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Well hear is my install and I will update this as much as I can to keep all the info correct and to show you the presses that I took to transform a mild 440 trail race sled into what I believe to be close to the perfect mountain sled. This sled was and is currently being built aon a very tight budget so I don’t have $10,000 poured into the engine or a $3000 suspension but I still think the sled is going to be sick when im done. Hear is a list of parts I have added and changed, I will try to explain them in order.
1. Bad Oscar Customs 800 VES
2. Remounting and modifying the carbs to fit
3. Crankshop Twin chrome pipes and silencer install
4. Chassis mods to install the engine
5. Other little mods that I did
6. Boss Seat install
Hears a list of all the parts
03 800 VES
Crankshop twin pipes
C/A Pro Skis for spring
Polaris Gripper skis for Pow
RSI hand guards
RSI Handle bar heaters
RSI Bar Pad
Protaper Handlebars
Mountain Machine Performance riser
Mountain Machine Performance Billet 8” rear wheel kit
Walker Evans factory race shocks with remote reservoirs, revalved and rebuilt
Custom skid plate
Boss seat
151x15x2.25 Maverick track
121x15x2 (on sled and for spring riding)
Custom drop down brackets
Buying soon (if you got it shoot me a PM)
Ice age MFG Rails
Boondocker or BD nitrous kit
V-force 3 reads
Drop and roll kit???
Used blue plastic fenders
Chrome windshield???
Also I am going to be building my own tunnel extension so that should be interesting…
I purchased the sled, a 2005 polaris 440 race chassis. The previous owner had installed a 600 ves so that was the first thing to go.
Then I had to find an engine to replace it. I originally looked into putting a mod 05 900 engine in that I had sitting on my floor in the garage but decided that it would be to much work. I looked at getting a 07 or 08 600 and making it into a 660 or 680 but that would be about $4000 by the time I was done. I also looked into getting some of the older mod engines but I decided that I would use an 800 VES.
1.The reason I chose the Bad Oscar Customs kit is because of the piece of mind that a well know engine builder who rides modified race sleds him self went through the engine, completely rebuilding it from the ground up and having the piece of mind that it’s not going to grenade on the first ride.
The Kit I purchased came with the following~
03 Polaris 800 VES completely rebuilt
Bad Oscar Customs Motor plate
Crankshop Chrome Pipes and silencers
Carbs
Cables
All electroncs
Exhaust springs
All sensors needed
Coil
Another thing that I did not buy was included free of charge was countless hours of help from Spank him self, the owner. With out his help and great knowledge I would still be scratching me head with the sled laying in pieces in my garage floor!
2.In order to get the carbs to fit I had to do a few mods. First off, at the angle that they were at it would be impossible to mount the pods on the carbs with out them hitting the jackshaft. Some things we did was shim the back of the engine up 1/8” and we turned the carb boots upside down to angle the pods up so they would clear. This of course required some mods to the carbs. We had to grind down 2 bolts that hold the boots on the engine in order for the carbs to sit right in the boots. We wanted to be 100% sure we had a perfect seal as an air leak could cause severe damage to the engine. That alone was not enough so we ground off some excess mettle on the carbs to give the extra clearance we needed. I will show some pics next time I have the engine out.
We threw the engine in and it all fit PURFECTLY! So I was messing around and noticed that the cables that attach to the carbs would hit the head… So we pulled the engine out again to modify the brackets. We heated them up with a torch and rotated those about 20 degrees or so.
3. Crankshop chrome pipes and silensers Fit great and look AMAZING! It makes my average mod look like a show sled and best of all I can see my reflection when ever I look at them. The only downside is they are so shiny that when I have my hood open they blind me lol.
The install is very easy; if you can’t install pipes then you really shouldn’t be swapping an engine. The only thing I had to mod was my hood and where they exit the sled. These pipes sit VERY close to the hood so the first thing I did was whip out my trusty aluminum tape and I went to town on the hood putting 2 layers of it directly above the pipe. I also applied it to the inside of my fender wells, my side panels console and water as they sit very close and in a bad wreck I don’t want all my plastic melted to the pipes. Heck I don’t want my plastic melted to anything.
The only thing remotely challenging thing about the install was figuring out how to mount the silencer and have it exit cleanly. Remember that my sled has had 3 different engines in it before so there are 5 holes in my fender from the other pipes. Also, the previous owner stole a road sign and used it as a plate to mount the silencer to so I thought I should make a new one. I simply took a piece of 1/8” aluminum plate and made my own block off. I have not yet cut them out for the pipes but I will post pics when I do.
