I just had to buy 2 new A arms for mySP 500 and was wanting to remove the new ones and reinforce them to prevent damaging and buying new ones again. Compared to other arms, these do not have any support between the leading and trailing edges. I am going to weld a plate, on the top and bottom to reinforce the whole assembly. Anyone ever think of this or rebuild theirs?

 

I never even notice the bike does not have the support bar that most bike have, but I see now.If I was you I would only put the plate on the bottom because it will also act as a skid plate.If you do both sides of the arm the front end of the bike will weight more and that the last thing the Sportsman needs. If you do not make the welds all the way around each plate mud and stuff that gets in between the two plates will be hard to clean out.I would think one side would be plenty strong enough.

 

I'd weld a thin (1/16") plate to the bottom. You don't want to make them too strong. I'd rather replace a contol arm than break a ball joint or tear the control arm mounting ears off the frame or worst yet,bend the frame.

 

Okay, got ahold of some 3/32" plate and decided to weld on to the bottom of the A arm only. This ought to stiffen up the whole assembly enough to handle the occasional tire smack.

 

Swac...
What about bolting on a set of OXLITE boot guards?... That would give you the added reinforcement you need, but won't be a permanent thing... And it will protect your CV Boots.
Another question... does your Sportsman have the digital tripometer? I have wondered about any adverse effects of welding on the machine. If it will harm the digital speedo and or the ignition/charging system.

 

SWAC,

You must be really torturing that poor Sportsman to be damaging suspension components like that, and having the stock tires rub on the body!

As for welding on the suspension arms, a word of caution. Sometimes less is better. Welding to the existing tubing will create a weak point in the existing tubing at the point of the welds. You may end up weaker than you began.

When you see a note on items such as roll cages and tractor cabs that says do not drill or weld, there is a reason for it. It causes a weak point.

You may be better off to work out a system that clamps the extra braces to the existing tubing.

Have you ever considered buying a Hummer?

DJ

 

Hmmm, a hummer, what an idea. I think I set out to make mine into a mini hummer, and its pretty darn close. Except for a few bangs on rocks that jumped out in front of me. Now that its lifted up and with 27" tires, I don't get near them A arm breaking rocks. For fun I tried crossing the railroad tracks, not on a crossing, no problem! Room to spare, just wouldn't want to get hung up there.