Well, I finally decide to get started on the snorkel for my 2001 Sportsman 500 H.O. I bought about $100 bucks worth of parts from the hardware store after I came up with an initial plan. I wanted to build one that folds down on the rack when not in use. So far, so good. My only problem is that I can’t figure out how to come out of the airbox with a 2” pipe. It seems that any hole I drill would be almost impossible to seal since there is not flat spot anywhere on the box. Another problem is that I don’t have room to clear the exhaust and shift linkage. I have researched this quit a bit and it seems 1 and ½ inch pipe is just not big enough for the breather line. Can someone send me some pictures of how you did it or a really good description? Here is a link to some photos of my dry fitting. The two lines are the PVT intake and exhaust. Any suggestions are more than welcome.

Pictures

 

I can't help with the box, just wanted to say looks like you did some nice plumbing there. Wouldn't it be nice if they made olive green PVC? Nice work.
I think I read where someone got a small length of rubber hose that would fit on the outside of the PVC and then cut a hole in the air box just a tad smaller than the hose and worked it in for a sung fit. Just a thought.

 

Hello Snif: If you live near me I'm sure we could figure it out. Looks like you have done alot of work tho. But here's the way I see it. The predator 500 has only a 1 1/2" tube on it, for air flow. I would think that would be big enough for your 500. On the air box I would just run two 1" or 3/4" rubber hoses. Buy the high temp ones and they do'nt kink easily. You could put a quick connect on them, that way when not in use. You can cap them off, and the air box is good as new. You can also roll the hoses up and keep them in a box on your mach. This is just an idea also, but instead of using 2" pvc pipe.
You could use 2" dreging tube, or smaller. The tubing is used alot for gold mining. Pretty cheap and tough, and bends real easy. Hope this helps out a little.

later

 

Boy Maddog419, I sure wished I lived closer to you. I could sure use some help on this one. Do you have a link to where I might be able to buy that dredgin pipe? I still don’t have a clue how to get a 2” pipe in there. I stared at it for about 2 hrs tonight and I figured I could get a 1 and ½ in pipe in there fairly easy but it would come out in an awkward place (not to mention I still think it’s too small). It would come out right on top of the brake peddle on the right hand side. I’m scared that I would keep kicking it accidentally and eventually loosen up any water proofing that I do. The two 1” O.D. lines would work but the I.D. of those two combined would be closer to the I.D. of a 1 and ½ in pipe. I would actually need about three of those to get the air I need. That’s just too many. I guess I’ll sit and stare at it a while longer. I’m sure it can be done. There are just too many folks out there that have them installed for there not to be a way. I’m just missing something….I can feel it.

I got just about everything glued tonight for the PVT lines and they work great. I didn’t list my personal design requirements so for those of you that may be interested, here they are.

1. Has to fold down out of the way for regular (woods) trail riding and hunting.
2. The gun racks have to continue to be fully functional so that guns can be carried.
3. Has to be easily supported in the upright “mudding” position using the gun racks.
4. Has to be out of the way of the floor boards so that I don’t keep kicking them.
5. Has to have quick disconnects for vehicle maintenance and any draining that may be required due to an accidental roll over in the water.
6. Has to be installed without cutting or drilling holes any of the existing body panels (with the exception of the airbox)
7. Four Wheeler has to retain all the existing body panels.

It wasn’t easy but it wasn’t as hard as I thought it would be (so far). I’m half way there. I have all the vent tubing for the trans, diff, carb etc ready to go. I’ll do those last. Again…..any suggestions are more that welcome. Photos and info much appreciated!

 

More Photos....new ones to come as I progress.


Snorkel Photos