The Green Goat Build Thread

The Green Goat

The Green Goat

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Welcome to the official build thread for The Green Goat. It's been a long haul, but we're finally here.

-Backstory:
The story of how I ended up with a P52 is kind of ironic. I started off having no desire to own one; didn't even know what they were. I originally inherited a MY2000 Honda Rancher from my stepfather. His son, my stepbrother, was the original owner of it. It had clearly lived a life of misery, being beaten on and generally neglected by my stepbro in his younger years. About 6 year ago my stepfather somehow acquired it back. It sat in a barn, rarely seeing the light of day, and never worked when my stepfather went to use it; we chalked it up to lot rot. So, he pawned it off on me since I had recently purchased a house and could/would use it frequently for yardwork and such. Little did I know, his problems with it not running would become my problems with it not running.

I made several trips over the next couple years to the local powersports shop. They'd charge us $500 here, $800 there, claiming they had 'fixed' it. The sumb**** never did run right. On one beautiful fall day, I finally had enough of its shenanigans. I was under a time crunch to overseed my yard and that MFer wouldn't start....again. Enough was enough. I was ready to set it on fire.

I pawned it back on my stepfather and told him I was done with it; I'm going to buy something new and reliable. He sold it, not running, for $1000 to one of his employees. I was shocked. Never would I have thought that thing would bring in even $250 in its current condition. Take the money and run!!!

So the search was on for a replacement. I'm not particularly brand loyal, but I did have several Yamaha and Kawasaki dirtbikes and ATVs when I was a kid, so I started my search there. I liked the Kodiak 450s. Kawasaki had nothing I was impressed with. I also looked at Rancher and Foreman, because, why not? On a whim, I started wondering if a UTV could fit my criteria. I knew a little about side by sides years ago when I was younger and into keeping up with this stuff, around the time the Yamaha Rhinos were about the only thing out there. I didn't want something 'big' since I would mostly be using it around the yard. I also had the thought that if I was going to get something, I might also get back into riding just for the enjoyment of it; something I had put aside as the adult years progressed and life got in the way.

I used to frequent Wayne National Forest in my younger days and knew that it had a 50" width restriction. So if I was going to also throw UTVs into the mix, it had to be on the smaller side. I did as most people do and looked at Polaris. Their stuff was flashy, but I was never impressed with their reliability from my numerous encounters with them year ago. In September 2020, I stumbled upon the Pioneers on Hondas website, and the P5. I liked it! What a neat little machine! Small, nimble, geared low for work, (well-maintained) Honda reliability, metal gears, no belt, and an odd little rack on the back. I was sold. I wanted one.

From there, I did as I always do; I researched everything I could. I wore Google out for the next month. I came across this site and never left. What a wealth of information! It was also somewhat poor timing on my part, because I also came to find out that a new, updated model was on the way. One whose details were being kept secret for now. Fast forward a couple months of agonizing waiting and it was finally revealed. An updated version was here, and it came with a bed. Perfect!

Fast forward again >>> more waiting. When were these things coming out? January? Nope. February? Maybe. I put a deposit on one from a dealer that didn't sound very confident on getting one anytime this Spring. Great, another missed yardwork season. I had to have green, as I also planned on using it for hunting and didn't want it to stick out like a sore thumb in the woods. Turns out, green seemed to be the least produced color. Just my luck.

So, I waited some more. I called every dealer in Ohio every two weeks. I checked ATVtrader at least 2-3 times every day just hoping for something new to pop up. If I wanted a red, blue, or camo, I could have had one pretty quickly. I noticed a green one listed in Western Pennsylvania but figured its probably already sold. I was super busy with work and there was no way I would have time to go get it, even if it wasn't already sold. I had a free day from work coming on a Saturday. I decided to call this dealer on Friday, just to see. To my astonishment, it wasn't sold. Sweet Jesus, don't sell it, its mine and I'll be there tomorrow.

Drove almost 4hr one way, got there 15min before they closed, signed the paperwork that was already ready for me, handed them $11,200, and loaded it onto the trailer. Freaking, Finally!!! 6 months after discovering and perseverating over the little P5, I had one of my own.
 
