Author Topic: Gator 825i Build Thread (Read 51472 times)

Flyin6 · « **Reply #150 on:** September 16, 2014, 03:57:59 PM »

The winch can be operated through a rocker switch or by plugging a hand held controller into the circut. Initially, I opted for option one, while retaining the option of also dash mounting the rocker switch at a later time.

Flyin6 · « **Reply #151 on:** September 16, 2014, 03:59:11 PM »

With all the wiring run, the front end reattaches with 2ea. large bolts, a lower skid plate and the two side rub rails. That went pretty fast and before I knew it, it was done! I also added a tree saver strap to the accessory gear stored under the hood. I'm now self recovery ready!

Flyin6 · « **Reply #152 on:** September 16, 2014, 04:07:57 PM »

Turkey day!
Great weather, like mid 70's, sunny and wrenches were all a' gleamin'!
So to burn off some of the calories I consumed, I did some Gator projects, pushing that ball down the field a bit more.

I have that bok of Roto-pack gas, water, and storage cans, so I mounted a couple more.

The first to go in was a general equipment container, olive drab, which I needed to store various things.

The location would be onto the underside of the roof just like the existing first aid kit. THis time, however, I am using locking handles so the stuff in there just doesn't go marching off.

Here's what that looks like:

Flyin6 · « **Reply #153 on:** September 16, 2014, 05:10:15 PM »

The mount boss and locking handle mounts to the base the same as the non locking handles do:

Flyin6 · « **Reply #154 on:** September 16, 2014, 05:12:03 PM »

Actual mounting is a snap. Line it up, drill 4 holes, secure the hardware and add a stiffening plate to the top side and you're done!

Flyin6 · « **Reply #155 on:** September 16, 2014, 05:13:10 PM »

Next up was the mounting of the 3 gal gas can.
I am not allowing convention to drive the train here. I will think out of the box whenever I think I need to and with regard to the gas can mount I did just that.
You would think I should mount it in the bed. But if I did that, then less room for the Rangers and stuff like sleeping bags, 81mm mortars and things like that. So I decided to go outside but try to place it in such a way as to flow into the vehicle lines affording it some protection while not taking up valuable space. I wanted to keep the CG of the thing between the wheels and close to a suspension point so I wouldn't have unusual gyrations with the 20 extra pounds hanging on out there.
Here's where I decided to place it. Passenger side outside of the bed, above the brush bar and slightly forward of the rear wheel. I wanted it to be strong so I started with a sheet of stainless steel and bent it into the piece you see here:

Flyin6 · « **Reply #156 on:** September 16, 2014, 05:15:04 PM »

I mounted it to the roll cage bar with 2ea. 3/8" bolts resting on rubber blocks to isolate vibration and used a U-bolt to capture the round steel tube on top of the truck bed.

Flyin6 · « **Reply #157 on:** September 16, 2014, 05:15:49 PM »

Those were rose welds to keep it all fairly neat, yet super strong. The fuel can fits right on and inclines the gas can intoward the vehicle at the top to follow the contour of the front of the vehicle. I am not done yet, but just this slight tilt should help it clear some wait-a-minute vines.

Flyin6 · « **Reply #158 on:** September 16, 2014, 05:17:07 PM »

I decided to use locking handles on the gas can as well. Since I'll have three keys once I mount the white water cans, I decided to just spray paint the keys the same color as the cans. Green, red and white. Simple enough for a pilot!
I have not finished the installation, owing to some more rubber sway bar bushings which I like to use, various lengths bolts which I could not find in the Don shop, and some other hardware, but this is what it looks like at the minute:

Flyin6 · « **Reply #159 on:** September 16, 2014, 05:18:23 PM »

I still have to rubber line the mount, trim off the U-bolts, and round off the stainless sheet edges, but it's coming right along. Here's a few more shots:

Flyin6 · « **Reply #160 on:** September 16, 2014, 05:20:08 PM »

Since I still had time and no more hardware to complete the gas can mount, I decided to finally decide where to mount the rifle.
Since I am going to use the Gator down on the farm initially and then who knows where afterward, I think the perfect weapon to mount there would be a M4. So that's the gun I used to model the mount up, however I will ensure it also can secure an AK-47.

