rolled rzr rebuild

Yeah the front passengers a arms(got new ones) and the rear drivers a arms(have them coming from "liftedpowerstroke" off of "pay it forward". Thanks liftedpowerstroke). And also the roll bar, but I will fabricate that myself. Oh, and the small sub frame that the rear bumper plastic screws to (have new one).

I went headon into a tree on my new 2010 RZR. shattered my foot did some serious damage to my new ride. I just ordered about $3k in parts and will be swapping everything from the old bent frame to the new one. thanks for the pictures and updates.

What was your total time for swapping everything out? any problem areas you can warn me of? Thanks!

Sorry to hear about the bad news. You can always repair the rzr, but I don't like to hear about injuries.

The plastic was off already along with the front a arms and hubs when we started. I had pulled them earlier to try and see if I could straighten the frame, but that only took about 1.5 hours. We left the engine, trans, clutches, and rear diff in one peice. That saved alot of time. We never had an engine lift so we hand bombed everything. We cut the old frame apart to make the engine removal easier. The first few tries to get the engine in the new frame failed. The answer here was a stiff mug of rum and some thinking, and it paid off. We positioned the engine so that the rear diff was slightly lower that the rest of the engine and it dropped right in with ease. Another thing that saved alot of time and confussion was that we left all the wiring harness conected to the engine during removal. We just coiled it up ontop of the engine. You will have to install the cooling lines and rear brake lines before you install the engine. The trick to fast progress is to leave as much parts together as possible. We removed the rear suspenssion in parts but if I were to do it again I would leave the hub attached to the a arms and just remove the inboard bolts on the a arms and pull the hub, axle and a arms off in one peice. How ever you do it though, you will have to remove the brake caliper from the hubs. Another thing you will have to remove is the front drive shaft from the front diff. On my 08 there was a roll pin that held it to the splined shaft. Just pound the roll pin out just enough to remove the shaft. This makes it easier to pound back in during instalation. I had some difficulty removing the front axles from the front diff. The just pull out but mine were a little rusty. I just placed a peice of 3/8" plywood up against the diff casing and used a pry bar to pop them out. It helps if you have some one pull on the axle while you pry. One thing that I thought was cool, was anywhere on the frame where something was bolted to it, on the new frame there was just a hole. The screw/bolt was self tapping. If there is anything that I run into when I put the rest back together I will let you know, but the rest of what I have left is pretty basic, just reverse the removal steps. It took us 6 hours to remove and install everything to the point in the pictures with the exception of the front a arms and axles. I would say if I could get a good solid 4 hours on it, it would be done.
If you have any other questions I would be glad to help out.
Good luck and I hope this helps.

Spent another hour at it today, thats all I could get before the wife cought me. I was suposed to be packing for a ski trip. But I got the front suspenssion back together. all thats left of the front end is the rad, and that will only take a few minuites. six bolts to mount it and two hoses. I reeeaaalllyyyy wish I wasn't leaving town tomorrow.

Thanks for the advice stomper. As soon as all my parts come in I'll get started. Hopefully the foot will be healed and the repair to the RZR will be done soon!

Well, I was out in the shop within a couple of hours of returning from my ski trip last night. My buddy called and wanted to come help. I think he's just as excited or maybe even more (I highly doubt more)excited than I am to get this thing going.LOL. We put another 5 hours into it and it is done to the point where I just have to finnish making the roll bar and put the skid plate back on. There was a lot more pissing around with the plastic than I thought there would be, so it ate up some time. So far I have about 12.5 hours into it. Before I start driving it I am going to change all the fluids in it and start fresh and replace the rear a arms, when they get here. I just put the old ones back on so I could get it off the jack stands and move it around my shop. I never had my camera unpacked last night so I will get pictures today.

Here's a link to some pictures. This is the final product minus the roll bar. It will be built in the next couple days. Hopefully. I wish I knew how to post pictures directly to this post.


http://s848.photobucket.com/albums/a...w&t=1265673873

Just playing around and trying to post pictures directly in a thread. Looks like it worked. All I have to do is remember how i Did it.

Nice job. Looks like you are moving along great!!!

You did a great job and faster than I could have done it..I was wondering how much did new frame set you back?

Thanks for the compliments. I live in canada and the cheapest I could find around me was $1200 cdn. Babbitsonline has them for $850 us, but with shipping and exchange it was around the same cost.
I'm a little pissed, I just checked with the guy that was suposed to order my tube for the roll bar and he had forgot to order it, so it looks like I will have to wait even longer to finnish the roll bar.

Brent, Hopefully the Arms will be there pretty quick. I'm ready to check the cage out. I'm wanting to fabricate my own. post some pictures of your new tubing notcher and bender.
What type/grade of Tubing are you using? What type of welding machine are you using?
Keep up the good work and lets home them dang arms get there this week...

Well I finally got some quality RZR time and this is what I have come up with so far. It's just tacked together. I will be adding some more bracing, seat belt tabs and a front bumper, but it's the basic design.
Derrick, I haven't recieved the arm yet but with the canadian postal service it doesn't surprise me that they arn't here yet. They will come. I will take some pictures of my tubeing bender tonight for you and as far as the notcher, I have the pro tools racer model. I am using 1.75" x .095 wall erw tubing. I wanted to use dom but I almost crapped my pants at the price. This cage will be way stronger than the stock cage. I purchased some new rims, tires, lift kit, windsheild and wheel spacers but I have yet to put them on.

That looks good.....Can't wait to see the finished product.....we'll give it another two or three days and then i'll get worried about the arms.......

Well this is the final result. I added some bracing to the rear bumper, some grab handles and seat belt mount tabs. Just have to weld it up and powder coat. Oh and build a front bumper similar to the rear. It would have looked better I think if it was a full roll bar right back to the rear bumper but I didn't want to obstruct the acsess to the box.