pictures then!

Having a blast with this build and learning a ton!!!

Cheers,

Brett

cuflipn

08-03-2010, 11:46 AM

Couple more pictures....

In the one picture (sorry crappy cell phone shot) you can see the first A-arm design on the left not allowing the arm to travel below a certain point and on the right the new ones over 6 inch's of additional drop.. and a loss of only 2 inch's of up travel... Fun stuff :D

MAGNUM OFFROAD

08-03-2010, 12:49 PM

I haven't read through the entire thread, but how is the leg room gonna be in this bad boy? Look's slim.

cuflipn

08-03-2010, 12:53 PM

I haven't read through the entire thread, but how is the leg room gonna be in this bad boy? Look's slim.

Its not bad very close to what I had before... here is a pic that may give you a better idea.

Thanks!

fundad

08-03-2010, 02:01 PM

There we go! Great Pics that show your hard work. Now everyone can see your attention to detail in the design.

Good Work!!!!!

Can't wait to start on my 4 seater :) KRAWLER

cuflipn

08-09-2010, 08:59 AM

Update:

Well I didn't get as much done as I had hoped but every tube counts in the end.

So I have the front of the chassis tacked in and HOLY COW the shock hoops are huge!! LOL :eek: but then again so are the King shocks... The pictures really don't show it in proportion IMO you will have to trust me when I say it looks pretty cool with the hood held up next to it! I still have some work to do on the nose and how it ties into the front stinger but that will have to wait for the steering unit at the end of the month (also thinking about pulling that radiator out of there to clean up the structure...).

The backside is starting to take shape as well. It truly is amazing how much the stock parts weight!! There is a ton of doubler plates on top of doubler plates on the stock chassis, looks like they just kept adding to it...

Well off to Cal. for work this week next update this weekend.

Cheers,
Brett

Team Green

09-16-2010, 03:03 PM

Hey, where is our updates! It's been a month and I want to see your progress!

cuflipn

09-21-2010, 10:35 AM

Sorry for the radio silence... work is really starting to get in the way! LOL I have been out of state for work the last 7 weeks so I really dont have much of an update.

Update:
1.Rear chassis mod tacked up and ready for welding still need to remount the Muzzy should get that done tonight.
2. Relocate radiator
3. Rear shock hoops I still need to tie them in for lateral support
4. Frame mod i.e. tapper the leading 90deg corner (Great idea Ed)
5. Shock mount mock-up

My next step is to get the gussets and shock mounts designed and laser cut. Then order my axles so I can get this thing on its feet again!!

The current shock mock-up is giving 20in of wheel travel hard stop to stop. I will dial this back to about 17in and use limiting straps as well as the bump stops.

I hope to have more updates coming and get the energy back into this build. I am way behind my schedule to try and do King of Hammers so I will need to really turn it up!!

Cheers,

Brett

cuflipn

09-21-2010, 10:37 AM

More pic's

tatum

09-21-2010, 10:55 AM

JoeyD23

09-21-2010, 11:41 AM

looking really good!! Thanks for posting the updates!

Darryl89

09-21-2010, 06:23 PM

Brett, what length of shocks are you using and how much wider are the arms than stock
Looking really good, glad to see you back on it.

cuflipn

09-22-2010, 08:44 AM

Be careful when using limit straps to control droop because they stretch. Hard to get 20 inches of wheel travel unless you are going super wide.

Yea it isn't easy to get that wheel travel but hell if I'm not going to give it a shot! :)

looking really good!! Thanks for posting the updates!

Thanks Joey its nice to be back at it!!

Brett, what length of shocks are you using and how much wider are the arms than stock
Looking really good, glad to see you back on it.

Hello Darryl,

I have to laugh because I am sure from the outside what I'm building must seem crazy... Yes the shocks are full size buggy King 2.0 14 inch stroke :) The long arm kit is of my own design and is a 6+ over with 3 forward and 3 back.
Thanks Darryl!

Cheers,
Brett

Darryl89

09-22-2010, 10:05 AM

Yea it isn't easy to get that wheel travel but hell if I'm not going to give it a shot! :)

Thanks Joey its nice to be back at it!!

Hello Darryl,

I have to laugh because I am sure from the outside what I'm building must seem crazy... Yes the shocks are full size buggy King 2.0 14 inch stroke :) The long arm kit is of my own design and is a 6+ over with 3 forward and 3 back.
Thanks Darryl!

Cheers,
Brett

Not crazy Brett, you are building a good machine there. Sometimes we have to take matters into our own hands and build what the bg corporate attorneys and cost saver execs won't let the factories build.
It's looking really good though. Perhaps you might bring it to the King Of The Hammers in February.

cuflipn

09-22-2010, 10:29 AM

Not crazy Brett, you are building a good machine there. Sometimes we have to take matters into our own hands and build what the bg corporate attorneys and cost saver execs won't let the factories build.
It's looking really good though. Perhaps you might bring it to the King Of The Hammers in February.

Thank you Darryl, yes the plan was and still is to run it in the UTV KoH 2011. I have a ton of work to get done on a tight budget but I am still very hopeful to make it.

Thanks again for your feedback and encouragement!

cuflipn

10-28-2010, 09:55 AM

Update:

The lack of activity on my build has been due to funding… LOL but good news a resent infusion of cash has given new life to my King of Hammer build!

