I read some of you guys built your own bumper update with all custom parts or just a few cat parts and it results in a really cheap and functional bumper. How did you guys build them? What cat parts did you use and what can you get by without? What about a snowflap and LED? Where do you get all this stuff too?
DIY 09 bumper update
- Thread starter tdbaugha
- Start date
Search, you will find....
T
http://www.snowestonline.com/forum/s...d.php?t=172286
I used the stock 09 cat parts on my 08. I bought the Bumper, Right and Left Gussets, and rear block-off plate. It was about $50. I am going to use a LED tail light from SLP
http://www.startinglineproducts.com/catalog.cfm?pageID=detail&catalogID=2&catID=10&productID=33
I am not going to use a snowflap.
You will need to flatten your stock heat exchanger and cut the inflow and outflow tubes on the heat exchanger, or find/buy one of a 09 or 10. If you buy a new one from an 09 they are about $100 bucks.
I used the stock 09 cat parts on my 08. I bought the Bumper, Right and Left Gussets, and rear block-off plate. It was about $50. I am going to use a LED tail light from SLP
http://www.startinglineproducts.com/catalog.cfm?pageID=detail&catalogID=2&catID=10&productID=33
I am not going to use a snowflap.
You will need to flatten your stock heat exchanger and cut the inflow and outflow tubes on the heat exchanger, or find/buy one of a 09 or 10. If you buy a new one from an 09 they are about $100 bucks.
I was more or less looking for specific materials and places to buy them for things like snow flap, LED lights, homemade tunnel supports, etc. And maybe some fabrication tips. I've never done anything like this and would like to learn how to make my own stuff as opposed to buying a kit. I would like to only buy the foot rests from Cat and fabricate the rest. Another specific question I have is wouldn't it be better to weld all these things in place as opposed to using rivets?
heres a tip, spend a hundred hours building from scratch and prob screw something up which you wind up spending just as much money. Or buy the 09 parts and install in one night. If you have a powerclaw there is rarely a need for a snow flap.
You are most likely right. I like the idea of doing it myself but I like my money more! I just priced out the bumper, gussets, and rear end cap at alpha-sports.com and it came out to 81$ plus shipping. I probably do need a snow flap for the sake of the poor saps behind me on the trail.
T
You will be doing enough fabrication as it is using the stock cat parts. Spend the 50 bucks on the bumper, gussets, and rear block off plate. You will have enough fabrication cutting the tunnel, and flattening and cutting on the heat exchanger.
If you want to buy materials to fab it all up, call your local metal supply shop.
That price from alpha is high. PM free agent on here, I bet it will be closer to $60
If you want to buy materials to fab it all up, call your local metal supply shop.
That price from alpha is high. PM free agent on here, I bet it will be closer to $60
H
I built my own from scratch. It was a VanAmberg inspired design. 1M snow flap, and tailight from SLP. It was a fun project!
S
uh huh
x2!
x2
I did mine this way and took 3hrs in the shop. would only take 1.5 next time...(but i'm getting my 2010 in 2 weeks, so I don't need to!) I tried to bend the exchanger flat on my 06 m7 and i did that(one crack, fixed w/ J.B. Weld) but I couldn't get the bugger to fit. too wide, maybe if you cut the tubes like The Breeze said but I didn't think there was enough length, maybe I could have.
Definitely use Freegent. WAY CHEAPER than anything local.
x2!
x2
I did mine this way and took 3hrs in the shop. would only take 1.5 next time...(but i'm getting my 2010 in 2 weeks, so I don't need to!) I tried to bend the exchanger flat on my 06 m7 and i did that(one crack, fixed w/ J.B. Weld) but I couldn't get the bugger to fit. too wide, maybe if you cut the tubes like The Breeze said but I didn't think there was enough length, maybe I could have.
Definitely use Freegent. WAY CHEAPER than anything local.
S
Here is my DIY bumber. I used some 3/16" alluminum for the sides, a piece of 1" round tubing for the grab bar, and 1/8" sheet for the tunnel/flap piece. I also took more 1/8 in sheet and mounted it on the inside of the tunnel to give it strengh other wise the tunnel would flex when you pushed down on the grab bar. I then bent the original foot extrusions up to look more like the newer style tunnel and mounted them to the top of the tunnel. I also flattened my heat exchanger by running it over with a dulley. Its been two years now with no problems.:face-icon-small-hap
This is great! I was planning to do something like this on my daughter's M5.
But........... is there a more reasonable way one can flatten the curved rear heat exchanger so it will be flat and not leak?
