February 2007 Feature DAVE?Alexander
Something Different
If you picked up any one copy of SledHeads this year, you are probably familiar with project Rev Revival.
This sled was different from anything SledHeads or SnoWest has done in the past on a project sled. We went about it the same way, adding some of the best parts the aftermarket has to offer, but instead of starting with a brand new sled, Revival (as the name implies) began as a junker.
This was a lower cost, budget alternative to the "sky's-the-limit" mod sleds that SnoWest builds. The idea was to build a working man's mod that would run well against other mods and stockers, but cost thousands less-a way to beat your buddies on the cheap. We saved even more coin by browsing the swap sections at the snowmobile shows and by using SledHeads discount providers for parts and service. This is a program that gets SledHeads subscribers discounts from aftermarket companies and resorts. If you want to get on this discount program, check out
On a project like this, every penny counts and is part of the bragging rights when laying waste to sleds that cost tons more to build or buy.
Another difference between this sled and a SnoWest mod was in the way the information was presented. We built the sled over the summer and fall, chasing copy deadlines along the way, and then showed readers in a "how to," installment format literally what progress had been made over the last month. When things got busy at the office or at home, less got done on the sled. When we did manage to get something done, it was usually with the help of skilled professionals.

Opportunity Knocks
The idea for Rev Revival was hatched when we were talking to our friend at Snobunje about a '05 Summit X he purchased at auction. He bought the wrecked sled for the engine and was going to part out the smashed chassis. We smelled an opportunity and took the sled off our buddy's hands for the lunch-money sum of $1,500. In the deal was a '04 Rev 800 engine that had been lean-seized. We knew that the engine's cylinders were junk, so we also scored a used '05 800 motor for another grand. It turned out that the `05 motor had a broken case. So we had a damaged chassis, one junk engine and one that we may or may not have been able to use. It was time to make some choices about what to do and more importantly, who would do it.

Do It Like The Pros
Mountain Air Power and Sports was called on to fix the tacoed chassis. Clare Martin showed us how to replace the Rev's "Flying Nun," an infamous weak link and the reason this sled had been totaled. We also beefed up the nun with factory Ski-Doo parts that will hopefully keep the nun intact the next time a rock or other hidden obstruction rears its ugly head in Stumpy Meadows. Fabcraft A-arms were chosen for the fact that they are supposed to fold up before the nun. It's much easier and cheaper to replace an A-arm than repair frame damage. Plus, with a whopping 6 lbs. of weight savings, the decision to use Fabcraft arms was easy-a literal slam dunk.
Precision Performance Products made our two tweaked engines into one solid one. While they were at it, we opted to have them do their porting, which combined with an SLP single pipe, SLP head, SLP High Flow air intake and Precision Superlite silencer, is good for 163 ponies. This sled will rip-and run on 91 octane pump gas.
Always looking for new products to try, we choose K-Mod as a remedy for our rear suspension that had its h-arms bent downward in a permanent frown. The installed weight of the new skid was only 48 lbs. and is also the most economical rear set-up that we know of. Many people we know ran this suspension last year and all said it works great. Pounding the bumps is something we look forward to with Rev Revival.

Other Goodies
One of the most fun aspects of building a mod sled is picking the parts. We used a super-trick EdgeWorks 2-wheel conversion billet wheel kit and rail extension combo, awesome Avid CNC-cut extrovert drivers, SLP Hiperfax and a Camoplast 150-inch Challenger Extreme track which was ported by Tom's Snowmobiles told us their rolled chaincase will make Revs climb 30 percent higher-and of course we had to have one after hearing that. We dressed up the sled with a BR Tech lightweight hood, R&M mesh side panels that really help with cooling, excellent quality Skinz Protective Gear shock covers that practically install themselves, Snobunje tunnel and handlebar bags and Fabcraft handlebars with their often copied, but never duplicated mountain bar.
Chassis refinements come from Simmons via their new 10-inch wide Generation II skis and a Snobunje Throttle Logic left-hand throttle. We also scored a new windshield and skid plate from

Are We Having
Fun Yet?
This was a really fun project, but a lot of work. The deeper we got in to the sled, the more damage we found. That's the negative side of working from a used sled to build your next mod. The upside is if you're not afraid to get your hands dirty (and scarred and bloodied), you can save a bunch of money, which can then be used to make even more mods. Or you can put the money you saved into the bank for next year's mod-but what's the fun in that? 
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