P1000m5 Adam490's Short Bus

Adam490 submitted a new Garage Item:

Adam490's Short Bus Budget Build

Bought new from Honda Powersports of Covington. Went with the P1k5 after riding a few times with my daughter on my Rubicon and realizing we needed something more secure and comfortable to fit the whole family. She's been dubbed the Short BusView attachment 142813

Read more about this showcase item here...

 

[Adam490]

Lock tight, I had the same problem.

They were loctited and double nutted. Still came loose. The terrain we were in didn't do it any favors so I just thread locked again and gorilla tightened it.

 

[Adam490]

Wasnt there an older version of the fox rear shock that took the 2.5" spring?

Mine are newer and were 3".

Mine are newer as well. If you get rid of the plastic junk you can run the 2.5 ID springs. That stupid plastic sleeve just held mud and rocks

 

[Russ989]

They were loctited and double nutted. Still came loose. The terrain we were in didn't do it any favors so I just thread locked again and gorilla tightened it.

🤔 back to the drawing board.

 

[ohanacreek]

Figured out where my slack was when I pulled the wheels to change brake pads. Damned driver upper SATV arm. Anybody ever figure out how the hell to prevent this from loosening or should I just check it every ride??

nope I used red loctite and had to tighten them constantly. Go ahead and order a couple extra bolts.

 

[Adam490]

nope I used red loctite and had to tighten them constantly. Go ahead and order a couple extra bolts.

Yep... Talking to the mad scientist as we speak

 

[Ragnar406]

They were loctited and double nutted. Still came loose. The terrain we were in didn't do it any favors so I just thread locked again and gorilla tightened it.

I had/ have some issue .. several have been replaced because the threads wear when the nuts get loose .... just need to get the time but I am thinking tac welding the nuts this time

 

[Adam490]

I had/ have some issue .. several have been replaced because the threads wear when the nuts get loose .... just need to get the time but I am thinking tac welding the nuts this time

I thought about doing that but I think it'll just spin it in the nut

 

[LarryAmboy]

nope I used red loctite and had to tighten them constantly. Go ahead and order a couple extra bolts.

Can you drill them and then use safety wire?


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[BWAF]

Full size nut not jam nut ,drill and tap for set screw maybe

 

[Adam490]

... Finally killed a side view mirror on a tree at some point.

Reached out to Chupacabra Offroad to see if they'd sell me one mirror after I killed one running the 50" trails. Found out they have a lifetime warranty! Really easy to deal with and my new driver mirror and mount came in today.

 

[Adam490]

Been getting some maintenance done on the old girl since I hit my 1200 mile service at Tackett. Changed all the oils, welded in the rest of my tee nuts for the skid plate mounts, and ordered up a PV3 as a Father's Day present . Started rerunning wires to the rear for some reverse lights and to try and figure out why my whips died.

Still trying to figure out what I'm going to do about my side rails, but since they are pretty trashed I'm leaning towards cutting them and welding in some real tubing. I know @snuffnwhisky @Delton @ohanacreek (and others I'm sure) added the bracing to the rear but that won't help mine at this point since they are beat to s*** in the middle. @Delton did you ever look into making the side rails any further? I know you had posted about it a while back... Looks like a lot of bends. I was going to cut it right after the first support tube and weld in a new straight piece of thicker wall tubing, then sleeve it on the inside with a couple plug welds. Never done anything like this before but figure I can't screw it up anymore than it already is....right ??

Oh, and added my TCM sticker to the hood

 

[Pilotadam]

Been getting some maintenance done on the old girl since I hit my 1200 mile service at Tackett. Changed all the oils, welded in the rest of my tee nuts for the skid plate mounts, and ordered up a PV3 as a Father's Day present . Started rerunning wires to the rear for some reverse lights and to try and figure out why my whips died.

Still trying to figure out what I'm going to do about my side rails, but since they are pretty trashed I'm leaning towards cutting them and welding in some real tubing. I know @snuffnwhisky @Delton @ohanacreek (and others I'm sure) added the bracing to the rear but that won't help mine at this point since they are beat to s*** in the middle. @Delton did you ever look into making the side rails any further? I know you had posted about it a while back... Looks like a lot of bends. I was going to cut it right after the first support tube and weld in a new straight piece of thicker wall tubing, then sleeve it on the inside with a couple plug welds. Never done anything like this before but figure I can't screw it up anymore than it already is....right ??