I will have some progress to report over the next weeks and hope to finish in early December (at least that’s the plan). I never thought it would have taken so long!
Cheers,

Brett

Team Green

10-28-2010, 03:59 PM

LSRGreg

11-02-2010, 09:13 AM

Just something to keep in mind, your going to have to use a super hi angle cv joint to get that much travel out of those a-arms. Either a Gorilla, or Tuner type set up, and those will cost you around $1800 for the complete set up. The stock cv joints will only allow you around 15" or so of travel at that length of arm before they will bind.

Build looks awesome though! Keep up the good work!

G-

RuggedRadios

11-04-2010, 01:14 PM

you rig look awesome. I think you are ready for an intercom.....

cuflipn

11-15-2010, 12:20 PM

Welcome back Bret! Race projects are nearly always behind schedule and over budget so welcome to the club and good luck with the rest of the build.

If you didn't hear we will going to the KOH event site the second weekend in November to teach event promoter Jeff Knoll what UTV's are capable of . Who knows maybe we can start some basic event layout ideas for the Feb event?

Yes I am new to the whole race build over budget and taking to long!! LOL

I am a little late in getting back to you about your second point but I have read your thread and I wish I was closer to take advantage of your offer!! I am very excited and killing myself to be ready for Feb 6 through the 12th K of H oh yea!!

Just something to keep in mind, your going to have to use a super hi angle cv joint to get that much travel out of those a-arms. Either a Gorilla, or Tuner type set up, and those will cost you around $1800 for the complete set up. The stock cv joints will only allow you around 15" or so of travel at that length of arm before they will bind.

Build looks awesome though! Keep up the good work!

G-

LSRGreg, I do appreciate your input here and I do see the limitation of the stock CV's!! I thought I had this in the bag because I in fact already own a full set of the Gorilla axles/ CV's. The PROBLEM is they are not good for full suspension travel. If you are looking for a super lift for deep mud and dont need the travel they may work ok... But what I found after taking my set apart (because I broke one in Maob) is a sub-par design to the automotive that are stock! See in the Gorilla axles the inner CV cage does NOT translate it is fixed out at the end of the housing (this is how they get the high angles I would guess) instead they have the splines sliding and you could imagine that a none bearing surface under load sliding the surface will break down and fatigue! This is what happen to mine the splines are twisted on the shaft and as soon as that happens it is the end because that twist will stop in from being able to slide binding the axle and compounding the problem.

So I am VERY unhappy with the fact I have spent $1800+ dollars on these axles and would NOT recommend them to anyone unless of course you don't need your suspension to move then you might be ok.

I am going to be using the stock CV's with Summer Brothers 300M axles!!!

Thank you for the compliments and encouragement!! I have been traveling a ton for work but hope to do some serious work in the next week so an Update is in the works!!

you rig look awesome. I think you are ready for an intercom.....

I will be very excited when I get to the point I am thinking of stuff like radios!! LOL and I will be sure to call you!

Thanks!

RuggedRadios

11-15-2010, 12:27 PM

Keep up the good work I will see this thing rip at KOH

tatum

11-15-2010, 03:18 PM

[QUOTE=cuflipn;46978]Yes I am new to the whole race build over budget and taking to long!! LOL

I am a little late in getting back to you about your second point but I have read your thread and I wish I was closer to take advantage of your offer!! I am very excited and killing myself to be ready for Feb 6 through the 12th K of H oh yea!!

LSRGreg, I do appreciate your input here and I do see the limitation of the stock CV's!! I thought I had this in the bag because I in fact already own a full set of the Gorilla axles/ CV's. The PROBLEM is they are not good for full suspension travel. If you are looking for a super lift for deep mud and dont need the travel they may work ok... But what I found after taking my set apart (because I broke one in Maob) is a sub-par design to the automotive that are stock! See in the Gorilla axles the inner CV cage does NOT translate it is fixed out at the end of the housing (this is how they get the high angles I would guess) instead they have the splines sliding and you could imagine that a none bearing surface under load sliding the surface will break down and fatigue! This is what happen to mine the splines are twisted on the shaft and as soon as that happens it is the end because that twist will stop in from being able to slide binding the axle and compounding the problem.

So I am VERY unhappy with the fact I have spent $1800+ dollars on these axles and would NOT recommend them to anyone unless of course you don't need your suspension to move then you might be ok.

I am going to be using the stock CV's with Summer Brothers 300M axles!!!

Thank you for the compliments and encouragement!! I have been traveling a ton for work but hope to do some serious work in the next week so an Update is in the works!!