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The Green Goat

The Green Goat

LGBTQ Compliance Officer -Lotta gays in this place
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Ownership

  1. 520
-Plans and Mods:

I'll have you know, this site and all of you have cost me a lot of money and I don't see an end in sight for that.

Do you know what One does while waiting 6 months to get one of these things? Plan. Lots and lots of plans.

Here is a list of just about everything I can think of that I would (eventually) like to do to/with this thing. I'm trying to think of EVERYTHING I might install so that I can plan accordingly. I don't like undoing or redoing things because something I decided on later conflicts with something I've already done.

Here are the plans,
In no particular order:
-Fluid Film/Wool Wax interior of the frame
-Check all bolts/fasteners/lube, anti-seize, and Loc-Tite anything that needs it.
-Reverse mod
-LED headlights and align them
-Frame caps
-Seat belt bypass
-Cut oil filter access hole, maybe
-Ruff Tuff seat covers
-Trigger Shields
-EMP poly top
-Honda floor mat
-SSS UHMW full skids
-Auxiliary battery (SLA) under driver's seat
-Blue Sea Mini add-a-battery kit
-Automotive style fused relay boxes for all electronics
-NOCO battery charger with panel mounted charging port
-Dual voltmeter
-Auxbeam light bar
-Auxbeam selectable L/R scene/work lights
-Auxbeam rear scene/reverse lights > on with reverse or with a switch
-Auxbeam 6 button light switch panel
-Goochbox with internal USB charging port
-Honda sub harness
-Strongmade front bumper
-Honda rear bumper
-Viper Elite Widespool 6000lb synthetic line winch
-KFI 66" Pro-Poly plow w/ side wings and winch strap
-Tusk power steering
-Torq Locker
-Tusk 28 (27.25") x 10 x 14 Terrabite Aramid tires - (5) of them
-Tusk 14x7 (5+2) Uinta beadlock wheels in gunmetal
-Motion alarm
-GPS tracker
-MFG supply 2" receiver
-EMP radiator screen
-Hornet Outdoors spare tire holder for 2" hitch
-Hornet Outdoors chainsaw holder
-Honda bed rack
-Fabricobble a folding front rack
-Honda nerf bars
-RAM phone mount for upper rollbar w/ USB charging cable
-Boss audio BRRC27 speaker w/ dash mount control panel
-Seizmik pursuit night vision breakaway mirrors
-Rotopax mount on spare tire holder w/ 3.5gal fuelpax
-XTC self cancelling turn signal kit w/ horn
-Ohio street legal registration
-Field repair tool kit
-Bubba Gear UTV recovery kit
-Electric dump bed actuator
-Rear accessory switched power, for sprayer and spreader
-Seat heaters under seat cover
-Inferno cab heater
-Tusk 1/2 + 2" windshield for summer
-SxS windshields glass windshield for winters
-EMP hardcoated back window for winter
-New Honda P520 fabric doors for winter
-ThrottleMaxx
-Walker Evans shocks
-Electric windshield wipers
-Xroad3d overhead rollbar mounted switch box; 6 gang
-MY2015-2017 dash
-relocated MT/AT switch, possibly near cigarette power port
-Main power switch, winch switch, stereo controller mounted on dash where MT/AT switch was
-6.5/7' x 14' tandem axle trailer to haul it

OK, that's enough for now. I have not, and will not, add all of this up.
 
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The Green Goat

The Green Goat

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Phase 1 of my plans:

Here's a list of the mods on hand or on order:
-Triggershield
-HondaSxS seatbelt bypass
-HondaSxS frame plugs
-Honda keychain (totally necessary)
-Diode Dynamics 881 LED bulbs
-SJM 881 LED bulbs (will return, didn't realize DD made 881s when I bought them)
-EMP poly roof
-Honda sub harness
-Blue Sea Mini AAB
-(2) 6 gang automotive style fused relay boxes
-12 post +/- bus bars
-Goochbox v2.0
-NOCO 1a charger
-NOCO panel mount charger port (discontinued and nearly impossible to find)
-Auxbeam 32" curved combo light bar
-Auxbeam 6 button switch panel
-Auxbeam 5" scene lights; 1 per side, 2 for back (didn't show up with today's shipment???)
-Chinesium motion alarm
-Chinesium USB charging port (for Goochbox)
-Dual volt meter
-Tusk powersteering (on order)
-Honda floor mat (on order)
-Tusk 1/2 + 2" windshield (on order)
-Ruff Tuff seat covers in Multicam Black (on order)



Here she is before I defile her. Doggo seems to like it. He can ride shotgun, but only after the seat covers arrive. No holes in the seat right now...

