P500 My 520 Build So Far

[CanadianHondaFan]

I've had the little 520 since late May and picked up lots of ideas here for mods and wanted to share some I made up along the way.

I built the windshield, roof and back wall out of a 5'X8' sheet of 16 gage steel and coated it with a layer of primer, then rubberized rock guard, and finally couple coats of gloss black paint. It's holding up well. Saftey glass for the windshield and plexiglass for the rear window. I'm really happy with how the windshield frame turned out and the opening flap on the bottom is awesome for airflow when needed.

I installed a hard wired interior led light strip for a dome light and a 9" lightbar on the front bumper. I mounted a 3500LB Champion winch in the stock location which came with a 10' lead on the switch that I made a Velcro strap for under the dash so the wire lead can be bundled up and stored when not in use or can be used outside the rig too if needed. I also added some side view mirrors and built a couple phone holder and a satellite communicator holder. I added a plastic ammo box that acts as an armrest and storage and is held onto the bottom bench seat by frabic elastic bands.

Next I wasn't happy with how open the inner front fender area was to inside the hood so to help keep stuff from splashing up under the hood I made inner fenders with some rubber floor matting which I also used for heat/sound deading under the seats and to span the gap between the back wall to under the seats. The under hood area stays completely dry now.

I added the 27" ITP Blackwater Evolution tires along with 1.5" wheel spacers all around plus the Honda center caps (that should have come with the machine in the first place).

Some future plans are build a set of hard doors out of the same material as the windshield frame/roof, install a heater, powered windshield wiper, some Elka Shocks, a horn and backup lights.

So far it's a practical little rig and my first SXS and I'm enjoying the extra space compared to the old four wheeler.

Anyways I figured I'd share what I've done to maybe inspire others as I was inspired by members posts in what I've done so far.

 

[Smittyp]

Looks good Nice work

 

[monaco]

Looks good man! The wheel spacers will solve a lot of the side-hill tippyness. I have 2" all around

 

[silvertrd09]

Nice work !!

 

[Rayger143]

Nice custom work. Looks great!

 

[DaddyDubbs]

Very nice.

 

[gullyjumper]

Looks great !

 

[CanadianHondaFan]

Thought I'd share another mod I did. I opened the airbox to check/clean the filter and was concerned with how much dust there was inside after the first 1200kms(745mi) of riding. So I figured it was time to raise up the air intake point. I used 2" PVC central vacuum pipe/fittings which was the same size as the stock intake pipe. I'm happy with how it turned out and it was a pretty straightforward project.

 

[NTCPrezJB]

Thought I'd share another mod I did. I opened the airbox to check/clean the filter and was concerned with how much dust there was inside after the first 1200kms(745mi) of riding. So I figured it was time to raise up the air intake point. I used 2" PVC central vacuum pipe/fittings which was the same size as the stock intake pipe. I'm happy with how it turned out and it was a pretty straightforward project.

View attachment 423861 View attachment 423862 View attachment 423863 View attachment 423864 View attachment 423865 View attachment 423866 View attachment 423867 View attachment 423868 View attachment 423869

Looks great! Definitely a great move IMHO.

 

[trigger]

Thought I'd share another mod I did. I opened the airbox to check/clean the filter and was concerned with how much dust there was inside after the first 1200kms(745mi) of riding. So I figured it was time to raise up the air intake point. I used 2" PVC central vacuum pipe/fittings which was the same size as the stock intake pipe. I'm happy with how it turned out and it was a pretty straightforward project.

View attachment 423861 View attachment 423862 View attachment 423863 View attachment 423864 View attachment 423865 View attachment 423866 View attachment 423867 View attachment 423868 View attachment 423869

Looks good CHF. Consider stealing a black pantyhose stocking and throwing it over the end of that. Cheapest prefilter you can get.

 

[CanadianHondaFan]

Looks good CHF. Consider stealing a black pantyhose stocking and throwing it over the end of that. Cheapest prefilter you can get.

Thanks, I was actually thinking of that for a pre-filter.

 

[CanadianHondaFan]

Well I built a water tight storage box and mounted it to the frame under the driver's seat. I figured why not make some use out of that big empty space under there. I sealed all the joints with PL adhesives before nailing it together. Added a coat of oil based paint then a coat of rubberized rock guard and another coat of paint over top again. Did two coats inside too. I also added an aluminum heat sheild on the side that faces the engine. Pretty happy with how it turned out and looking forward to the extra storage space!

 

[silvertrd09]

Very nice! Thinking out of the box , with a box.

 

[CanadianHondaFan]

Well I got out for a ride to test the air intake and fuel tank snorkel I rigged up. I ran the fuel tank vent line with some 3/16" fuel hose up to the air snorkel height and put a stainless steel J-tube at the end. I'm pretty happy with how they turned out and I can no longer smell any fuel fumes inside the cab like before. I rigged up a backup light(just to a toggle switch) and an arm rest pad for my center console storage box. Next up I'm going to try and rig up a windshield washer fluid tank and a powered windshield wiper.

 

[CanadianHondaFan]

So I installed a wiper motor/arm that I picked up on Amazon. Fitment was good but I'm not sure how it will last in the long run. The motor seems to be working hard(although I've only ran it with the glass dry). It doesn't park automatically in the same place when you turn it off and it only has about 110 degrees sweep. It clears 2/3's of the windshield that I need to see out anyways. We will see how it holds up but either way I don't have much into it. Next up is the washer fluid pump/tank setup. Not 100% sure where to mount the spray nozzles yet.

 

[silvertrd09]

Can you twist the motor counterclockwise a little ?

 

[CanadianHondaFan]

Can you twist the motor counterclockwise a little ?

Yes for sure, but then I'd lose some swipe on the driver's side. I rarely have a passenger so it's not a big deal if that side doesn't get cleared totally. Where I have it now I can stop the wiper up high and out of my view.

 

[silvertrd09]

ok, yeah I'd want it up out my view when not in use also. I have somewhat the same problem with my work truck. I'm not allowed to modify it in any way. The truck comes with a 16" wiper blade and a gigantic driver windshield (its a two part windshield). So I'll stop at the auto parts store buy a 20" or 22" one to get a little more wipe. Maybe an inch or two longer blade might could help.?

 

[CanadianHondaFan]

ok, yeah I'd want it up out my view when not in use also. I have somewhat the same problem with my work truck. I'm not allowed to modify it in any way. The truck comes with a 16" wiper blade and a gigantic driver windshield (its a two part windshield). So I'll stop at the auto parts store buy a 20" or 22" one to get a little more wipe. Maybe an inch or two longer blade might could help.?

I'm afraid to add any more length to the wiper as it will result in more friction. The poor little Amazon motor seems to be working pretty hard as is LoL. Worst case of it doesn't last I'll move to a automotive rear window wiper.