We run the same type of set up in long travel buggies were the axle plunges inside of the cv joint all the time.On a buggy the cv is fixed on either end but on a utv it wants to pull the inner cv out of the diff.
You will have much better luck with stock cvs and good axles than gorillas.Ihad them once and would not own them again.
Everybody who does there own build is going to reinvent the wheel and get more travel than everyone else.The key is to get good usable travel.I have seen people build them were the frame hits the ground before the suspension bottoms out.

cuflipn

11-24-2010, 10:23 AM

Update:

Well I am finally getting somewhere! I have some good momentum going after I received my Summer Brothers Axles (Thank you Jose they are awesome!!).
My biggest lesson/ learning so far I would have to say is wheel travel. Greg you are right in that it is difficult to get more than 15" but what I have found, is that it isn’t because of the CV's. In my design I was on the aggressive side (easy to do when your designing in the computer haha) but when the time came last night to tack weld my shock mounts and go through everything I found that most of the additional 3 inches of travel I was looking to get was 'UP' travel. This is only a problem when you have to make the call on what tire you are going to run... I was planning on putting some monster 32" tires on but in an effort to control the cost and scope I pulled back to use the 30" that I have. So with the tire picked I could then look at ‘Bottom-out’ Tatum you nailed it man!! I didn’t have enough ground clearance from the frame to the ground most of my travel I was getting on top of what everyone else gets was in up travel!! GOOD thing to learn now J so all in all I may have purchased a little too large of shock and had my head in the clouds but I will end with a total of 17” with 16 usable (at least that’s what I am strapping for).
Feels good to be building again! Here are some shots of the front end.

Cheers,
Brett

LSRGreg

11-24-2010, 11:02 AM

ahh.. yes..if your using bigger diameter tires, you can get more uptravel. We set up our teryx long travel kits to have about 3" of ground clearance with a 26" diameter tire. We feel that by the time the tire flattens out, and the ground not being perfectly flat in all scenarios, this will leave you with a good amount of clearance. The chassis can still hit the ground, especially in soft sand and such, but its not very often, when the car bottoms out. But if your running a 30" tire, you should be able to get at least 2" more up travel, and still have the same clearance when its bottomed out.

Lookin good!!

cuflipn

11-29-2010, 09:56 AM

Thank you Greg!

Update:

I made some good progress over the Turkey day weekend!

All the suspension is done (still need to weld the mounts but otherwise done...) the suspension has to be the biggest achievement so far!! There is a lot that goes into it and I have a new found respect for the companies out there providing the long travel kits!!

Both seats are mounted and are 7 inches lower then stock position!! :D That will go a long way in the C.G.

Pedals mounted as well as the steering wheel. WOW its starting to look like a side by side again LOL!

With the radiator mounted I am on a roll...
What’s left?

Fuel cell, electrical, steering, skid plates, hood mount (I need to find a black one!!) testing and then paint. A lot to do before K of H but I think I will make it!

Cheers,
Brett

fundad

11-29-2010, 10:36 AM

That looks so GOOD!!!
I've been gone for 2 days and you've made major progress!!!
Good Job!

tatum

11-29-2010, 12:38 PM

You were busy this weekend,keep up the good work and keep the pics coming.

cuflipn

12-13-2010, 02:08 PM

Update:

The past three days I have completed the steering and all the welding on the chassis...

Some may have noted that in the beginning of my thread, I said I was doing something different for the steering, Reid was on top of the pic's and saw I was doing a front steer but that wasn't all :D (hhmmm that's a funny box up front???) LOL It will be so nice driving with one hand through the rockiest trails...

Next on the list is the electrical, skid plates and some body panels. Wow I think I am getting close I should (the plan is) to test drive it over the X-mass break

Cheers,
Brett

tatum

12-13-2010, 02:13 PM

Are those aftermarket spindles or did you just swap sides?

cuflipn

12-13-2010, 02:15 PM

Are those aftermarket spindles or did you just swap sides?

I swapped them and adjusted for the caster...

cuflipn

12-21-2010, 09:53 AM

Update:

Well I have made a big step forward in my build. to date I have completed the Hydraulics for my hydrostatic steering that included mounting the filter reservoir assembly, steering control valve, oil cooler and the hydraulic pump (this was no small feat not a lot of room after lowering the seats 7 inches). All though this system is a parisitic system (robbing H.P. from the motor) I feel it is a good trade for my style of riding. Now I will just have to be careful not to break my front hubs off LOL.

I also re built the front of the chassis (it wasn't quite on center). With my front axle nuts arriving today (funny how things get lost in the build process) I will be able to button things up and set it on the ground may even wire it up and see if it still runs haha.

Hope you guys enjoy it I know I am!

Cheers,
Brett

Team Green

12-21-2010, 10:02 AM

cuflipn

12-21-2010, 10:07 AM

Bret, It is hard to tell in the pictures but if your pump is mounted to the chassis you may have issues with throwing belts. I know the original UTV Inc Alternator kit that was mounted that way ate belts. If you can mount to engine cradle or the engine itself you'll avoid belt issues.

I like your thought process on this baby!

Thank you Reid your feedback is always helpful!!

Yes I remember they had a problem with that... My pump is very carefully mounted to the engine mount so it is one with the motor :) LOL and might I add it is very ridged with a jack-screw tension system so keeping the belt tight should be a breeze.

This picture shows the mount but is difficult to really see how it works...

Brett

fundad

12-21-2010, 10:13 AM

Thats just BAD ASS!!!!!

Cant wait to go for a test drive :)

mtoma

12-21-2010, 11:31 AM

Lookin good man, that's some great work and design.
I really like the gull wing style a-arms, gives you that extra ground clearance.
I've always wondered why other manufactures don't make theirs like this.

cuflipn

12-28-2010, 09:55 AM

Thats just BAD ASS!!!!!

Cant wait to go for a test drive :)

Lookin good man, that's some great work and design.
I really like the gull wing style a-arms, gives you that extra ground clearance.
I've always wondered why other manufactures don't make theirs like this.

