Ive got an old 94' 4x4 400 Kodiak thats been sitting outside and a wild idea: Mini Sand rail. Its the only ATV I personally own, but I want a little rig that'll turn heads to make a project out of. So far Im a welder's assistant, so making a frame is a go, and my buddy re-builds his own dirt bikes and is a machining student. Our plan is to completely butcher ths thing, using the front suspension, Tranny, Motor, and ICM; rewiring everything like start switches by using the old wiring and splicing onto it. We are going to part out the transaxle and 4WD equipment, and rear axle. My plan is to use some 1-5/8 in 1144 machining steel hex bar as a rear axle, accompanying it with its respective high speed hex bearing, and attaching this to a hand made swingarm. We would like very much to actually turn the engine and tranny sideways and rig the system to be chain driven, as to simplify the rear end (completely stupid smart). My first question: What style/brand/shocks would you recommend? The maximum weight of the entire vehicle should be roughly 700 pounds, the motor will be rebuillt to accomodate the extra 150 pounds (the sprockets too will help accomodate such a weight), and the maximum rider weight is 200 lbs. I am leaning towards dual shocks. Next question for you guys: Does anyone make a high performance crank for that motor? Thats one of the few parts we cannot find for a rebuild. That, and a good cam. Next in line would be, does the front end of this ATV require the front independent axles to be attached in order for the front wheels to remain attached? So far I cannot determine this, as I got as far as disassembling brake assembly before calling it quits the other night. We also want an electric shift kit (actuated) that allows us to not only upshift but downshift also with pushbuttons rather than rigging a lever, and we dont know if the system we found allows for downshifts. To put it basically, we are about to do something so stupid it requires a brain, and that is take a perfectly good design and scratch it out, and put in place our own. Any help you guys can lend would be massively appreciated......

 

you are crazy !

 

You could save a lot of time and money and just buy this.

Honestly don't see that being as easy as it may sound. Wiring harness alone would have to be spliced and stretched, which can lead to a nightmare trying to find any electrical problems if they arise.

 

If you decide to do the project....Pics allot of Pics!!!! I would love to follow your project. So keep us posted.