Say a person has a 99 Polaris Sportsman 500 4x4 that they really don't have too awful much money in.

Just how hard would it be to widen it a bit with some tube work, toss the factory plastic, and throw on some plastic racing seats to create a little side-by-side?

R :flipoff2:

http://www.pirate4x4.com/forum/attachment.php?attachmentid=303972&stc=1&d=1179053234
http://www.pirate4x4.com/forum/showthread.php?t=580192

pretty pictures, but not much info there :p

I don't really have anything to offer on this either: but I would wonder:

what are you going to be using it for?
Is the 500 really a good platform to start from? Is it going to have enough go to haul 2 people around and through the mud, especially when you add the extra weight of the tube amd other "stuff"

what are you going to be using it for?
Is the 500 really a good platform to start from? Is it going to have enough go to haul 2 people around and through the mud, especially when you add the extra weight of the tube amd other "stuff"

Good question.

My ideal use would be as a "chase" vehicle when we go to the local off road parks, for my wife and one of the kids to putt around in while I'm in my 4runner or buggy. Also just general atv use - no hardcore bogging, etc - more normal trail riding, farm driving, etc.

So mainly it would be an adult and a 6-7 year old kid riding in it, not 2 adults.

And it would just be neat to have and build :D

I know of a guy who used a quad drivetrain to build a 4wd golfcart, he built a tube frame and used the golf cart plastic, it was pretty sporty.



Brewchief:D

Good question.

My ideal use would be as a "chase" vehicle when we go to the local off road parks, for my wife and one of the kids to putt around in while I'm in my 4runner or buggy. Also just general atv use - no hardcore bogging, etc - more normal trail riding, farm driving, etc.
:D

Sounds like a big project to me. If you can fabricate then build it. Take into consideration how you would do the steering, how the extra weight is gonna effect the shocks and handling(atleast stiffen them), and add some extra power if you haven't already(intake, exhaust, cam maybe if they make them)
I'd also widen it with some wheel spacers but preferrably new a-arms which would probly need to be custom made.

Check out some of the quads that run the Mud Nationals. Might give you some ideas to make it wider and more stable.

But if you are willing to spend some money just buy Rhino or something comparable.

But if you are willing to spend some money just buy Rhino or something comparable.

If iIwas willing to spend money, I wouldn't have a $1500 quad and be trying to avoid dropping $10k on a Rhino :shaking: :p

If iIwas willing to spend money, I wouldn't have a $1500 quad and be trying to avoid dropping $10k on a Rhino :shaking: :p

AS usual, People are trying to help you and your being a douche. Hey Dumbass, do you think anything 'Custom' that needs to be changed that much is going to be cheap?

Also just wanted to mention that if you put that much more weight on that bad polaris belt your going to melt it.

Axiously awaiting your reply, fordfreak$ :massey:

do you think anything 'Custom' that needs to be changed that much is going to be cheap?

The only cost I see there is tube steel and sheet metal, some seats, and a good set of wheels & tires (which isn't necessary, just a nice addition). I can't see spending more than a couple hundred on metal, plus whatever the wheels & tires cost.

Even assuming I spent $2000 extra, I'd have $3500 in the whole thing. Are you suggesting I can get a similar vehicle for anywhere near that price?


Also just wanted to mention that if you put that much more weight on that bad polaris belt your going to melt it.

The extra weight should still be within the factory payload settings... It's not like tubing that small is very heavy, or plastic seats either.

The belt is brand new - and should hold up just fine for general use.


Anything else to add?

The only cost I see there is tube steel and sheet metal, some seats, and a good set of wheels & tires (which isn't necessary, just a nice addition). I can't see spending more than a couple hundred on metal, plus whatever the wheels & tires cost.

The extra weight should still be within the factory payload settings... It's not like tubing that small is very heavy, or plastic seats either.

The belt is brand new - and should hold up just fine for general use.


Anything else to add?

Wow....a serious response. OK let's talk.
1. Are you a welder #1 ?

2. Where are you going to mount all this tubing to? The stock frame is not going to have the support your going to need in ALL places. Some will be okay others will not. What I think your really looking into is a full replacement frame #1.

