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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #50 on: September 15, 2014, 09:04:49 PM »
These are very similiar to the roof mounted lights, however the green dots tell a different story.
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #51 on: September 15, 2014, 09:05:40 PM »
These lights attach to a heavy duty bracket which in turn bolts to the main uprights of the brush guard with carriage bolts
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #52 on: September 15, 2014, 09:06:31 PM »
This wiring harness plugs into the main harness as well via jumper terminalslocated on the last aux light set I just mounted.Once the wires were plugged in,I carefully ran and secured the wiring harnesses and pluged it all together.
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #53 on: September 15, 2014, 09:08:00 PM »
At this point I am lights complete in the front except for converting the headlights to HID. Next for lights is a "scene illumination which will turn on 360 degree floods and then som aft worklights and finally a dash light mod to NVG compatibility
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #54 on: September 15, 2014, 09:09:41 PM »
Some pics of what it looks like at the moment
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #55 on: September 15, 2014, 09:11:13 PM »
A few more:
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #56 on: September 15, 2014, 09:13:47 PM »
Here's some of the parts that are stacking up for the Gator
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #57 on: September 15, 2014, 09:15:12 PM »
There will be a bunch more photos of this ProMark 4500 winch when it gets installed
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #58 on: September 15, 2014, 09:17:20 PM »
OK, back from vacation, so it's time to get back to having fun!
This time I am going to install a rear head guard then follow up with the installation of the John Deere sports seats.
Here's the rack sitting out of the box:
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #59 on: September 15, 2014, 09:19:16 PM »
It's laser cut out of a piece of maybe 11 gage mild steel, or a tad lighter. Anyway to install that you just open the clamps, losen the poly roof, slap in in place and lock it down. Here it is going in:
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #60 on: September 15, 2014, 09:20:36 PM »
The metal grid is sufficient to keep you from being slapped in the back of the knoggin or keep the brain case enclosure group inside where crushing isn't taking place in the event of a rollover. Mostly I wanted it to be able to mount stuff onto it!
Nest is the seats.
Here they are:
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #61 on: September 15, 2014, 09:21:42 PM »
The factory supplied seat only has a 21" back which I think is sufficient for passengers, however I would like more in the front. THe stockers tilt forward exposing the 4 - 13mm head bolts which I quickly removed.
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Re: Gator 825i Build Thread
« Reply #62 on: September 15, 2014, 09:22:42 PM »
Here is the sport seat next to the stocker,each mounted in this pic:
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Re: Gator 825i Build Thread
« Reply #63 on: September 15, 2014, 09:24:22 PM »
One very pleasant surprise was the ability to move the mount around to achieve 4"-5" more leg room which is important in the space restricted Gator.
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #64 on: September 15, 2014, 09:25:10 PM »
Stock and Sport seat
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #65 on: September 15, 2014, 09:26:06 PM »
And here's the new seats fully installed:
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #66 on: September 15, 2014, 09:27:12 PM »
Here is the approximate location for the factory seats. I plan to build a square steel tubing frame to mount the seats onto and a console in between with a battery under one seat and something under the other (Aux fuel?)
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #67 on: September 15, 2014, 09:28:41 PM »
Here's the knuckleheads already occupying their new homes. I took them for a ride with the seats sliding all over, they didn't seem to mind!
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #68 on: September 15, 2014, 09:30:29 PM »
OK, got the Fox coil overs installed today. They are great quality, high tech lighter and mo-spiffy than the factory units which BTW rode very well themselves.
Here's the stuff in the box:
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #69 on: September 15, 2014, 09:32:22 PM »
As you can see, these things are fully adjustable for rebound and compression and of course ride height (Can anyone say "lift"?)

I started with the left front, then noticed the directions started at the right front. Significant because the picture of where to mount the resevoir mount is all reversed if you're on the wrong side...
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #70 on: September 15, 2014, 09:33:58 PM »
The stock ride height was 31 5/8" to the center of the fender guard. I cranked the shocks some to get me a little over 32"
I neglected to show these pics of the nifty spanner/combo tool and the resevoir mounts that mount to the frame and hold those cool Fox resevoirs out of harms way.
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #71 on: September 15, 2014, 09:34:56 PM »
 knocked out the right side, then took some time to paint the rotors and touch up any area that was not factory painted
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Re: Gator 825i Build Thread
« Reply #72 on: September 15, 2014, 09:36:17 PM »
I bolted the rear shocks on then lowered it to the ground. I had almost a 1.5" rear lift before doing an aggressive test ride. I loaded up my two biological dead weight units into the bed, then went tearing off across the countryside. In summary, I am amazed! Fear nothing except for the neutral zone and a Romulan bird of prey with these suckers bolted in place. I can generate just about any speed I want cross country and the suspension just soaks it up!
Now I feel the need for speed!!!!!!!!!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #73 on: September 15, 2014, 09:37:21 PM »
Originally Posted by KensAuto View Post
I really like the seat upgrade. First thing i noticed was how thick the bottom cushions were compared to the stockers, i bet that combined with the shocks will make it ride Caddyish