Thanks guys!!

cuflipn

12-28-2010, 10:12 AM

Update:

Well I had a little set back with my hydro steering... I missed a very simple but very important step, yep you guessed it direction of rotation. LOL you would think if you are going to spend a day and a half fabing and fitting a pump and pulley assembly you would check direction before hand. NOPE not this guy LMAO!!

Ok so my update:

NEW hydro pump mount DONE! System primed and tested! WOW this is going to be awesome!! POWER steering :)

Rear suspension final welding is complete with tie rod position set for little to no bump steer (it turned out really nice only have a little toe in and full drop).

The big test, it has been on a cart for 7 months and it was time for the rubber to hit the ground!

Fully bottomed out there is roughly 3 inches of clearance (tire pressure was low at first) shocks set soft or low pressure the top of the cage is 68 inches with 15 inches ground clearance, full extended top of cage 71 inches ground clearance 18 inches for 17inches of travel.

I have a lot left to do but its getting there. Next is the electrical and some cross bracing.

Cheers,

Brett

cuflipn

12-28-2010, 10:14 AM

More pic's

Question for any of the peps who sell long travel kits:

Do you sell just the front break lines for a +6 (Teryx) and if so how much (you can PM me that if you want).

Thanks,
Brett

Dirtdaddy

12-28-2010, 05:23 PM

DUNE DUMMY 29

12-28-2010, 05:39 PM

THIS IS A GREAT BUILD. I CAN'T WAIT TO SEE IT FINISHED.

cuflipn

12-29-2010, 09:46 AM

Oh I know you meant to say "Thanks ED for pointing out that the pump is turning the wrong way" :mad: and then I say no problem glad to help !!!!! LMFAO. Nice work by the way that thing is off the hook. Can't wait for the first run. Bring it up to the farm and run it in the field.

LMAO!!! YES that is exactly what I meant to say... Thanks for the second pair of eyes and hands getting that primed.

But seriously I really thought it was more appropriate for me to point out my lack of insight to check this up front rather then your MANY years of experience that only a OLD man such as yourself could have. :D But all in all yes your are right THANK YOU ED!!

THIS IS A GREAT BUILD. I CAN'T WAIT TO SEE IT FINISHED.

Thanks!
As an old man ounce said to me (just the other day) "It's going to be interesting".

Cheers,
Brett

racemx587

12-29-2010, 09:47 AM

Looks awesome!! If you need any help with your hydro power steering, after about a year and a half I finally got mine dialed

cuflipn

12-29-2010, 09:51 AM

Looks awesome!! If you need any help with your hydro power steering, after about a year and a half I finally got mine dialed

Thanks!!

I am always open for help! What do you have the hydro steer in? And what would you say was the toughest part to dial in?

Brett

DUNE DUMMY 29

12-29-2010, 10:11 AM

LMAO!!! YES that is exactly what I meant to say... Thanks for the second pair of eyes and hands getting that primed.

But seriously I really thought it was more appropriate for me to point out my lack of insight to check this up front rather then your MANY years of experience that only a OLD man such as yourself could have. :D But all in all yes your are right THANK YOU ED!!

Thanks!
As an old man ounce said to me (just the other day) "It's going to be interesting".

Cheers,
Brett
NO OLD MAN JOKES. I RESEMBLE THAT REMARK HA HA . (60 ON MARCH 29TH)

Team Green

12-31-2010, 07:56 PM

Bret,

Do you still plan on making it down for the Hammers? I can"t wait to see this in action!

cuflipn

01-01-2011, 06:43 PM

Bret,

Do you still plan on making it down for the Hammers? I can"t wait to see this in action!

Hello Reid,

My plan is to be there at K of H but I will be honest, the cards are stacked against me. I think I will have my TeryX done but work is not looking good around the first of Feb. I will work my butt of trying though!!!

I will for sure be at the Rally on the Rocks I have had that time scheduled off for the last three years LOL.

I will know about KofH by mind January...

Thank you I can't wait either :)

Brett

Team Green

01-01-2011, 07:12 PM

I can understand difficulties with work but try hard, I want to see that in action. If nothing else I'll see you in Moab!

cuflipn

01-05-2011, 05:16 PM

IT'S ALIVE!!

WOW what a great feeling and milestone... this last weekend I got my wiring mock-up done and did a test fit. After one misplaced wire was fixed it fired right up!! :) What a great sound after almost 8 months of nothing...

So with it running a full test of the hydrostatic steering was done and let me say it kicks A$$

After some brainstorming with my friends it was decided that the Teryx hood was not going to work as planned ( the idea was for a 3 piece hood) this may be done later with a custom??? In the meantime a design was landed with everyone's input and I must say I think it looks pretty bad A$$.

Next onto the front breaks and skid plates with body panels following close behind.

Cheers,

Brett

fundad

01-05-2011, 05:20 PM

Looks Great Brett!!!

But shouldn't you be working?

VIAIR

01-05-2011, 05:45 PM

Car would be ten times better with a VIAIR OBA
http://www.viaircorp.com/OffRoad/Images/home_main_image.png

Dirtdaddy

01-05-2011, 05:56 PM

Or just one nitrogen bottle and you don't need to carry around all the rest of that crap.:D

Nice build Bertt, Im still waiting to see if we can scale the car on Saturday.

cuflipn

01-05-2011, 06:20 PM

Looks Great Brett!!!

