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:



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.



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.

[Maize]

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



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

[Maize]

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:





Here is the caddy mounted:

[Maize]

Here is the sled in its completed state:

[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?