Ken,
Right you are, the ride is already great, but I will tune it after I add a few more pieces parts and get the thing up to fighting weight.
Still going to add a spare tire, some pioneer equipment, extra battery, winch, roof rack, gas can (s) and a couple widgets. I want to space the wheels out about 1.5" on all four corners, so after I get there, I will start screwing with the shock settings to get it to be able to terrorize the local terrain with reckless abandon!
But those seats do help. And the numbskulls sitting in the back don't weigh enough to need a lot of padding, and besides young bones heal quickly!
Site owner    IS 6:8  Psalm 91 
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Re: Gator 825i Build Thread
« Reply #74 on: September 15, 2014, 09:39:05 PM »
Originally Posted by KensAuto View Post
Can't wait to see those new gas cans installed to give me an idea for my ranger....not to worried about extra fuel (right now i can run 2 days on 9 gal in the stock tank) but i always carry water in the desert...and shovel, high lift, tools, icechest, etcetc

I bought one of everything they had so I could evaluate them on the Gator. I plan to rack out the truck and will have a half dozen or more of them swinging around back there somewhere. Here's a peek at what's coming:
Orange is the first aid, red is gas, OD is storage, white is water, drinking type...
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #75 on: September 15, 2014, 09:40:42 PM »
Yessir, they are good looking, sturdy, and now I can say, easy to install.
So, I just pasted the Roto-Pack first aid kit onto the roof of the Tac-Gator.
Here's some pieces parts of the latch kit:
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Re: Gator 825i Build Thread
« Reply #76 on: September 15, 2014, 09:42:10 PM »
I wanted to fit it to the inside of the roof above the passenger's head, sort of out of view (since it's orange) and yet easily accessible. So I held up there and picked a spot, then laid down some tape, and marked through the opening to get a reference,
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Re: Gator 825i Build Thread
« Reply #77 on: September 15, 2014, 09:43:50 PM »
My first marks were too close to a seam so I moved everything to the left a tad, checked the fit, then while holding the lock device in place marked the 4 mounting holes locations.
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Re: Gator 825i Build Thread
« Reply #78 on: September 15, 2014, 09:46:23 PM »
Next I assembled the base unit and then bolted it to the roof
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Re: Gator 825i Build Thread
« Reply #79 on: September 15, 2014, 09:48:10 PM »
Next I assembled the base unit and then bolted it to the roof
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Re: Gator 825i Build Thread
« Reply #80 on: September 15, 2014, 09:50:19 PM »
That didn't take too long so I moved on to fabbing up the rear seat mount. The bottom of the seat has 4 bolt holes which used to attach to a steel plate. So me thinks if a steel plate was good enough for the deere, then by golly, its be good enough for me!
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Re: Gator 825i Build Thread
« Reply #81 on: September 15, 2014, 09:51:27 PM »
No, Shawn, I did not use 1/2" A400 (or whatever that stuff was) plate. just a piece of steel about as thick as, well, who cares...
After that I took notice of a couple bolts ah' holdin' that bed together. What better place to use as an anchor point me sez! So's I's duz just like the picture:
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Re: Gator 825i Build Thread
« Reply #82 on: September 15, 2014, 09:52:13 PM »
I then laid in a piece of box tubing connecting the two sides
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Re: Gator 825i Build Thread
« Reply #83 on: September 15, 2014, 09:54:22 PM »
 decided to keep the seats mounted low to keep my CG as low as I could get it. I figure as the biological asset consuming units grow, they are only getting heavier. Right now I want to keep them safe in secure. In about a decade I'll want them to be ejected on a hard corner about a thousand miles from here, but for now we'll keep them as snug as a bug in a rug!
I built the frame 1.5" above the floor and fabbed up the aft mount
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Re: Gator 825i Build Thread
« Reply #84 on: September 15, 2014, 09:55:50 PM »
I tacked 4 legs of 3/4" square tubing to the plates affixed to the seat's undersides, then tacked them into place on the front and rear frames
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Re: Gator 825i Build Thread
« Reply #85 on: September 15, 2014, 09:57:40 PM »
Next came the knucklehead retention system. I went to summit to get some lap belts and shoulder harness made of 2" webbing which I vastly prefer over the way over done 3" stuff you see. Heck I flew most things that can produce lift and they all had 2" shoulder straps, so me thinks, ya know, that must be good enough!
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Offline Flyin6