Can someone please list the Cat part numbers needed to do the job?
But........... is there a more reasonable way one can flatten the curved rear heat exchanger so it will be flat and not leak?
Can someone please list the Cat part numbers needed to do the job?
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not sure about more reasonable but there is the poor mas press alternative: i sandwiched my cooler between two 2x12's and used a floor jack to press it against the bottom of the frame rail on my dads fishing boat trailer. worked like a champ and you can go nice and slow
Had a friend who used a electirc over hydraulic shop press. Do it slow. He put two cracks in the face of it. I welded it up for him and he ran all last season with no problems. A fast bend will crack them. The aluminum needs time to strech.
Don't let this stop you. Paying a shop to weld a crack is still less then a new cooler. :face-icon-small-hap:face-icon-small-hap
Don't let this stop you. Paying a shop to weld a crack is still less then a new cooler. :face-icon-small-hap:face-icon-small-hap
S
I actually had 2 small cracks in my cooler when I flattened it. I arc welded it and did a pressure test by caping both ends putting a shreader valve in one side and a pressure Gauge on the other. Filled it with 10psi and made sure it held pressure over night.
Awesome!
Could someone list the part numbers please....................
Could someone list the part numbers please....................
No problems so far Snowbound??? HMMMMMMMMM:doh:
Is this what you want Frostbite?
1 SKU: 2718-733
Tunnel Assembly (inc. 2-11) 1 $441.59
2 SKU: 2718-723
Tunnel, Front (inc. 3-4) 1 $220.79
3 SKU: 1623-562
Insert 2 $1.32
4 SKU: 1623-657
Insert 4 $1.87
5 SKU: 5606-499
Tunnel, Rear 1 $97.34
6 SKU: 5606-402
Bracket, Tunnel Support - Right 1 $23.09
6 SKU: 5606-403
Bracket, Tunnel Support - Left 1 $23.09
7 SKU: 8060-686
Rivet 1 $1.00
8 SKU: 2706-456
Bracket, Suspension Mounting - Right - Rear 1 $54.95
8 SKU: 2706-457
Bracket, Suspension Mounting - Left - Rear 1 $54.95
9 SKU: 8060-682
Rivet 2 $1.00
10 SKU: 8060-688
Rivet 1 $1.00
11 SKU: 8060-484
Rivet 1 $1.00
12 SKU: 5606-594
Gusset, Tunnel Roll - Right 1 $9.49
12 SKU: 5606-595
Gusset, Tunnel Roll - Left 1 $9.49
13 SKU: 8060-488
Rivet 4 $1.00
14 SKU: 5606-253
End Cap, Tunnel 1 $13.49
15 SKU: 5606-477
Bumper, Rear 1 $55.32
16 SKU: 8611-520
Decal, Reflector - Red - Right 1 $10.95
16 SKU: 8611-521
Decal, Reflector - Red - Left 1 $10.95
17 SKU: 0623-562
Plug, Hole 1 $1.00
18 SKU: 5606-490
Roll, Tunnel - Right 1 $38.49
18 SKU: 5606-491
Roll, Tunnel - Left 1 $38.49
19 Loading... SKU: 8060-482
Rivet 1 $1.00
20 Loading... SKU: 0609-855
Taillight, LED 1 $58.29
21 SKU: 0623-301
Screw, Self-Tapping 2 $1.00
22 SKU: 5606-525
Snowflap 1 $56.95
23 SKU: 8061-710
Rivet 5 $1.00
24 SKU: 5611-853
Decal, Warning - Towing (English) 1 $4.91
25 SKU: 5611-852
Decal, Warning - Towing (French) 1 $4.91
26 SKU: 0123-802
Washer 6 $1.00
27 SKU: 4606-790
Guide, Track - Tunnel - Right 1 $6.29
27 SKU: 4606-791
Guide, Track - Tunnel - Left 1 $6.29
28 SKU: 1623-671
Screw, Machine 2 $1.00
29 SKU: 1623-045
Spacer 2 $4.19
30 SKU: 0123-788
Tie, Cable - 8 in. 1 $1.00
S
Sorry, I forgot your tank bent the back half of my sled trying to piggy back you out. :focus:
B
Here's mine. Bought rear bumper and gussets from Freeagent and motorbike led taillight from local shop. Cut tunnel and straightened the heater by myself. Easy job! My sled is -06 so needed to weld the gussets into rolls. They snap if you don't do that - I lost one before weld them. Also did the float conversion at the same time.
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