So...I sold my wife's Mountain Cat 800 last fall and bought her an M8...PROBLEMS!!!!!

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borderstaff

New member
So...I sold my wife's Mountain Cat 800 last fall and bought her an M8...TOTAL REBUILD

I was in a hurry to buy a sled for my wife and didn't look it over well enough. The bulkhead was damaged underneath from a rock or something hitting it and I didn't catch it until a few days before a trip to the U.P. I bolted a plate to the bottom of the bulkhead and (luckily) it worked to get her through a 200 miles weekend.

So...my first project in the new garage has begun.

Here's the ride in pre-disassembled condition:
77ford020.jpg


And, here's the new chassis:
77ford022.jpg
 
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Skylar

Super Moderator
Staff member
WOOHOO! Can't wait to see watch this project come together, been there, done that! LOL.

I am currently armpit deep in taking the engine out of my buds 05 900 to replace busted motor mounts, and replace the stator. Stupid 900! LOL.
 
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borderstaff

New member
Skylar said:
WOOHOO! Can't wait to see watch this project come together, been there, done that! LOL.

I am currently armpit deep in taking the engine out of my buds 05 900 to replace busted motor mounts, and replace the stator. Stupid 900! LOL.
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And here I was running back to the computer because I forgot the thank the inspiration for this project in my first post. THANKS SKYLAR!!!, for showing us all how much fun this was last year.

The rebuild project will include a few upgrades. I've ordered the '09 rear bumper and gussets so I can update that part of the sled including the flap and LED taillight. I'm also looking into having the front suspension and rear suspension arms powdercoated orange. The driveline is getting new bearings behind the caliper and all new seals and bearings in the DD. I'm installing the '10 cat seat and adjustable risers. And my wife is polishing the tunnel. After all, this is her sled.
 
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borderstaff

New member
Seat, and bumper and taken off.
gnu006.jpg


Some of the front plastic is off along with the exhaust.
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The front bumper is off.
gnu016.jpg


I needed some help with the front suspension, so I asked the boss. And, after showing her how the wrench worked and breaking loose the bolts she really did take most of the front bolts off...it may have taken 5X longer but it was pretty entertaining and I was proud to have my 3 year old helping!
gnu022.jpg
 
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borderstaff

New member
Getting down there...
gnu027.jpg


AT LAST!!!!!!!!!!!!!!!!!!!!!!
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Now, before we put it all together, my wife is polishing her tunnel. Aaaah.
gnu136.jpg
 
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mikeh906

New member
Looks great! I remember so many days spent working in the garage. The wife, kids,[from 3to 29 years old now] friends, ect. Replacing the tunnel is not as intimidating as it seems, but paying attention to details in the re-assambly prossese is the key to a good job, or a picaso. Take your time, and double your budget. LOL. My latest project is my boat, not much snow down here. We have 82 degree water temp, dropping daily. So a few more dives and then its fishing time. I remember my sister and I sheathing and roofing my new garage in 1982, 36x40. My mom remodeled her kitchen before I finished, so the whole thing was installed, sink and all. Free is good. Get an air riviter, and one with 2ft handles
 
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borderstaff

New member
attack_06 said:
a allum welder could have saved alot of time and money
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Well, if the front cooler was in good shape I would have gone that route. But, it wasn't. The front cooler had a large dent and hole in it and the only thing keeping it from leeking all the coolant out was a huge patch of JB Weld. And, even that wasn't a perfect fix as we had to add coolant thoughout the weekend (it lost about 5oz a day). The whole new tunnel and bulkhead unit only cost me $350. And, its a fun husband/wife project - my wife is learning a lot about her sled and doesn't mind figuring out how everything works. And in 7 weeks she'll be riding it in Cooke City Montana.
 
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borderstaff

New member
I've been working on the sled project a lot lately, which is probably due to the deadline of having to get the sled running by next weekend so we can take it to Montana Dec. 14th.

I tore down the top end of the motor and replaced the pistons. There wasn't a problem but I just wanted the insurance of a new top end. I had the cylinders honed at Bill Bune's in Anoka for $24. They cleaned then up at the same time so they look like new.
TOBESORTED023.jpg


For those who like the look of the newer rear end I changed the style to look like an '09. I replaced the black plastic bumper, large taillight, and flap with the aluminum bumper, LED taillight and new style flap. I kept the tunnel brackets on the top for a gas can and re-used the old cooler without modifying it.
TOBESORTED016.jpg


And, just to REALLY set the sled off I had the front and rear suspension powder coated at Rob's Custom Powdercoating www.Robscustompowdercoating.com He cleaned the old stuff up by degreasing the parts, sandblasting everything, coating all the parts in a primer and then in an orange powder and baked it in the huge oven he has. He works out of a shop in his garage and was by far the most reasonably priced guy I could find to do these parts.
newwww002.jpg


I should have most of the sled done by tomorrow night.
 
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