4. Chassis mods included the removal of the aluminum bar that sits right above the steering arm. This bar is very important structurally. It is placed on the inside of the chassis and its purpose is to take the abuse from the rear part of the a-arm. With out it there I believe that the chassis is much more at risk for cracks and flexing. Many people cut the bar out and simply weld a new one about 2 inches lower. I will most likely do this but I do not believe it is enough to maintain the strength of the chassis so this next weekend we are going to also try and add a aluminum support that bolts to the black steel cross bar that runs from the top of the chassis and down to the original mounting spots just behind the a-arm mount. it’s going to be a tight fit because it has to fish around the water pump, exhaust, steering brackets, steering post, and it also needs to be removable. I will definitely get pics when we get it complete.
5. Also, you have to cut about an inch or so out of the chassis just behind where the primary would be. I have not reinforced it or filled the hole so when are looking at the pics and see a big hole don’t freak out!
We are also looking at running a aluminum brace going from the top of the shock tower on the PTO side of the engine running back and bolting around the bolts that hold the jackshaft in place. The mount would run just along side of the engine block and right next to the clutch cover at about the same height. The Brace would look a lot like the ones used in the 05-06 RMK chassis.
Some other little stuff that i need to do is make a mount for my oil tank. I am either going to mount it directly above the engine or on the PTO side fender well directly above the primary. My only thought about mounting it there is that it is moving the center of balance some by putting all that weight on the side. ANY ideas or responses would be appreciated!
5. I started out with a Boss seat designed for a 05-06 polaris RMK. The first thing did was unzip the underside of the seat and cut a little bit of the foam off the front of the seat and a had to shave a bit off the back to make it fit the 9 gallon tank that I have. The install is very easy and takes about 20 min. After you cut the foam down all you have to do is mark your holes and drill. I went to the craft store and just bought replacement Velcro to hold the back of the seat down and it feels GREAT and should be an awesome seat with storage, something that new sleds apparently don’t have for some reason?????
6. Race Chassis skid plate- To make a skid plate for the race chassis all you need to go is buy a IQ skid plate. You need to cut about 2” off the back of the plate and you will need to bend it about 10” from the front. To achieve the bend we heated it up with a torch and bolted it on so it would contour to the shape of the race chassis which is much different then that of the IQ RMK chassis. After it molded right we simply took it off, sanded all the edges to get a factory look. Drilled some more holes to mount it on the chassis. We sanded the bur marks with fine grit sand paper and covered it with some clear coat to get rid of the black burn marks and it looks factory now. I will probably build an aluminum skid plate and have it anodized orange so if anyone wants mine let me know and I will sell it to you.
SORRY! i went over the limit for one post!
1. Bad Oscar Customs 800 VES
2. Remounting and modifying the carbs to fit
3. Crankshop Twin chrome pipes and silencer install
4. Chassis mods to install the engine
5. Other little mods that I did
6. Boss Seat install
Hears a list of all the parts
03 800 VES
Crankshop twin pipes
C/A Pro Skis for spring
Polaris Gripper skis for Pow
RSI hand guards
RSI Handle bar heaters
RSI Bar Pad
Protaper Handlebars
Mountain Machine Performance riser
Mountain Machine Performance Billet 8” rear wheel kit
Walker Evans factory race shocks with remote reservoirs, revalved and rebuilt
Custom skid plate
Boss seat
151x15x2.25 Maverick track
121x15x2 (on sled and for spring riding)
Custom drop down brackets
Buying soon (if you got it shoot me a PM)
Ice age MFG Rails
Boondocker or BD nitrous kit
V-force 3 reads
Drop and roll kit???
Used blue plastic fenders
Chrome windshield???
Also I am going to be building my own tunnel extension so that should be interesting…
I purchased the sled, a 2005 polaris 440 race chassis. The previous owner had installed a 600 ves so that was the first thing to go.
Then I had to find an engine to replace it. I originally looked into putting a mod 05 900 engine in that I had sitting on my floor in the garage but decided that it would be to much work. I looked at getting a 07 or 08 600 and making it into a 660 or 680 but that would be about $4000 by the time I was done. I also looked into getting some of the older mod engines but I decided that I would use an 800 VES.
1.The reason I chose the Bad Oscar Customs kit is because of the piece of mind that a well know engine builder who rides modified race sleds him self went through the engine, completely rebuilding it from the ground up and having the piece of mind that it’s not going to grenade on the first ride.
The Kit I purchased came with the following~
03 Polaris 800 VES completely rebuilt
Bad Oscar Customs Motor plate
Crankshop Chrome Pipes and silencers
Carbs
Cables
All electroncs
Exhaust springs
All sensors needed
Coil
Another thing that I did not buy was included free of charge was countless hours of help from Spank him self, the owner. With out his help and great knowledge I would still be scratching me head with the sled laying in pieces in my garage floor!