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Here's the dealer's "Professional setup" job. I heard something dragging the gravel after I took it for a quick spin in my field. Well worth the $300 they charged me for an expert to bolt on the skid plate and install the steering wheel. FYI, the front tires are straight. 5/5 stars; would recommend.

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Current mileage and hours

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Pile 'O' mods
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While I was jacking it up, these showed up

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Official Honda Key chain

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First thing I did was jack it up and take the tires off to clear out some room to work. Most of what I planned on doing today were simple mods and brainstorming for the ensuing electrical nightmare I am getting myself into.

Removed the seats and seat pans.

Removed the bed to get access to all the good stuff. Bed removal was waaay harder than I anticipated. One plug to undo, removed the gas shock (this is going to be a blast to reinstall). Its under tension, obviously. I put all of my fatass weight into it when it was off and couldn't compress it, at all. Not sure how I'm going to remedy this. I might just leave it off until my wiring projects are complete, which will include an electric lift actuator.

Now, onto Satan's bolts. The bed has two shoulder bolts that it uses to pivot. Seems simple enough. 12mm head, 12mm nut. Got my nuts off in about 10 seconds (my usual time), and then proceeded to curse for 30 minutes while attempting to drive the bolts out of their respective places. Man, those things are in there. R side wasn't too difficult. I put the nut back on until the threads were protected, and then used a block of wood and a hammer to drive it home. L side, not so much. Block of wood wasn't going to cut it. I eventually resorted to saying, Fvck these things, and used just the hammer. Finally got it loose, with only minor deformation of the nut; now they're lock nuts! I will be putting some anti-seize on these things when they go back in.

Bed was surprisingly heavy. I didn't weigh it, but I'd guess 60lb, give or take. Definitely awkward to handle. However, I am certainly glad I removed it as it creates sooo much more room to work and get a good look at things. SO MUCH MORE ROOM FOR ACTIVITIES!!!

Tail light plug, passenger side
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The bolts of Satan
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Ahhh. It's off.
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Went around with some Goof-Off and removed all the marking paint I could find on all the fasteners. There's no place for yellow or pink paint on this machine. Left the witness marks on the drain/fill plugs.


Found these random sealed wires. Anyone have any idea what they are for? Found 3 of them so far (the green wires)
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SB bypass installed
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Reverse mod done
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Frame plugs in
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Sub harness in
How it came:
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Temporary taping out of the way:
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Halogens swapped out for Diode Dynamics LEDs
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Unadjusted beam pattern
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Adjusted beam pattern (wanted them level and pointing lower; light bar will cover higher stuff)
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Adjustment screw located here
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Temporary motion alarm placement. This thing works surprisingly well!
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That's about it for the simple mods today. I spent most of my hours drinking beer and staring at the thing trying to figure out how I'm going to tackle this wiring stuff. I opted not to go any further than this until I get some other mods installed first, because those will dictate where I can and cannot put things. I need to fabricobble a battery holder under the driver seat, mount the Blue Sea MAAB (probably on the panel behind your legs between the driver and passenger, run all the wires to the front, and mount the relay boxes. I'd like to get the power steering and Goochbox installed first as well as look at some install pics of the Inferno heater to see exactly where it sits.

Some rough ideas about mounting locations. Pretty sure some of this is not going to jive with the power steering components.
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That's it for today. Here's some random pics I took. I haven't seen much in the way of detailed pictures of the P52 prior to me buying one, so perhaps these will help someone.