But shouldn't you be working?

Yes I am this was a remote update from California :) Oh and I do get a lunch hour Aaron... LOL

Car would be ten times better with a VIAIR OBA
http://www.viaircorp.com/OffRoad/Images/home_main_image.png

That would be sweet thanks!! :) My address is 1506... wait I better PM that to you. You can ship it ground because I wont be back till this weekend. Thanks again oh please include decals and I will be sure to sport them! :D

Or just one nitrogen bottle and you don't need to carry around all the rest of that crap.:D

Nice build Bertt, Im still waiting to see if we can scale the car on Saturday.

I cant wait to see how much it tips the scales at!! Thanks again Ed for setting that up!

Cheers,

Brett

fundad

01-05-2011, 06:23 PM

you get a lunch break! Wow :)
Maybe its time I get a real job :)

Looks Good Brett!!!!!

cuflipn

01-05-2011, 07:21 PM

you get a lunch break! Wow :)
Maybe its time I get a real job :)

Looks Good Brett!!!!!

Thank you Aaron! I really appreciate all the support you and Ed give!! This has been a great project...

Brett

Team Green

01-05-2011, 07:38 PM

I'm heart broken it won't have a Teryx hood on it!

cuflipn

01-06-2011, 08:23 AM

I'm heart broken it won't have a Teryx hood on it!

I wouldnt say it wont have a teryx hood... I just havent figured out how to make it fit yet. I am a huge fan of the Teryx 08/ 09 look and I really want to maintain that in my design I still have a few ideas stay tunned...

Brett

cuflipn

01-10-2011, 10:17 AM

Ok so after some cutting I think I have landed the stock hood :D
Now I need to find a black one!!! Anyone out there have one?

Let me know what you think...

Cheers,

Brett

fundad

01-10-2011, 10:37 AM

bigmo450

01-10-2011, 10:43 AM

i like it but it looks like it will weigh a ton...literally

cuflipn

01-10-2011, 10:47 AM

Nice gussets on the hydraulic steering!!! Great touch.

The hood looks really good. You found a solution to have the hood line up with the cage. I know that was the big hurdle! Now it will still look like a Teryx... sort of :)

Thanks Aaron!!

i like it but it looks like it will weigh a ton...literally

Well I had it on the scales just yesterday and I can tell you I am VERY happy at the numbers I saw!!

Anybody care to guess?

Darryl89

01-10-2011, 10:52 AM

Thanks Aaron!!

Well I had it on the scales just yesterday and I can tell you I am VERY happy at the numbers I saw!!

Anybody care to guess?

1525....

everyone keeps thinking that because of all the tubing, that these cars must weigh a lot. My Prowler with over 220ft of 1.75 chromemoly isn't very heavy either. 220ft of 1.75x.095 CM weighs about 310lbs, removing the dump beds and old frame components removes over 225 lbs, so net gains are usually only around 50-100lbs.

cuflipn

01-10-2011, 10:58 AM

1525....

everyone keeps thinking that because of all the tubing, that these cars must weigh a lot. My Prowler with over 220ft of 1.75 chromemoly isn't very heavy either. 220ft of 1.75x.095 CM weighs about 310lbs, removing the dump beds and old frame components removes over 225 lbs, so net gains are usually only around 50-100lbs.

Darryl I could agree with you more!! The weight savings from cutting out all the factory frame is HUGE and yes the dump bed holly cow there's a 100 lbs right there..

Don't forget the total weight is not the only thing to keep your eye on. You need to balance it also :D and I am VERY happy with my front to back distribution!!

Darryl89

01-10-2011, 11:03 AM

Darryl I could agree with you more!! The weight savings from cutting out all the factory frame is HUGE and yes the dump bed holly cow there's a 100 lbs right there..

Don't forget the total weight is not the only thing to keep your eye on. You need to balance it also :D and I am VERY happy with my front to back distribution!!

Yeah, with the J-arms on my Prowler and putting the Optima battery up front, I ended up with an empty distribution of 47F/53R. Of course fuel and riders will change that.

Yeah, I think that Arctic Cat dump box weighs about 130lbs and then the additional stuff that is tacked on brings it up a bit. My car is sitting at around 1465 without the aluminum door skins or roof skin.

cuflipn

01-10-2011, 11:12 AM

Yeah, with the J-arms on my Prowler and putting the Optima battery up front, I ended up with an empty distribution of 47F/53R. Of course fuel and riders will change that.

Yeah, I think that Arctic Cat dump box weighs about 130lbs and then the additional stuff that is tacked on brings it up a bit. My car is sitting at around 1465 without the aluminum door skins or roof skin.

Nice!!

My car is 1485# and sits 50F/ 50R with riders and 1/2 tank of gas 1860# 48F/ 52R. I cant wait to get it on the trails!!! this thing should handle the rocks very well...

cuflipn

01-10-2011, 03:11 PM

Some more pictures with both sides on.

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Goodtimes

01-10-2011, 04:11 PM

Looks Bad ars !

Team Green

01-10-2011, 04:32 PM

Nice touch on those gussets!

JoeyD23

01-10-2011, 05:08 PM

WOW! Bad ass!!!

Darryl89

01-10-2011, 05:11 PM

WOW! Bad ass!!!

