New Project - Yard Sale's AKA The Great One's track extension

[Maize]

Just finished up the latest project in the shop today.

The project was to extend a 2004 Arctic Cat F7 Patriot Edition from a 128" to a 159", extend the tunnel and tuners, put a new bumper on the sled, build a mounting system for a 2 gallon gas tank and extend that brake light wiring.

Building a tunnel extension for an F7 is kind of like putting a 3-D puzzle together. Everything has multiple angles to it.

The tunnel was pushed off to one side and the rivets sheered off in a lot of places. I hammer and dollied out the body to get it back in shape then used a body hammer and wood to smooth out all the aluminum.

I got the tunnel extension bent up and put into place and then fit the rear cooler:

http://img841.imageshack.us/img841/1847/tgo2.jpg

Next I made a plate from 1/8" aluminum. The seat sits directly on this plate, thus the reason for using the thicker plate. I then removed the seat post from the rear cooler, and welded that to the new plate.

http://img851.imageshack.us/img851/3030/tgo5.jpg

I ordered a second set of edge rail coolers. I cut the old coolers off at the edge of the new extension. Then cut the new piece to butt up to old piece and then TIG'd them together.

http://img807.imageshack.us/img807/2890/tgo4.jpg

http://img37.imageshack.us/img37/2053/tgo3.jpg

[Maize]

Then it was time to test fit everything afer it was all welded, holes drilled and extension finished.

http://img221.imageshack.us/img221/1520/tgo1.jpg

Here is the sled with the edge rails riveted, foot plates riveted, seat on, rear bag mounted and rear bumper on.

http://img819.imageshack.us/img819/5655/tgo6.jpg

http://img249.imageshack.us/img249/1410/tgo7.jpg

http://img39.imageshack.us/img39/7974/tgo8.jpg

[Maize]

http://img337.imageshack.us/img337/5328/tgo9.jpg

Here is the mounting base I made with the mount for the 2 gallon fuel caddy. It is mounted on the tunnel and it extends out over the tail light:

http://img803.imageshack.us/img803/5756/tgo11.jpg

http://img521.imageshack.us/img521/9284/tgo12.jpg

Here is the caddy mounted:

http://img42.imageshack.us/img42/3928/tgo10.jpg

[Maize]

Here is the sled in its completed state:

http://img849.imageshack.us/img849/9403/tgo13.jpg

[The Great One]

See Santa does visit more than just kids. Well we will use the word kids loosley. another amazing kustom. But this one I get to ride. Woo hoo I need SNOW!!!!

[one2race]

As usual Awesome job lynn.....this now means the "yard sale" will be in the FRONT yard, as the back is good to go right ? Lol....sorry TJ, had to get that in. ;-)

[kioti]

Sweet Looks great Lynn. Its nice to see you work on a Cat. LOL TJ are you going to start helping O2O and I in the snow dance now?