The battery setup
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spare fuse in cover
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Random pics
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The Green Goat

The Green Goat

LGBTQ Compliance Officer -Lotta gays in this place
Lifetime Member
Supporting Member
Sep 7, 2020
2,249
16,612
113
Ohio
Ownership

  1. 520
Updates:

Tusk power steering installed, but not wired yet. I wanted to get the auxiliary battery system installed first and will then wire it into that. Still works just fine without power. Getting the steering shaft knuckle far enough away from the master cylinder was a pain in the butt, though.

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Decided to move the MT/AT switch to where the cigarette power port was. The hole is nearly the same exact size. Only had to drill 3 holes for the plastic mounting pins to fit through. Eventual plan is to put the bluetooth stereo control panel where the MT/AT switch used to be. I also plan to use the connector that powered the old cigarette power port to power the new cigarette/USB power ports that will be mounted in the back of my GoochBox.

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Used a light from the backside to illuminate the hole in order to line it up. Then used a push punch to mark the drill points. Kept upping the drill bit size until I got a tight fit.

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For some reason, it looks crooked in this picture, but it isn't from the front side.

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I then decided to install the GoochBox. Per AMR's install video, I measured 1/2" from the edge as my starting point for cutting. I went out and purchased a Makita multi-tool to make the cut (gave me a great excuse to buy a new tool...). It was a bit too tight, so I just used my pocket knife to slowly shave away the tight edges, and clean them up, until it fit snug. Looks great, IMO.

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I moved onto installing the Honda floor mat. I think I had to drill 5 holes total. The instructions are lacking (as in, they don't exist at all) for this thing. I pulled all of the factory plugs. The mat comes with ~10 extended length plugs. The factory plugs DO NOT fit back in their stock place, however, they do fit into some of the newly drilled holes. Basically, use the plug that fits.

My plan is to leave this thing in place for awhile and let the sun heat it up a bit to see if it lays down any better. It doesn't get the the way, at all, but the fact that it doesn't completely hug the floor contours bugs me a little. If it still sticks up a bit after some time passes, I'll probably end up drilling a few more hole and adding some more plugs.

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Decided to get serious about tackling my auxiliary battery system, which I have been dreading.

Started by installing the BS-MAAB selector switch and Automatic Control Relay. Centered them as best I could between the driver and passenger legs on the vertical panel. Marked the holes and got to drilling. Disclosure: I price all replacement parts before I drill into them to I can see what it will cost if I screw it up. I think this panel was about $35. The (2-3/8"???) hole saw did an...ok...job. Finish was a bit rough, but I cleaned up the edges with my trusty pocket knife. I also would have liked for the bit to be about 1/16" smaller, but, this is as close as I could find (another new tool!).

I'm using stainless hardware in everything.

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A Torx security screw is all the hardware store had in the sizes I needed. Guess no one is stealing them...


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Now for the battery box and tray.

Battery is a Mighty Max 12v 35ah SLA variety. Box is a U2 size that fits the battery pretty close. I attempted to use garage door rail to make the initial try, but wasn't satisfied with the results. So, I contracted my stepdad to fab one up for me out of aluminum. It won't win any art shows, but it'll work for what I need.

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I decided I wanted to try riveting it to the frame rails instead of bolting it. I opted to use 3/16" stainless steel rivets for this job due to their holding power. I also didn't have a rivet gun, so.....new tool again! I was/am a bit concerned about the dissimilar metals causing a corrosion issue, but, I filled all the holes with clear RTV silicone prior to inserting the rivet in hopes that it creates a barrier from corrosion and water intrusion into the frame.

I also marked and drilled all the holes ahead of time because once this thing is on there...it's on there.

BTW, my arms are jello trying to get those rivets to set down in this tiny area. Holy hell, did that suck.

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I'm about 75% sure this thing will work long term. It's on their pretty solid, but I'm curious how those rivets and hole are going to fair once there's a 20lb battery bouncing around in there. Time will tell. I suppose if I hear the battery dragging behind me one day while out on the trail, it will be time to drill all the way through the from and just bolt it on. We shall see.