Joey, I bet you say that about all the UTVs...LOL

Looking good Brett, gonna be at KOH right???

JoeyD23

01-10-2011, 05:24 PM

LMAO...Yeah well I am a sucker for a UTV...lol...but this one is one of the nicest purpose built units I have ever seen! Love the hood set up!

Crowdog

01-10-2011, 07:29 PM

Looking great Brett. Sure hope you can pull off KOH!

cuflipn

01-10-2011, 07:36 PM

Looks Bad ars !

Thank you Steve! Oh and it's going to look even meaner when I put that Rigid light bar on!!! :D

Joey, I bet you say that about all the UTVs...LOL

Looking good Brett, gonna be at KOH right???

I am shooting for the KOH but work may get in the way... But yes that is my goal.

LMAO...Yeah well I am a sucker for a UTV...lol...but this one is one of the nicest purpose built units I have ever seen! Love the hood set up!

Thank you Joey!!! Can't wait to slap the Underground badge on it!!!

cuflipn

01-10-2011, 07:42 PM

Looking great Brett. Sure hope you can pull off KOH!

Thank you Jon! I'm going to give it my best! I was telling Reid I will with out a question be at Rally on the Rocks.

I can't wait for you guys to see this hydraulic steering! It's amazing but not for everyone....

Cheers,
Brett

Crowdog

01-10-2011, 09:04 PM

Thank you Jon! I'm going to give it my best! I was telling Reid I will with out a question be at Rally on the Rocks.

I can't wait for you guys to see this hydraulic steering! It's amazing but not for everyone....

Cheers,
Brett

You are so close. Got to make it for KOH! Really glad you were able to get a nice Teryx hood on there.

Darryl89

01-10-2011, 09:21 PM

Brett, if we don't see you at KOH, I'll be at Rally On The Rocks also with several buddies. I'm looking forward to seeing this awesome machine up close. It looks like one of the most trail-worthy rigs I've seen in a long time...

Dirtdaddy

01-11-2011, 11:40 AM

Hey damn good job sticking with the stock hood. I did not think it was going to work but you got the cuts just right and it looks sweet and even better standing next to it. I guess I need to get mine done now that your getting so close. Now if we only had a place to ride them. Washington State motto " If you come here we will make sure you don't smile and fun is against the LAW ":mad: I digress. Hey Brett Aaron has more work than me to do on his.:D

Rusty5150

01-11-2011, 11:47 AM

Very nice build. I cant wait to see it in action.

cuflipn

01-11-2011, 07:00 PM

cuflipn

01-11-2011, 07:02 PM

UPDATE!!!

I have the thumbs up from work to stay home for the following weeks and try and finish the build!!!

The only thing stopping me from being at the KOH is getting this thing done!! :D SWEET!!!!

Anyone want to help? :eek:

cuflipn

01-17-2011, 03:45 PM

Received my new Rigid light today :D Thank you Steve for hooking me up!! And WOW you guys are fast!!

Cheers,
Brett

RuggedRadios

01-17-2011, 03:54 PM

Awesome set-up. Now its time for the RUGGED!!!! haha

cuflipn

01-17-2011, 04:13 PM

Awesome set-up. Now its time for the RUGGED!!!! haha

For sure but with the build budget currently at zero I will have to wait LOL

But it is in the future plans!!

fundad

01-17-2011, 05:41 PM

I can come over Tuesday after work to lend a hand. My weekend got away from me with the little ones.

Love the light bar!!!

Dirtdaddy

01-17-2011, 11:10 PM

Aaron you have to go to the gym. You heve sat around all weekend now back to the gym.:D LOL ! I'm moving can't go.:eek: Just stopped in on Brett and it looks damn good.

cuflipn

01-21-2011, 09:39 AM

Update:

As of this morning looking at what I have left it is going to be VERY tight time line to get to KOH but its achievable!!

The beast has been hanging out at my friend shop for a couple days while we bang out some aluminum work.

Skid plates 75% done
Roof started
Fuel cell coming today (UPS)
Limit straps coming today (FedEx)

Still need to:

Finish wiring
shift tower
parking break
mount the hood
Fire wall...

And all the stuff I cant remember or thought of LOL

Cheers,
Brett

Team Green

01-21-2011, 12:54 PM

Since when is "Race Prep" not last minute? I hope you make it!

fundad

01-21-2011, 01:24 PM

Drive suit question.

Are Fire suits required? If so how many layers?

Thanks

cuflipn

01-21-2011, 03:39 PM

Since when is "Race Prep" not last minute? I hope you make it!

Oh I will make it!!! :D Nothing stopping me know!!

VIAIR

01-21-2011, 03:42 PM

Go Get em...

Darryl89

01-21-2011, 04:55 PM

Drive suit question.

Are Fire suits required? If so how many layers?

Thanks

Yes, firesuits are required, single layer minimum, 2 layer recommended.

bigmo450

01-21-2011, 08:23 PM

Yes, firesuits are required, single layer minimum, 2 layer recommended.

the video from last year, i believe it was the redline crew one dude was in a hoodie and a paintball mask lol

Darryl89

01-21-2011, 09:27 PM

the video from last year, i believe it was the redline crew one dude was in a hoodie and a paintball mask lol

Yeah, I saw that, but Jeff did confirm that firesuits are required. The rules do state that 2 piece suits are allowed, even though most other off-road racing sanctioning bodies only allow 1 piece suits.

cuflipn

01-24-2011, 09:38 AM

Update:

WOW! What a weekend! Got a lot done Thanks Aaron, Ed and Jonas!!