Here's where I decided to mount it:

Flyin6 · « **Reply #161 on:** September 16, 2014, 05:21:02 PM »

Obviously, I still need to fab up a lower mount onto which, I can attach the gun-butt holder seen in the pic. I think a simple aluminum L bracket with some generous feet to spread the load and some fender washers, and that should get the job done.

The upper mount bolts directly to the factory steel handhold with two stainless U-bolts. I will trim off the ends of the U-bolts soon as I close in on finishing this little project tomorrow.

Flyin6 · « **Reply #162 on:** September 16, 2014, 05:22:16 PM »

The upper gun mount is pretty cool. It has a slot and thick rubber jaws. You need to twist a jaw up or down then press in the weapon. while releasing the jaw. The rubber closes around the barrel, and just like that the gun is pretty secure.

Flyin6 · « **Reply #163 on:** September 16, 2014, 05:23:32 PM »

I'm used to storing guns next to the door. We locked our M4's part inside and part outside in the doorway of the littlebirds I was flying around Baghdad. Worked fine. And if you were getting out, there was that gun right there so you wouldn't forget it.
Here's a couple more shots:

Flyin6 · « **Reply #164 on:** September 16, 2014, 05:25:51 PM »

Same-same with how I secured my weapon in the bird in Baghdad, I like the use of a clip on halo which then is attached to the vehicle with a carabiner. That way if all hades breaks loose, say a rollover at speed for example, the weapon will be retained even if it comes out of the mount and beats your face all up!

Flyin6 · « **Reply #165 on:** September 16, 2014, 05:27:26 PM »

Tomorrow I'll finish with the details and the base mount, but here's how it looks as of beddy-bye time tonight.

And the weapon secured to the vehicle:

Flyin6 · « **Reply #166 on:** September 16, 2014, 05:29:18 PM »

Well I finished up the M4 mount and added some pioneer equipment as well.

First while shopping for some bolts (On black Friday, what was I thinking???) I came across this cool brush clearing chopping device. I immediately saw it in my minds eye mounted to the over-grossed rear head protection.

Flyin6 · « **Reply #167 on:** September 16, 2014, 05:30:45 PM »

I picked up some emergency flares and tucked them away for some future use:

Flyin6 · « **Reply #168 on:** September 16, 2014, 05:31:53 PM »

While I was out at Harbor Freight, I picked up a bunch of cheepo LED lights. I thought I'd slap them all over creation to use as an expedient dome light that you could grab and go with.

Flyin6 · « **Reply #169 on:** September 16, 2014, 05:32:43 PM »

I got a little light happy, trying to reach my goal of having 300+ on the Tac-Gator. They had these cool hat bill clip on LED's which I picked up and slid home in a couple spots. Same thinking as the work/dome lights.

Flyin6 · « **Reply #170 on:** September 16, 2014, 05:33:44 PM »

While there spending my money while we can all still do that, I picked up some things to start outfitting the cargo utility box I installed yesterday. I forgot to put the roll of 100mph tape, but I bought it never the less

Flyin6 · « **Reply #171 on:** September 16, 2014, 05:35:22 PM »

Next I finished the construction of the gas can mount. It's plenty sturdy now. I welded in another brace, a stiffner, and bolted in another U-Bolt. THere is no wiggle in the mount what so ever now, and it is rubber isolated from the rub rail/cage thing. I downsized the hardware to 5/16" since the full gas can will not make it to 30 pounds.

Flyin6 · « **Reply #172 on:** September 16, 2014, 05:36:40 PM »

On to the M4/gun mount. That was a quick fab project where I used (T-5???) Aircraft aluminum. With some quick cuts and a few simple bends I had it. Later I decided to double it so I bent up another piece to lay over the base.