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Re: Gator 825i Build Thread
« Reply #86 on: September 15, 2014, 09:59:21 PM »
From Shawn:

Next came the knucklehead retention system. I went to summit to get some lap belts and shoulder harness made of 2" webbing which I vastly prefer over the way over done 3" stuff you see. Heck I flew most things that can produce lift and they all had 2" shoulder straps, so me thinks, ya know, that must be good enough!
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Re: Gator 825i Build Thread
« Reply #87 on: September 15, 2014, 10:00:37 PM »
Ah I see part of my security system got into the pic. Here's the other biological units. These eat about the same as the ones which ride around with me, don't wear clothes, seem to like me and never complain.
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Re: Gator 825i Build Thread
« Reply #88 on: September 15, 2014, 10:01:43 PM »
Anyway, I'm done for the day, here's the "state of the mess" at the moment!
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Re: Gator 825i Build Thread
« Reply #89 on: September 15, 2014, 10:03:39 PM »
Originally Posted by bkleinhans View Post
Lookin tough! It looks like the headache rack could be molle compatible.

How long is it going to be before you start working on some sort of tactical trailer thingy for this little monster?


Remember you mentioned the head guard rack might be MOLLE compatible?? Well, it is! That was a great idea BTW, so you get the credit. I dug around my kit bags and came up with all sorts of pouches and mounted them in there.
Here's part of the selection of stuff now hanging on that rack:
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Re: Gator 825i Build Thread
« Reply #90 on: September 15, 2014, 10:05:11 PM »
First to go in were three M4 30 round double mag pouches. Not sure if they will sport double mags, but they sure as heck will fit something!
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Re: Gator 825i Build Thread
« Reply #91 on: September 15, 2014, 10:06:28 PM »
Then everything else wnet in. All total I have 3ea. M4 mag pouches, a radio pouch a double pistol mag pouch a small cargo pouch and a medium cargo pouch all neatly woven securely onto that screen. Be fun filling them up with M&M's and er, I meant hard core survival stuff...
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Re: Gator 825i Build Thread
« Reply #92 on: September 15, 2014, 10:08:08 PM »
I had just washed the floor so welding on the seat frame was a no-no. Therefore I decided to start mounting the pioneer equipment. First to get tacked on is a shovel. I will carry a shovel, an axe, and a jack as a minimum along with the rest of the recovery gear that I'll throw in when I bolt on the winch.
I started by bending up some steel strap to form two stud base mounts.
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Re: Gator 825i Build Thread
« Reply #93 on: September 15, 2014, 10:10:03 PM »
I prefer to drill 1/2" holes in my gear so that it just slides onto a dedicated stud where it is secured with a wing nut that I can get off in a hurry. Here's how it all works:
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Re: Gator 825i Build Thread
« Reply #94 on: September 15, 2014, 10:11:24 PM »
I have also learned to soft mount anything that could vibrate onto a rubber base to prevent buzzing from harmonics. You get the shovel vibrating the same frequency as say the tire tread at 35mph and you will no longer be having fun. It's the helicopter thing. Buzzing is always bad!

Here it is temporarily mounted on the back of the poly roof out of the way. The fit was good and my only concern is for the left seat occupant. There is possiblity of head contact to the shovel blade, but the knuckleheads will be wearing OD green Pro-Tec helmets so bang away
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Re: Gator 825i Build Thread
« Reply #95 on: September 15, 2014, 10:12:24 PM »
Using my favorite John Deere blitz paint and gun lube, I gave them a coat or two
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Re: Gator 825i Build Thread
« Reply #96 on: September 15, 2014, 10:13:10 PM »
I used some kool stainless button head screws, nylon lock nots and large stainless fender washers to mount the dried parts
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Re: Gator 825i Build Thread
« Reply #97 on: September 15, 2014, 10:14:16 PM »
So here it is looking all show car pretty. Might have to splash some of that black paint onto the handle of that rescue me now yellow signal device!
I followed up the install with another rubber bisket under a large fender washer and the stainless wing nuts...All done and pretty as a spring rose!
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Re: Gator 825i Build Thread
« Reply #98 on: September 15, 2014, 10:16:15 PM »
Got the seats installed today. I welded the frame yesterday and painted it last night. After letting it dry overnight it was ready for assembly this morning. Here's the frame painted
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Re: Gator 825i Build Thread
« Reply #99 on: September 15, 2014, 10:17:39 PM »
I bolted on the seats with new hardware, then started on the seat belts
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