ATV Turn Signals.

This has been a long time in the works.  I started ordering parts in early to mid June. Took about 3, 3.5 weeks for everything to come.  Then I had to find time to start it… 

Then decided I had to do the fuse block first, which took several days over last week. Now I’ve finally got the turn signals wired in, which also too a few days spread out over several total. 

Covering the fuse block install and the turn signals, I believe I have about 50 hours in this wiring and mounting. 

 Yes, I’m epically slow at wiring! 

Why turn signals? I dunno, just seemed like it’d be cool . 😎 Why not?  (No, unlike in some states I can’t make a quad street legal in Alaska.)

When I get the second flasher hooked up and have hazard lights, that could have a practical use, for emergencies, or simply visibility. But, these I don’t really need–but who cares? 😉

I bought two styles of small cheap motorcycle turn signals, off ebay. Serriously, these things were about $5 a pair!  

I originally intended the round ones for the rear, and the pointed ones for the front, to match a bumper bar angle.

But in the interim while waiting for them to come, I mounted the front bull bar,  and changed the bar angles and openings.. 

Tuned out great though, I really think the look fits better this way. 

I did the rears first, designed mounts, and spacing, working off the right side… Then got ready to mount the left side and realized it didn’t clear the rear winch motor. Oops. 

Slight rearrangement, flipped the brackets side to side, and turned over, and a small angle, and it’s perfect!

The brackets are a simple angle iron, but at least 3″ on one leg… Not common, and especially not in my scrap bin..  

I remembered some 2″x4″  rectangular tube I got from scrapping a BowFlex.  Slightly bigger than what I wanted. Then again I remembered some other older tube I had, that is 1.75″X3″. Used that. 

Cut off 1″ long, then split into two “L”s.  

Worked great, being tubing made by  forming then welding it up one side; It has a crease halfway along one long side. 

That gave me a perfect locator to drill mount holes exactly the same distance from the end on both. The crease also worked as a centering locator on the front bumper tube, keeps it from twisting as easy.   For the rears I used the other side Ls, that were flat and straight. 

 The rears mounted;

Bracket is on the lower bumper mount bolts, sandwiched between frame and bumper. Since these lights had ground wires, I ran them to the upper bumper bolts.

The fronts turned out to be really easy, using the exact same brackets, bolted to the bull bar, and angle trimmed to match it for looks. 

And amazingly they ground! Even though that bar isn’t directly bolted on, it has great continuity! I didn’t have to use the ground wires I first installed.  (These lights came setup to ground off their mount studs,  I was adding wires.)

Yes, I’m an electronics techs’ nightmare lol. 😉 Looks worse than it is actually, it’s all cleanly routed together(as clean as possible without a bare frame to start with anyway), down each side of the wheeler, and zip tied off. 

If I was installing everything at once it would get wire loom/covering… but I don’t have that luxury(kinda glad actually –that stuff is expensive!)

Hot wired test half way through;

Finally had to pull all the front plastic half way through… really wanted to do it with it on, but my hands are just too big.. lol. 

Getting the wires from the switch pod tail run..

More progress;

Yeah, I even did indicator lamps. getting fancy here, I know! The custom dash in my truck doesn’t even have the indicators installed and it’s been 4 years since I put that in! Lol. 

Finished, front;

And back(hard to see, but they’re there); 

And dash/switches; 

The other two switches on that pod are designed as a 2 position low/high light switch, and a momentary horn button. 

When I get the hazard flasher wired in, I’m going to use the light switch for them. Simply leaving nothing on the “low” circuit for “off”,  and “on” on the “high” beam position/circuit. 

Not completely sure about the momentary button yet(working on an idea though!). 

Categories: ATV, ATV Accessories, Automotive Work, Custom, EDC/MT use, Fabrication, Improviser, Modifications, Vehicles, Wiring, Wrenching | 2 Comments

Higher Work?

Got really really tired of everything being too low to work on, even sitting down…

 I do have a hydraulic motorcycle/atv lift, but it goes under the frame only, isn’t really stable for this type of work. 

I’ve also done stuff with it on my wheel ramps before, about 9″ of lift, but that’s still a PITA at times. 

Thus, my redneck Alaskan ATV lift.

My two old truck boxes (one a Rubbermaid chest, I wasn’t sure if it would take it, but it seems to not care about the weight! ), some scrap 2×12, and voila 16″ of lift! 

Front box being wider turned out great, didn’t plan it, but it’s enough to straddle and sit on, or stand on if needed.

Should have took pics of the first try getting it up there… Used my wheel ramps and one turned over after the front wheels when up… Was awkward getting it off at an angle with no ramp under one side. Lol. 

Categories: Alaska-Life, ATV, ATV Accessories, ATVing, Custom, Improviser, MacGyver, MacGyverism, Modifications, Repurpose, Vehicles, Wrenching | 2 Comments

ATV Auxiliary Fuse Block

I got tired of running everythi g straight off the battery… Was running out of space for the wires around the terminals too.   

