P500 P500 project

[aauman88]

Picked up cheap P500 knowing it had blown rear diff. New one on order so took it down to bare bones to see what I’m dealing with. Putting new top end on engine while it’s down.

Have Jaks long travel kit ordered and planning on 35’s. Not much plan beyond that other than I want it solid black. Is pretty cool got red white and blue pioneers in shop right now.

Already has 69% gear reduction so no portals on this one.

 

[Admin]

 

[906UP]

Might as well upgrade to the 518cc cylinder/piston if you're this far into it. I've got the engine out of mine doing just that. Waiting on the clutch puller that seems to be lost in the USPS system so I can split the cases to finish clearancing for the bigger bore.

 

[aauman88]

Might as well upgrade to the 518cc cylinder/piston if you're this far into it. I've got the engine out of mine doing just that. Waiting on the clutch puller that seems to be lost in the USPS system so I can split the cases to finish clearancing for the bigger bore.

Well guess I’m a week late for that. Paid for the new top end last week and sent the head to machine shop few days ago. Thanks though, make sure on next one to do that

 

[gullyjumper]

Im sure it will be nice when your finished but I would never get that all back together !

 

[aauman88]

Piece of cake compared to the 1000’s 😂😂

 

[Adam490]

Be a fun little mud buggy. I see quite a few around here

 

[Adam490]

Going to do the locker up front or just spool it? They are beasts with the IGR and that locked front and rear

 

[aauman88]

That’s one of the reasons I picked this one. It has the locker in the front and it has 69% gear reduction. Also has power steering. As far as I can tell thats $2k worth of stuff I saved because I would have added all three.

 

[aauman88]

Well got to start somewhere. 🤷🏻‍♂️ Put new winch on while waiting for long travel kit to come in.

 

[aauman88]

40” intimidators. The 500 is either getting 38” BKT’s or the 40” 😎

 

[Splorin]

Those look serious! Do you guys upgrade the clutch springs as well as gear reduction and portals?

 

[aauman88]

Finally got the new rear diff. Waiting on Jaks long travel kit now

 

[aauman88]

Some pics from New Year’s Day. Bolted the 40’s up to get it outside to pressure wash it. Have new diffs front and rear, torq locker in front. New top end for engine and Jaks long travel suspension coming this week. Should start seeing some progress soon

 

[alloutdoors]

Looks great..... Did you do any gear reduction modifications to compensate for the 40's???

 

[Bastardchild]

Nice project! I love seeing custom P5's.

 

[aauman88]

It has 69% primary reduction, 3% secondary reduction and Hunter Bennet springs so the clutch can hold them. I’m at or slightly under stock ratio with the 40’s so hoping that’s it. I didn’t plan on portals but may have to for the 40’s. But I can always put my 38’s on the 500 and the 40’s on my 1000 if need to.

 

[The Green Goat]

How did you accomplish the gear reduction?

 

[aauman88]

How did you accomplish the gear reduction?

It’s a Ron Shaw setup I believe. That part was done by previous owner

 

[DG Rider]

This should be interesting.

 

[aauman88]

This should be interesting.

I hope so. My little local mud park has a bounty hole that nobody has came out it yet, SxS or ATV. Big boys running 50” plus don’t make it and we ran a 1000 on 35’s through it and I believe we would have came out but broke front axle. Hoping the 500 will have the right combo to walk out the end. Soon as I try the bounty hole there it will probably get sold. Just doing it for fun