Now the battery box. Holes were pre-drilled prior to riveting the tray. Again, stainless hardware was used. Nyloc nuts for everything. Had to drop the side skid to get to the front two nuts.

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I used some foam I had lying around to pad the battery a bit from jostling about.

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Now, the next big thing I have been avoiding: the electronics panel.
This is the best way I could think of to organize all the electrical components under the hood.

I had a 0.25" x 8.5" x 10.5" aluminum plate cut at the local metal supermarket. They rounded off the edges for me on a bench grinder. I used a palm sander with 150gr paper to clean up the finish a bit. Gives it a bit of a jeweled look too.

I started by positioning it about where I wanted it to be on the shock brace. I loosely laid all the components on the plate where I wanted them. I also double checked that the hood will close with everything on there. Plenty of room.

I pulled all the wires out of the way underneath the brace so as not to run a drill bit through them. I marked everything as close as I could. The holes are spaced 2" apart, starting from the right, which is drilled directly in the middle of that vertical support brace.

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Plate laid on there. I opted to used (stainless) counter sunk screws. I bought a counter sink (new tool!) bit but it wasn't big enough to fully seat the screw heads, so, I bought an even bigger one (another new tool!).

This is the rough fitting before sinking the screws to their proper depth.

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Here's everything mounted on the top side. (2) 6-gang fused relay boxes and a positive and negative 12-gang bus bars.

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Here's everything mounted to the bottom (front) side. A 500a stinger relay and a 200a Blue Sea breaker. I REALLY wanted to buy one of the cheaper Chinesium Amazon relays, but everything I read said they won't hold anywhere close to their rated amperage. So, I bought the Blue Sea.

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Power from the Aux battery will come from the driver's side. The negative will go to the main terminal on the negative bus bar. The positive lead will go through the Stinger, then a quick jump to the breaker, then loop up to the main terminal on the positive bus bar where it will be distributed to the various accessories and relay boxes.

I haven't decided how I am going to tackle the relay boxes just yet. Once they are bolted onto the plate, there is virtually zero room to get to the wiring. I'm pretty sure I'm going to have to wire the stuff in, and then bolt them down, running the wires out some holes I drill in the plate. This doesn't bode well for disassembling it in the future. So, my current thought is to install some sort of Deutsch connectors to make it easy to disassemble should I need to. We'll see how that goes.

That's it for now. Next step will be wiring everything in and routing cables cleanly. After that is done, I can start installing some actual accessories.
 
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The Green Goat

The Green Goat

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Back to wiring and such.

Battery box/tray/wiring complete. I'm now 95% sure it's not going anywhere.
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Redundant straps. Black/gold goes around the battery box but on top of the tray to hold the lid on. Black/red goes all the way around the box, tray, and frame and is on there tight. Even if the rivets work loose, this strap won't let it go anywhere.
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Main battery re-wiring:
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Routing wires:
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Plate mounted:
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Power steering connected and grounds tied in. Ran out of heat shrink (but not Bud Light) in the photo:
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Boss Audio BRRC27 sound bar installed. I'm not overly impressed with this thing for the money. It's loud, but it just doesn't have much fidelity. I didn't expect it to have any bass with just 3" speakers, but I was hoping it would at least sound better. Also, the fact that it powers on automatically and connects to my phone's BT, then proceeds to blast music on max volume is infuriating.
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Wire fished through roll cage. HUGE pain in the ass to do this, but I like the clean look. Hopefully I don't compromise the structural integrity too much by poking holes in it. I don't anticipate (famous last words...) any high speed rollovers, but I think it'll still hold up just fine for the occasional tip over.
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Exit near hood:
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Scribing the dash for the BT control panel. It's where the MT/AT switch used to be.
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Took a break from wiring to install some other things. MFG Supply 2" hitch. Fit perfect:
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KFI tailgate levelers. I'm mildly miffed that the tailgate still isn't level. It's close, but it still has a slight upward angle to it. If you attach it in the holes they intended, then it has a serious downward angle to it. A waste of $17, IMO. Perhaps the cables will stretch after my fatass sits on it a few times.
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Back to wiring...
Installed EMP poly roof and Auxbeam Chinesium lights. We'll see how long they hold up, but I think they will work just fine for SxS duties. Any bets on how long it'll take a stray branch to knock off the side scene lights?
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Installed an Auxbeam control panel. Again, I decided to fish all of the wires through the frame. This one sucked even more than the sound bar wires.
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Everything wrapped in wiring harness tape:
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Mounted the control panel's fused relay box:
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Wired in:
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Onto turn signals/hazards/horn/plate mount to make it street legal. It's a TurnProsignal Plug & Play kit. This thing was a pain in the ass as well, and it still doesn't work completely. I think the converter box is bad or something because the rear passenger signal doesn't work, the driver's signal is quite dim, and the plate light won't come on. I'm praying it's a faulty convertor box, which is easily swappable. If the whole harness is bad, I might have a stroke as it took me forever to get that thing in there the way I wanted. Lesson learned: check it before you install it. I also opted to go my own route with the switches. I chose to mount them to the steering column, which also sucked. There was a LOT of tedious Dremeling and shaving of plastic with my pocket knife to get everything to fit just right. 2/5 stars; would not recommend doing this.
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I have no idea what the purpose of this plate is. It's not attached to anything. It's held in by one plastic rivet. Nothing is attached to it. I dunno, maybe a dust or mud guard or something? It was in my way though, so out it came.
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These switches have the capability to be backlit, however, I opted not to wire it that way. I was unable to find the switch configuration I wanted with the backlight color I wanted, so, I'm leaving them without. I have intentions of wiring signal arrow indicators into the areas next to the dash display.
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Last edited:
The Green Goat