2.In order to get the carbs to fit I had to do a few mods. First off, at the angle that they were at it would be impossible to mount the pods on the carbs with out them hitting the jackshaft. Some things we did was shim the back of the engine up 1/8” and we turned the carb boots upside down to angle the pods up so they would clear. This of course required some mods to the carbs. We had to grind down 2 bolts that hold the boots on the engine in order for the carbs to sit right in the boots. We wanted to be 100% sure we had a perfect seal as an air leak could cause severe damage to the engine. That alone was not enough so we ground off some excess mettle on the carbs to give the extra clearance we needed. I will show some pics next time I have the engine out.
We threw the engine in and it all fit PURFECTLY! So I was messing around and noticed that the cables that attach to the carbs would hit the head… So we pulled the engine out again to modify the brackets. We heated them up with a torch and rotated those about 20 degrees or so.
3. Crankshop chrome pipes and silensers Fit great and look AMAZING! It makes my average mod look like a show sled and best of all I can see my reflection when ever I look at them. The only downside is they are so shiny that when I have my hood open they blind me lol.
The install is very easy; if you can’t install pipes then you really shouldn’t be swapping an engine. The only thing I had to mod was my hood and where they exit the sled. These pipes sit VERY close to the hood so the first thing I did was whip out my trusty aluminum tape and I went to town on the hood putting 2 layers of it directly above the pipe. I also applied it to the inside of my fender wells, my side panels console and water as they sit very close and in a bad wreck I don’t want all my plastic melted to the pipes. Heck I don’t want my plastic melted to anything.
The only thing remotely challenging thing about the install was figuring out how to mount the silencer and have it exit cleanly. Remember that my sled has had 3 different engines in it before so there are 5 holes in my fender from the other pipes. Also, the previous owner stole a road sign and used it as a plate to mount the silencer to so I thought I should make a new one. I simply took a piece of 1/8” aluminum plate and made my own block off. I have not yet cut them out for the pipes but I will post pics when I do.
4. Chassis mods included the removal of the aluminum bar that sits right above the steering arm. This bar is very important structurally. It is placed on the inside of the chassis and its purpose is to take the abuse from the rear part of the a-arm. With out it there I believe that the chassis is much more at risk for cracks and flexing. Many people cut the bar out and simply weld a new one about 2 inches lower. I will most likely do this but I do not believe it is enough to maintain the strength of the chassis so this next weekend we are going to also try and add a aluminum support that bolts to the black steel cross bar that runs from the top of the chassis and down to the original mounting spots just behind the a-arm mount. it’s going to be a tight fit because it has to fish around the water pump, exhaust, steering brackets, steering post, and it also needs to be removable. I will definitely get pics when we get it complete.
5. Also, you have to cut about an inch or so out of the chassis just behind where the primary would be. I have not reinforced it or filled the hole so when are looking at the pics and see a big hole don’t freak out!
We are also looking at running a aluminum brace going from the top of the shock tower on the PTO side of the engine running back and bolting around the bolts that hold the jackshaft in place. The mount would run just along side of the engine block and right next to the clutch cover at about the same height. The Brace would look a lot like the ones used in the 05-06 RMK chassis.
Some other little stuff that i need to do is make a mount for my oil tank. I am either going to mount it directly above the engine or on the PTO side fender well directly above the primary. My only thought about mounting it there is that it is moving the center of balance some by putting all that weight on the side. ANY ideas or responses would be appreciated!
5. I started out with a Boss seat designed for a 05-06 polaris RMK. The first thing did was unzip the underside of the seat and cut a little bit of the foam off the front of the seat and a had to shave a bit off the back to make it fit the 9 gallon tank that I have. The install is very easy and takes about 20 min. After you cut the foam down all you have to do is mark your holes and drill. I went to the craft store and just bought replacement Velcro to hold the back of the seat down and it feels GREAT and should be an awesome seat with storage, something that new sleds apparently don’t have for some reason?????
6. Race Chassis skid plate- To make a skid plate for the race chassis all you need to go is buy a IQ skid plate. You need to cut about 2” off the back of the plate and you will need to bend it about 10” from the front. To achieve the bend we heated it up with a torch and bolted it on so it would contour to the shape of the race chassis which is much different then that of the IQ RMK chassis. After it molded right we simply took it off, sanded all the edges to get a factory look. Drilled some more holes to mount it on the chassis. We sanded the bur marks with fine grit sand paper and covered it with some clear coat to get rid of the black burn marks and it looks factory now. I will probably build an aluminum skid plate and have it anodized orange so if anyone wants mine let me know and I will sell it to you.
SORRY! i went over the limit for one post!
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