View attachment 207974

Oh, and added my TCM sticker to the hood

View attachment 207975

I would just cope a new outer tube in. Basically replace the outside rail with a new thicker wall tube.

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[Smitty335]

Been getting some maintenance done on the old girl since I hit my 1200 mile service at Tackett. Changed all the oils, welded in the rest of my tee nuts for the skid plate mounts, and ordered up a PV3 as a Father's Day present . Started rerunning wires to the rear for some reverse lights and to try and figure out why my whips died.

Still trying to figure out what I'm going to do about my side rails, but since they are pretty trashed I'm leaning towards cutting them and welding in some real tubing. I know @snuffnwhisky @Delton @ohanacreek (and others I'm sure) added the bracing to the rear but that won't help mine at this point since they are beat to s*** in the middle. @Delton did you ever look into making the side rails any further? I know you had posted about it a while back... Looks like a lot of bends. I was going to cut it right after the first support tube and weld in a new straight piece of thicker wall tubing, then sleeve it on the inside with a couple plug welds. Never done anything like this before but figure I can't screw it up anymore than it already is....right ??

View attachment 207974

Oh, and added my TCM sticker to the hood

View attachment 207975

If I would have known how flimsy the side rails are when new and not bent up, I would have slid some 1 1/4 SCH 80 BLK pipe in them and tacked them in, I measured and the 1 1/4 is a good fit.

 

[ohanacreek]

Been getting some maintenance done on the old girl since I hit my 1200 mile service at Tackett. Changed all the oils, welded in the rest of my tee nuts for the skid plate mounts, and ordered up a PV3 as a Father's Day present . Started rerunning wires to the rear for some reverse lights and to try and figure out why my whips died.

Still trying to figure out what I'm going to do about my side rails, but since they are pretty trashed I'm leaning towards cutting them and welding in some real tubing. I know @snuffnwhisky @Delton @ohanacreek (and others I'm sure) added the bracing to the rear but that won't help mine at this point since they are beat to s*** in the middle. @Delton did you ever look into making the side rails any further? I know you had posted about it a while back... Looks like a lot of bends. I was going to cut it right after the first support tube and weld in a new straight piece of thicker wall tubing, then sleeve it on the inside with a couple plug welds. Never done anything like this before but figure I can't screw it up anymore than it already is....right ??

View attachment 207974

Oh, and added my TCM sticker to the hood

View attachment 207975

Mine were bent some I put the angle on it anyway. Behind the B-Pillar was bent up 2-3 inches I cut it bent it down and welded it. The strength will be from the angle and bracing. Ill post some pictures at some point this week kinda busy right now and I haven't taken any yet.

 

[Adam490]

I would just cope a new outer tube in. Basically replace the outside rail with a new thicker wall tube.

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That's what I was thinking of doing.

 

[Adam490]

If I would have known how flimsy the side rails are when new and not bent up, I would have slid some 1 1/4 SCH 80 BLK pipe in them and tacked them in, I measured and the 1 1/4 is a good fit.

Same. I would have done that and the angle iron. If these are too far gone I will definitely do it with the new ones.

 

[Adam490]

Mine were bent some I put the angle on it anyway. Behind the B-Pillar was bent up 2-3 inches I cut it bent it down and welded it. The strength will be from the angle and bracing. Ill post some pictures at some point this week kinda busy right now and I haven't taken any yet.

That's the problem, mine is bent from the side and upward just after the first bend coming from the A. The rear section that has no support is surprisingly pretty straight still...go figure.

 

[Adam490]

You can see the extent of the damage on the driver's side pretty good in this pic:

Passenger is just a slight upward bend that would be easy to fix, but the driver's side is pretty smooshed.

 

[Smitty335]

You can see the extent of the damage on the driver's side pretty good in this pic:

View attachment 207982

Passenger is just a slight upward bend that would be easy to fix, but the driver's side is pretty smooshed.

You can buff it out! HA!

 

[BigOL3]

Same. I would have done that and the angle iron. If these are too far gone I will definitely do it with the new ones.

Yeah, if I had it to do over, I would have done a LOT different before it had a scratch on it, been a lot simpler then.