Flyin6 · « **Reply #173 on:** September 16, 2014, 05:37:44 PM »

Those were rivited together on 1" centers

Flyin6 · « **Reply #174 on:** September 16, 2014, 05:38:44 PM »

Next the rubber gun base was screwed into place with some stainless hardware and nylon lock nuts. That assembly was then secured to the fender with the same hardware

Flyin6 · « **Reply #175 on:** September 16, 2014, 05:39:46 PM »

It now holds the rifle securely in place!

Flyin6 · « **Reply #176 on:** September 16, 2014, 05:41:36 PM »

So here's what it all looks like at the moment:

Flyin6 · « **Reply #177 on:** September 16, 2014, 05:43:01 PM »

Originally Posted by GreatLakeOffRoad View Post
Don, have you purchased tires and wheels yet? If not think steel wheels and custom weld on b-locks.........

Nope and for now I'm now 5 wheels deep into the John Deere product line. Now having said that, I could swap these wheels/tires onto the wifes Ga-Tor and free up some room for some steeleis...
You making them (yet?)
Hint: go 15" since the Ga-Tor has a 5 on 4.5" pattern same as you jeepers, the tire size selection would be pretty good. And me thinks you drive over a kia and get your tires all crunched up, find yourself a dead jeep, there should be olenty of them along with the fords to source a tempo spare...just sayin...

Flyin6 · « **Reply #178 on:** September 16, 2014, 05:45:04 PM »

Originally Posted by nmeyer414 View Post
looking mean Don, i like it!

It's gettin an attitude, that's for sure.
So one day I was flying resupply to all those FOBs along MSR1 from Kandahar going out toward Bastion and Lash. I landed in that one on the Wadi about half way, a Canadian FOB me thinks. ANyway while sitting there a Polaris all cammoed out with a M240 mount comes motoring by. Why was I looking at it so closely, you ask? The guys drove under my rotor system, and I was in a AW-139, an aircraft they were not familiar with! They had multi-cam on before anyone had it, so you know who they were, but that little vehicle struck me as pretty cool. So that's where I'm going with this one. More suspension, more lift, more engine, more range, more stuff...Got a lot more stuff to bolt on there!
Here's my actual AW139 based out of KAF, ever see it?

Flyin6 · « **Reply #179 on:** September 16, 2014, 06:09:36 PM »

OK let's get busy on the Gator again.
Previously it was destroyed when multiple layers of dust settled over it rendering it inoperable!

I started it anyway and it roared to life!

Well, even with the dual batteries, the voltage had slowly trickled away requiring a bump from a battery jumper pack.

So, since it is parked in a garage next to a window, it should get some sun and therefore a daily charge, trickle though it may be.

After some research I found some 5 watt solar panels on sale, so I purchased a few. One went on the Case Track loader this morning and the second onto the Gator.

Here it is:

Flyin6 · « **Reply #180 on:** September 16, 2014, 08:44:48 PM »

The panel itself mounts simply by drilling 4 holes which I did into the poly roof. Using #8 stainless screws with nylock nuts I laid the panel over the studs which also had 4 rubber isolation bushings fitted between the panel and the roof.

Flyin6 · « **Reply #181 on:** September 16, 2014, 08:47:16 PM »

I got out a can of the John deere flat black to touch up the shiney parts, and that's when I got a little crazy!

Before it was all said and done, I was looking at this:

Flyin6 · « **Reply #182 on:** September 16, 2014, 08:49:37 PM »

A few more

BobbyB · « **Reply #183 on:** September 16, 2014, 09:04:35 PM »

Oh Tactigator you were never forgotten !

Flyin6 · « **Reply #184 on:** September 18, 2014, 11:33:33 AM »

Yea, and after reading how Ken ciphered out a turbo on his F250 Polaris, I want to turbo this one!
Think about it, I already have a big auto engine, which ought to respond to turbocharging pretty well.
But that clutch thing is something that is a black art known to but a few...

Pulley · « **Reply #185 on:** May 08, 2015, 10:10:43 PM »

Surprised I've just now found this build, pretty cool. Do you still have it? A turbo on this puppy would be sick.

Pulley · « **Reply #186 on:** May 08, 2015, 10:12:01 PM »

I probably should have looked before posting haha. Just saw the thread saying it's gone.