The Green Goat

LGBTQ Compliance Officer -Lotta gays in this place
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Plate holder installed and wired in:
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More blows to the cages structural integrity:
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Took a break from wiring to do some yard work. Wasn't long before I took a break from that and decided to bolt on my wheel spacers. RB3 1.5" fronts, 2" rear. Prior to the spacers, the tires rubbed on the inner wheel well. After installing, they no longer rub on the inner well...now they rub on the posterior wheel well. FML. That's what I get for insisting on square profile tires.

Also, I think the p52s come with an additional stick guard that the 500s do not, which seems to encroach on your usable real estate. Can anyone confirm?
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Definitely going to need some Mud Busters. I'm curious to see if they will come out with anything for the rear for the p52s.
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Installed the Tusk 1/2+2" windshield. I'm not overly impressed with this thing. The seal they give you for the bottom is useless; I threw it in the trash. I then decided to mount it up a bit higher so I could get into the hood to continue my wiring projects. The clamps leave something to be desired. Aw well, I just got it as a temporary solution for summertime riding. A full 801 glass shield will take it's place come winter time.
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Siezmik Pursuit mirrors installed and wired into Auxbeam control panel.
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OK, that's it for now. Next up are the rock lights, Torq Locker, Strongmade bumper, Viper Elite 4500 winch, SSS skids whenever they get here (please be here before PTO...), Trigger Shield, and then I'm done for awhile. It's got a whopping 20 miles on it, so I might actually ride it for a change.
 
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The Green Goat

The Green Goat

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Strongmade Bumper and Viper Elite 4500 installed:

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Torque Locker installed. I had a minor hiccup where-in I had a mysterious O-ring that I couldn't quite figure out where it went. Took quite a bit of digging through schematics and thread pics before I finally figured it out. Overall, wasn't too bad of an install.

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Stinger relay activation switch. This switch opens the Stinger, sending power to the positive bus bar, which all of the accessories are tied into. Completely eliminates any parasitic draws from any accessory that tend to do that (winch).


Key off:
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Key on:
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Auxiliary Power switch on:
20210531 225037


Rock lights installed. I tied them into the came circuit that handles the white Siezmik mirror lights:
20210531 232212

20210531 232233

20210531 232330


20210531 232349


Got a couple new accessories for T.O.:
20210531 225156


My Co-Pilot, Prudence the Safety Goat (name that YouTuber...):
20210531 225002
 
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The Green Goat

The Green Goat

LGBTQ Compliance Officer -Lotta gays in this place
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Sep 7, 2020
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