3. With the full frame development your going to need suspension,steering and longer axles. Some pcs will be reused, others won't.

3.5---Let's say you figure out a way to place all that extra stuff on top without a custom frame. YOur still going to need to make up some kind of steering system so your not sitting in the middle of the creation turning handlebars bumping your passenger in the nose with your elbows.

4. WEIGHT- YOur stock springs even though rated for a specific load will not hold up to carrying that load 24/7. Your shocks will blow out and lose oil, but you can use them to get started and see how it goes. Eventually even if you upgrade with some OEM units you'll still be dropping another $1000-1500.

5. With all this extra weight, width, and higher center of gravity are you really not going to make it wider? OR even longer? MAYBE, MAYBE, MAYBE you'll be able to get lucky and use some quality wheel spacers. ($200) SO that takes care of wider but how about longer? Longer d-shafts?

6. Your going to be lacking in the power department, but I feel as if it doesn't matter so much to you. AGAIN, your belt is going to melt.

These are just a few ideas off the top of my head, but more are coming as I type. For example, when you go wider, your going to need longer brake lines. I do like your idea and creativity but first of all, a 500 is to small, and I think your going to end up spending much more then your thinking. With this said, YES, it may be feasable to buy a used 1st year production Rhino. And if it's not this year, it may be in a year or two. In my experience the words 'custom' or 'modified' and 'budget 'don't really go together. Anyone can build a halfass piece of garbage, but judging from your attention to detail I don't think that's what your looking for. Oh...and bigger wheels and tires, you can add another $600 to $1200 depending on what you want.

1. http://www.4x4spot.com - I think I can handle welding and custom fabrication just fine ;)

2. I see no reason not to re-use most of the frame, just widen it as needed. It's just steel - it's easy to modify.

3. Off the top of my head - I'd imagine moving the A arms out a few inches per side - re-using the factor hangers as much as possible to cut down on having to fab new hangers. Though I see nothing terribly difficult about building new hangers as needed. Cutting and lengthening the axle shafts doesn't present much of a problem to me either.

You asked about length - lengthening driveshafts is easy - as is extending the frame. I've done plenty of driveshafts in the shop and if they can holdup to on-road speeds and not wobble all over the place, an ATV should be fine.

4. I think you're stuck looking at this from an ATV parts standpoint, which is why you are having trouble considering a custom project like this. Why would it cost me $1000-1500 to upgrade the suspension to handle the weight? I can have a set of brand new 14" travel air shocks on the thing for less than $900 - so I'm pretty sure I can figure out a way to upgrade the suspension for less than that with a little creativity and parts shopping. Hell -I can have it riding on airbags for cheaper than that :laughing:

5. Since seat height is several inches lower than the previous seat height, and most of your tube weight is below centerline of the chassis, I don't see how you are raising the COG much, if at all. I think I already covered how I'd make it wider and longer for just my time and some steel tube.

6. As for power - I currently wheel a 300 Prairie 4x4, so I'm thinking if I'm satisfied with that now, a little heavier 500 will still fit *my* needs. There is also nothing saying that I can't add go-fast goodies later as needed.


Dude - I've got what started out as an IFS 4runner running on 60's with leaf springs up front and a 3 link rear on air shocks. I;m in the process of building a budget tube buggy using a TJ long arm suspension kit and will have less than $2000 in the whole thing. Point is - "custom fabrication" is not really something that bothers me... if making longer brake lines is what holds me back, I've got issues :laughing:


But hey, thanks for taking the time to share some valid concerns about a build like this. Obviously this is a project that really depends on your fabrication comfort level, and ability to source non-standard parts to keep things on the cheap.

Even if I could get a $3500 rhino - it's nowhere as cool as a mini-sniper built by my own hands :cool2:

This topic could use a good build up thread. I hope you get it done. I would love to see how it turns out.

This topic could use a good build up thread. I hope you get it done. I would love to see how it turns out.

I'll be honest - I'm also in the midst of a buggy build as I mentioned - and the possibility exists that the Polaris might get sold to help fund that.

Say a person has a 99 Polaris Sportsman 500 4x4 that they really don't have too awful much money in.

Just how hard would it be to widen it a bit with some tube work, toss the factory plastic, and throw on some plastic racing seats to create a little side-by-side?