Ok skid plate is done and man it turned out awesome!! T6 6061 Alum welded one piece :D

Parking break modified from foot control to hand way bad ass!

All the templates for the body panels cute and ready for fitting

Fuel cell mount 80% done...

I have all the electrical to do and mounting of the body panels as well as the 5 point harnesses...

Ordered fire suits and on schedule for KOH!!

Oh yea almost forgot to mention; I was able to take it for a short spine and cross a couple curbs to fill out the suspension. Very cool I cant wait to go all out!!

Cheers,

Brett

Rusty5150

01-24-2011, 09:47 AM

Very nice. I cant wait to take some pictures of this car at the hammers.

cuflipn

01-24-2011, 10:17 AM

Very nice. I cant wait to take some pictures of this car at the hammers.

I wish I was going to have it painted for those pictures!!

Are you planning on going to Moab Rally on the rocks this year? I will have all the finish work and paint done by then...

Rusty5150

01-24-2011, 10:26 AM

I wish I was going to have it painted for those pictures!!

Are you planning on going to Moab Rally on the rocks this year? I will have all the finish work and paint done by then...

I don't know about rally on the rocks. Paint is not for rock crawlers, you wont want to scratch it.

cuflipn

01-24-2011, 10:28 AM

I don't know about rally on the rocks. Paint is not for rock crawlers, you wont want to scratch it.

LMAO!! You have a good point there!! :D

cuflipn

01-31-2011, 10:25 AM

update:

Well the 80/ 20 rule has never been more true!!

So with help from friends I have made some real progress this weekend.

Body panels done
Roof 90%
Fuel cell mounted (fitting leaking though...)
Engine shroud done (using some stock plastic to save time)
Rock windows done
Hood mounted done
Tail lights done (for now...)
Rigid light mounted done
Dash 90% done
Harness mounted done

Last night I ran it up and down my street (I'm sure my neighbors loved it LOL). Every thing seemed to work but if I gave it full throttle it would cut out and backfire??? not sure what that's all about.

I'm sure I have missed something but if I had to run tomorrow I think I have all the NEEDED stuff done :)

Cheers,
Brett

cuflipn

01-31-2011, 10:26 AM

More pic's

justinsrex

01-31-2011, 11:31 AM

plexi glass idea is sweet! Well, the whole ride is awesome!!

cuflipn

01-31-2011, 12:20 PM

plexi glass idea is sweet! Well, the whole ride is awesome!!

Thanks!!

Rock windows have been done before and I believe Crowdog was the first on a UTV. I got the idea from Jon :D

Thanks for the compliments!!

Brett

Crowdog

01-31-2011, 03:44 PM

Thanks!!

Rock windows have been done before and I believe Crowdog was the first on a UTV. I got the idea from Jon :D

Thanks for the compliments!!

Brett

And I got the idea from a rock buggy!

Can wait to see this first hand.

Could you be running lean at WOT?

Team Green

01-31-2011, 03:49 PM

Brett,

Good work but you know me, always wanting to throw in my 2 cents. Did you consider moving your light bar down to the front on that cross brace instead of on top of it. I think (just from the pictures) that mounted up there might be in your field of view (?)

tech3sandcars

01-31-2011, 03:56 PM

I'm with Jon, i think with the bigger tires and the weight of everything that the load is far greater on the motor and you may be lean. When it laid over and back fired which end did it come from? Intake backfire of exhaust. Also was the air cleaner off or modded?

cuflipn

02-03-2011, 10:34 AM

And I got the idea from a rock buggy!

Can wait to see this first hand.

Could you be running lean at WOT?

I don't think so I haven't changed anything on the tire motor setup for some time now... We tested it further and couldn't get it to do it again?? It could have been a air plentum leak I did go through and tighten everything after and now it wont do it...

Brett,

Good work but you know me, always wanting to throw in my 2 cents. Did you consider moving your light bar down to the front on that cross brace instead of on top of it. I think (just from the pictures) that mounted up there might be in your field of view (?)

I can see what you are talking about from the picture but it is all good from inside the car. I will have to make some custom mounts to get it lower and sitting between the shock hoops (this was the original idea and plan...). Oh and I always appreciate your input Reid!! :D

I'm with Jon, i think with the bigger tires and the weight of everything that the load is far greater on the motor and you may be lean. When it laid over and back fired which end did it come from? Intake backfire of exhaust. Also was the air cleaner off or modded?

No on the tires and load I have been running this setup for 2 years this was something I did while working on it... I think its fix now thank you for all the input.

cuflipn

02-03-2011, 10:46 AM

Update:

WOW!! I am very happy to say at around midnight last night me and my friends (Ed, Aaron) finished!!! my Teryx!! A BIG Thank you to everyone that took time off work and helped tirelessly I would not have been able to get it done without you!!

I am looking forward to showing everyone at KOH and getting all your comments as well as seeing how it does in the race.

We will try and get some video up later...

