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Old 03-13-2009, 11:43 PM
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Custom Polaris RZR S
Here is another Polaris RZR that I am building.

Cage work is all DOM tubing in various sizes from 1" to 1.75". Sheet metal is all .050" 3003 aluminum.

All welding is TIG done with my Syncrowave 250DX.

Here is how it started...


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Old 03-13-2009, 11:46 PM
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Re: Custom Polaris RZR S
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Old 03-13-2009, 11:49 PM
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Re: Custom Polaris RZR S
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Old 03-13-2009, 11:53 PM
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Re: Custom Polaris RZR S
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Old 03-13-2009, 11:56 PM
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Re: Custom Polaris RZR S
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Old 03-14-2009, 12:03 AM
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Re: Custom Polaris RZR S
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Old 03-14-2009, 12:06 AM
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Re: Custom Polaris RZR S
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Old 03-14-2009, 12:14 AM
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Re: Custom Polaris RZR S
looks really good Paul!!
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Old 03-14-2009, 12:33 AM
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Re: Custom Polaris RZR S
looks great man. i know of a company that makes a bolt on turbo kit for the RZR if you're into that kind of thing. i rode in one and it was amazing. i'm not too sure if that was a direction you were going to be taking your RZR, but i thought i'd throw that out there. here's their website if you're interested www.aerocharger.com.
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Old 03-14-2009, 01:29 AM
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Re: Custom Polaris RZR S
Nice work with the tubing Paul, I have extensive time beatin' on Yamaha Rhinos, this thing looks like its a step above a Rhino. How do they match up, in stock form?
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Old 03-14-2009, 01:42 AM
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Re: Custom Polaris RZR S
ZT,

Why did you only 'clean' the notched pieces (all the way to really-really shiny!) and nothing on the 'main' tubes/pieces?
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Old 03-14-2009, 06:39 AM
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Re: Custom Polaris RZR S
Hi.
Really top class job. fit up excellent,and welding I can only dream about.

Cheers Gordon.
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Old 03-14-2009, 07:13 AM
paweldor paweldor is offline
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Re: Custom Polaris RZR S
WOW!. Really great work. I'm jealous. I enjoy seeing work from someone with the talent you have.
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Old 03-14-2009, 10:42 AM
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Re: Custom Polaris RZR S
Nice work. Do you drill a small hole near the welds to let the pressure escape?
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Old 03-14-2009, 10:45 AM
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Re: Custom Polaris RZR S
Quote:
Originally Posted by Burnit View Post
Nice work with the tubing Paul, I have extensive time beatin' on Yamaha Rhinos, this thing looks like its a step above a Rhino. How do they match up, in stock form?
The RZR makes the Rhino look like a big golf cart. The standard LE model RZR is impressive but this "S" model will do 63 mph off the showroom floor and comes with long travel suspension and Fox shocks.

Quote:
Originally Posted by MoonRise View Post
ZT,

Why did you only 'clean' the notched pieces (all the way to really-really shiny!) and nothing on the 'main' tubes/pieces?
When I de-burr the tubes after notching I use my Burr-King belt sander and I'm in the habit of running a few inches down the tube. I wipe all of the tubing down after bending and clean it off but I didn't sand the mating tubes.

Ideally, I would run all of the tubes through the centerless grinder/sander at work and remove everything but I don't have one at my shop.

Thanks for the comments guys.
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Old 03-14-2009, 10:47 AM
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Re: Custom Polaris RZR S
Quote:
Originally Posted by mr2man View Post
Nice work. Do you drill a small hole near the welds to let the pressure escape?
Yes, all the welds are vented
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Old 03-14-2009, 10:53 AM
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Re: Custom Polaris RZR S
Here are some more pics that I didn't have time to post last night....

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Old 03-14-2009, 10:57 AM
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Re: Custom Polaris RZR S
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Old 03-14-2009, 11:05 AM
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Old 03-14-2009, 11:10 AM
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Old 03-14-2009, 11:15 AM
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Old 03-14-2009, 11:19 AM
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Old 03-14-2009, 11:21 AM
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Re: Custom Polaris RZR S
Nice work partner. It made me daydream about getting some tig work, its been all fluxcore by the spool for me.
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Old 03-14-2009, 11:25 AM
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Old 03-14-2009, 11:29 AM
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