C'mon.....You went from the above statement to the below paragraph. Now it makes me wonder why you even asked in the first place. Sounds like you don't even need any help.

1. http://www.4x4spot.com - I think I can handle welding and custom fabrication just fine ;)

2. I see no reason not to re-use most of the frame, just widen it as needed. It's just steel - it's easy to modify.

3. Off the top of my head - I'd imagine moving the A arms out a few inches per side - re-using the factor hangers as much as possible to cut down on having to fab new hangers. Though I see nothing terribly difficult about building new hangers as needed. Cutting and lengthening the axle shafts doesn't present much of a problem to me either.

You asked about length - lengthening driveshafts is easy - as is extending the frame. I've done plenty of driveshafts in the shop and if they can holdup to on-road speeds and not wobble all over the place, an ATV should be fine.

4. I think you're stuck looking at this from an ATV parts standpoint, which is why you are having trouble considering a custom project like this. Why would it cost me $1000-1500 to upgrade the suspension to handle the weight? I can have a set of brand new 14" travel air shocks on the thing for less than $900 - so I'm pretty sure I can figure out a way to upgrade the suspension for less than that with a little creativity and parts shopping. Hell -I can have it riding on airbags for cheaper than that :laughing:

5. Since seat height is several inches lower than the previous seat height, and most of your tube weight is below centerline of the chassis, I don't see how you are raising the COG much, if at all. I think I already covered how I'd make it wider and longer for just my time and some steel tube.

6. As for power - I currently wheel a 300 Prairie 4x4, so I'm thinking if I'm satisfied with that now, a little heavier 500 will still fit *my* needs. There is also nothing saying that I can't add go-fast goodies later as needed.


Dude - I've got what started out as an IFS 4runner running on 60's with leaf springs up front and a 3 link rear on air shocks. I;m in the process of building a budget tube buggy using a TJ long arm suspension kit and will have less than $2000 in the whole thing. Point is - "custom fabrication" is not really something that bothers me... if making longer brake lines is what holds me back, I've got issues :laughing:


But hey, thanks for taking the time to share some valid concerns about a build like this. Obviously this is a project that really depends on your fabrication comfort level, and ability to source non-standard parts to keep things on the cheap.

Even if I could get a $3500 rhino - it's nowhere as cool as a mini-sniper built by my own hands :cool2:

Tease :flipoff2::flipoff2::flipoff2:

I'll be honest - I'm also in the midst of a buggy build as I mentioned - and the possibility exists that the Polaris might get sold to help fund that.

C'mon.....You went from the above statement to the below paragraph. Now it makes me wonder why you even asked in the first place. Sounds like you don't even need any help.


lol... If you're done, thanks.

http://www.glamisdunes.com/invision/index.php?showtopic=127354

Here is the chassis you can start with, and adapt your drive train to it. In my opinion it may be easier than building your whole unit.

1998 EzGo TXT electric cart, has the mid-grade controller (goes faster), includes the battery charger

I replaced all 6 batteries a year or so ago.

We used this in G in the washes without a problem, great camp cruiser. We use it all summer at the river as well.

Currently collecting dust and taking up space in my garage in Murrieta

$1300 or trade for a LT80, trx90 or similar quad 25deal.gif

Brian
951-314-4344

here is an older pic of it on the way to BMV beer.gif

http://img210.imageshack.us/img210/5659/index598ef0eyz7.jpg (http://imageshack.us)
By az_gold (http://profile.imageshack.us/user/az_gold)

here is another one, even better:

http://www.glamisdunes.com/invision/index.php?showtopic=116545

Say a person has a 99 Polaris Sportsman 500 4x4 that they really don't have too awful much money in.

Just how hard would it be to widen it a bit with some tube work, toss the factory plastic, and throw on some plastic racing seats to create a little side-by-side?

www.Ridgerunner.biz does it.

2. I see no reason not to re-use most of the frame, just widen it as needed. It's just steel - it's easy to modify.


I wouldn't recommend it. The frame isn't made to support the kind of weight your talking about. You'd be better off starting from scratch. The amount of modification, just to support the additional weight, would outweigh the time required to build from scratch.