A lot you don’t get to see here, like removal of the front inner fenders,  pulling the rack and tank cover, and routing wires… 

I have it now run as;

Battery-> main fuse-> key switch-> signal into relay-> 

And the battery-> relay(switched)-> fuse panel.

I tapped the keyed hot wire that I previously tapped for winch switch signal, -what was the speedometer power wire-.
That activates an 80A relay. The relay hot activates a heavy 10ga wire from the battery, to the new fuse block.  I didn’t have one on hand, so later I need to add a heavy 60A or 70A fuse between the battery and the relay. 

Relay wiring;


Battery box wiring, fuse for relay activation is the black spade holder center frame.

Relay next to battery

Also found that even with key off, I have 0.10V after the relay… It’s bleeding power. But there is no amperage there, so no drain, it’s fine. (Or so my electronics technician friend tells me 😉 ).

The box will also house a switch panel when I’m done, thus it’s placement on the fender(and honestly it’s getting hard to find places to put wiring on this thing!)

When done I’ll have that fancy split wire loom/cover stuff on the wires. Will also silicone seal all box holes, and some connections.


Categories: ATV, ATV Accessories, Custom, Modifications, Vehicles, Wiring | Leave a comment

EDC, July 1st to 16th.

Ok, a couple of these are from late June, but most are this month.

Categories: Daily-cary-log, EDC | 1 Comment

ATV Rear bumper/brush guard

After I got the front guard on, on my trail ride test run, the day I posted about, I also did some brush busting. Going forward was great, a lot less worry with that push bar, I was plowing over sma 2″ to 3″ diameter trees! 

But when I couldn’t get through where I was trying to make a trail, turning around meant a 12(more like 20!) point turn in narrow quarters, pushing against/over what I had to… And it was a lot of pushing against the rear rack, rack walls, and fenders. 

Decided then that I need a rear bumper/guard. 

Lots of research later, I decided on the simple tube bumper style, and preferably one big tube. Hoping I could get curved ends.. 

To the scrap pile we go!

Bunk bed frame ends, just happened to be wider than the racks and plastic, but narrow enough to match overall… 

Some creative cutting, and more cutting… 

Amazed me, those 3/8″ cross bars were solid, not tubing! 

Mock up of Mount positioning…

Simple brackets, angle irons welded into slits cut in the tube. 

Getting it all squared and oriented right, those slits aligned, and the brackets squared in to get the curved bumper ends level/square was a pain… But worth it.  

And some welding, which I didn’t get pics of.  Worked out perfect… Ran everything together, got it all. Then decided to touch up a spot, ran about 1/4″ of bead, and the wire stopped… Ran out of welding wire right there! (Man, that roll went FAST!!)
Had to move the winch fairlead down about 3/4″ to clear. Was easier to do that than notch the tube. 😉

 Voila, crooked bumper mounted. 😉 

I’d squared and leveled it to my accessory receivers… Forgot that the left side of the rack is still tweeked down a little, thus that tube is low on that side as well.  

Adjusted the mount holes, little bigger for some tilt, and thus a level bumper!  

Not sure I like the clearance I ended with. The rack wall corners stick out further than the bumper corners.

And everything else is only an inch, or two inside it…  The idea was a brush guard more than anything, and a push bar so I don’t push with plastic or rack, and it should accomplish that.

  Will run it for a while and see if I need it spaced out some (thinking 1″ max), but I *think* it’s ok. 

Also wasn’t thrilled about the winch roller fairlead being recessed slightly.. But it’d take an extreme upward cable angle for it to rub the bumper, so that too *should* be fine. I didn’t want to space the fairlead out very far, reducing it’s stiffness to its bracket (figure all the pull of the winch, and weight of the wheeler rides on this rollers when in use!).

Amyway, thar she be!

Categories: ATV, ATV Accessories, Custom, Fabrication, Modifications, Recycle, Repurpose, Scrounging, Vehicles, Welding | Leave a comment

Mud anyone? 

So, for the record, Yes, I do ride the thing, not just build stuff on it! 😉😎👍
Had to go out and test the new mud flap, and make up for my Saturday(had planned a day of riding,  but ended up going to help some friends with a few things instead).

The new rear mud flap works great, just as well as the stock one on the other side, which really is pretty good!

On the other hand, the front tires throw a LOT up past the sides of the fenders. Especially at full bore in deep muck! Front fenders need fender flares, or mud flap extensions… something.  

But, had a lot of fun, even if it was Messy! 😉

really amazes me what this thing Will go through!  Most reviews from when these wheelers came out have them as underpowered for their size/weight. 

But I’ve found it to have a LOT of power! Specs compared it has more bottom end power than the old Bayou 300s, and 400s, and those would crawl through almost anything as long as you had ground clearance to do it… This one’s the same, I’ve yet to completely bog the wheels down to where they won’t turn!

This was after the first big mud hole I found that I couldn’t get through.. Couldn’t go through it forward, got high centered, then couldn’t back out. Had to rock it and crank the steering around a lot to get traction for a slow 4′ backwards before it wouldnt go any more.

 Still had great traction foreward, did that routine 3 times, before I drove it up over the ruts sideways, with a 4 point turn across the ruts, and back out the way I came.. So I wasn’t ever really “stuck” . 