Cheers,

Brett

#8901 Racing for Krawl Ind.

fundad

02-03-2011, 10:54 AM

megonzo

02-03-2011, 01:40 PM

WC_NDN

02-03-2011, 02:05 PM

Just read this ENTIRE build thread, wow! incredible Teryx and top notch craftsmanship.

cuflipn

02-03-2011, 02:55 PM

Hey Brett!
Where are the completed Bad Ass Crawl Industries modified Teryx pictures!

Want to give a shout out to Brett for working unbelievable hours on this build!!! He's done a great job and I can't wait to see how it performs at KOH. Also need to give a shout out to his wife Katie! Not once have I heard her complain or give Brett any grief about working a full time job and then spending every free second working on his Teryx. Just awesome!!!!!

Now go have fun and enjoy KOH!!!

Yes how did I miss that??? You are right Aaron I have the BEST wife ever! Not only understanding but hot as hell :D. Oh she said thanks!

Yes know let the second wave of fun begin! KOH here we come!!

Just read this ENTIRE build thread, wow! incredible Teryx and top notch craftsmanship.

Thank you Lee, funny it all started with a broken axle in Moab last year... LOL I think it got out of control but with it all done I am very happy it did.

WC_NDN

02-13-2011, 01:06 PM

so how did this bad mofo do in the hammers?

cuflipn

02-13-2011, 08:15 PM

so how did this bad mofo do in the hammers?

It did great!! Very happy for the first time out!!

Thanks,

Brett
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luthernil

02-17-2011, 05:08 PM

I like the concept of the build. It seems to be working.

wheelchairacer

12-02-2011, 10:14 AM

Would you make another a arm fixture for sell?

cuflipn

12-02-2011, 10:32 AM

Would you make another a arm fixture for sell?

Hmmm :rolleyes: not sure about making fixtures... I could be talked into making A-arms though.

My 2cents, the fixture is the easy part! Getting all the cut and notched tube to fit and be correct is where the real work is.

Thanks

cuflipn

12-02-2011, 10:40 AM

Love it when a plan comes together :D

Darryl89

12-02-2011, 11:38 AM

Love it when a plan comes together :D

Dang, that is a good looking machine... you do great work Brett....

cuflipn

12-02-2011, 11:55 AM

Dang, that is a good looking machine... you do great work Brett....

Thanks a bunch Darryl :D

Freeezen

12-02-2011, 12:02 PM

That thing looks bad ass!

eatsand

12-02-2011, 01:01 PM

Digging the new colors. It looked great before but now you are legit!:cool:

Darryl89

12-02-2011, 01:28 PM

Digging the new colors. It looked great before but now you are legit!:cool:

Yeah, now it looks so...so.. so Kawasaki...

cuflipn

12-02-2011, 01:40 PM

Digging the new colors. It looked great before but now you are legit!:cool:

Thanks Troy! Maybe some day I will make the cover :D

Yeah, now it looks so...so.. so Kawasaki...

LOL not easy being green :rolleyes:

FabMan

01-14-2012, 11:53 PM

Crowdog

01-15-2012, 06:48 AM

FabMan

01-15-2012, 04:26 PM

Thanks for your response CrowDog. Hopefully Brett will chime in and let us know for sure. I was also wondering if those are Teryx wheels or truck wheels with some type of adapters. Thanks

Crowdog

01-15-2012, 05:43 PM

Thanks for your response CrowDog. Hopefully Brett will chime in and let us know for sure. I was also wondering if those are Teryx wheels or truck wheels with some type of adapters. Thanks

http://crowleyoffroad.com/wp-content/uploads/2010/02/KawasakiTeryx-PrairieCity-079.jpg

Look familiar? The smallest LT tire Pit Bull makes is a 31x11.50-15 Growler.

I am running an OMF billet center beadlock, but there are more and more 15" wheels coming out that fit a Teryx.

FabMan

01-15-2012, 06:13 PM

Jon, Thanks. I love your rig man. I watched that video of you going through that rock obstacle the other day, AWESOME! I am looking forward to ordering one of those engine kits probably mid summer. Your wheel and tire combo would be perfect for my riding area's but I can't seem to let go of the bills for what they want for a set of utv beadlocks when I see what you can get in, say a 5 on 5 standard chevy truck 15" beadlock. LOL Thanks

cuflipn

01-15-2012, 07:04 PM

Brett, your rig is my favorite utv. I was wondering what size wheels and tires you are running. At the riding area's here in Missouri, they are mostly rock crawling type trails so ground clearance will be an issue for me. Thanks

Hey Fabman,

Thanks for the great complement!!! I have been running truck tires from day one. I started out with 29x 10.50 TSL SX swompers. They where a good tire but I found the lug to be a little to aggressive... I am currently running the Pitbull Growler 31 x 11.50 15R LT on a ITP 15" rim for the TeryX. This rim is priced just right IMO. I also would love a set of bead locks but like you just can't let the money go on a set. My experience over the last 3.5 years running light truck DOT tires has shown me that with the stiff side wall popping a bead is not really an issue even at a low PSI of 3!!!

Hope this helps!

Cheers,
Brett

FabMan

01-15-2012, 07:58 PM

Brett, Thanks for the information. Good to know you have run the Hammers and didn't break a bead with the LT tires so I would be fine. I do like the looks of a beadlock, but not that much.LOL I will check out the 15" ITP line of wheels. Thanks again, helps alot. Great build, Later...