Guess I should have zipped that revolver all the way in… 

stopped to see a friend close by for a while, then I tried that hole again on the way home… Straddled the ruts this time and powered right through. 

This is about 1/4 mile firther down that trail. REALLY stuck this time, high centered and deeper ruts so I couldnt rock it enough to grab traction and pull out.

What I’d just been through… 

For the most part burried, just barely over the floor boards, 3/4? Way up the tires. 

After I finally let the wheel spin stop, I almost couldn’t get them to turn again! Stuff was thick and gloppy, had great suction to it. BUT I did say almost! Motor is torquey! (The front locker doesn’t hurt! 😉 )

After I winched it out. 

And you thought the front of it was muddy in the pics up top from the first spot! Ha! 

Made the 3 hours I spent earlier in the day re-wiring the winches with new contactors, a new switch, really routing wires etc. All worth it!! 😉😆😎👍👌👌 (more on the wiring job later!)
It’s actually funny, I’ve had the front winch on it over a year, year and a half, and I’ve never used it. Get the rear one on less than a month ago, and I already had use of it. 😆

Of course, if it wasn’t for having just fixed both winches, and knowing I had them to get me out, I’d have never been on that trail trying my luck at those boggy areas. 🙂

Bonuses;

😎

I’ll have to go try that spot again sometime soon, when it isn’t late(was 930ish pm) and raining… When I can try it a few times in a row. 

Categories: Uncategorized | 1 Comment

ATV Brush guard/bull bar/bumper. 

I wanted a brush guard for the Prairies headlight area. Not sure what Kawasaki was thinking when the guard loops ended up below the lights, with nothing really behind them, and Nothing in front of the lights… 

Also wanted a bumper, not just for protection but for pushing things.  Had planned it to probably be separate from the brush guard, but wasn’t adverse to one piece either..  

Not having a tubing bender, I went through Everything in my scrap piles with a bent tube or corner trying to find something I could make work, even if I had to weld it all up in a loop… Nothing. 

Then I remembered this set of chrome motorcycle engine guard bars that my Dad bought 20 years ago, but couldn’t use, that I knew I still had a couple years ago… somewhere.  Was easy to find, amazingly(my scrap piles are literally that; piles). 

 Perfect width for the headlights, and the brackets, when bent in a touch went between the existing uprights almost as if made for them. 

But, when swapped around, put on “backwards” from intended use direction it put the outer sweep toward the back as needed.  Only problem there was all the mounts were now useless… 

The downward taper angle fit the flow of the machine shape, and the fender cut angle really well too. 

But I wasn’t sure how I really liked it with my first couple mock ups…

Liked that it fit around the lights great, and even though it stuck out a lot, that’s what I was after for a push bumper (too close to the plastics and you still break plastic if you hit anything hard,  defeats the purpose of having a bumper!). 

It is still a bit more forward than I’d prefer, but it’s not Too far, in my opinion. 
 Anyway, didn’t have anything to lose,  wasn’t using the bars anyway, so I started cutting brackets off, and trimming to fit around the winch.

Have I mentioned how much I Really like my angle grinder? 😆

One side down, one to go..


The look improved, but still with a “But…”  Got it all mounted, and still a “But..” 

It seemed to frame and magnify the big square hole above the winch, like a gaping open mouth below the eyes(headlights). (No, couldn’t close off the hole,  radiator is there… although I do have a grill in mind)
Figured I’d live with it for a while.  Decided to go ahead and paint it.

 Bang! That did it! In black instead of chrome, it blends in and it just plain works!  😎👍✌👌 

Love it when a plan comes together!





You will also note that I cut the front racks wall/upper front horizontal bar off. It was mangled beyond being worth the work of straightening it. MUCH cleaner look without it. And, the plan is a wall set for the front like I did on the rear,  anyway.

Now, the mounting bolts. I wanted to drill the new bar, and run the u-bolts through, and around the existing brush guard bars. 

I couldn’t get u-bolts the right width.  So I got what I could, a size bigger,  and did full crosses around both… it’s not perfect,  but it’s pretty damn solid, and working. 

 And like the bar itself, painted they blend in , and don’t look bad. 

  I *think* I can make my first plan work with u-bolts a half step in between these and what I wanted. Might try that in the near future, as I’m able to afford more hardware. 
Will also be interesting to see how well the headlights work through it, this fall when it actually gets dark enough to tell.  Of course by then I should have the new LED lights installed, but still, I’m hoping it works OK, and doesn’t shadow terribly.  

Categories: ATV, Custom, Fabrication, MacGyver, Modifications, Outdoors, Scrounging, Vehicles

Reflections of the past?

😉😁


Pulled an old motorcycle out of storage,  to fix, to sell.  Bikes here only require one mirror, left side… I’ve been wanting a mirror on the ATV…. The bike just happens to have loooonnng neck mirrors. 😆😇

Only hitch wad the windshield had to come off he bike to make clearance to unscrew the mirror. Never easy, right? Lol. 

Categories: ATV, Funny, Modifications, Outdoors, Vehicles

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