Category Archives: Custom RZR Buggies and Builds

Custom SxS using RZR 800 and GSXR 600

I thought some of you folks would enjoy my latest project. I’ve built dune buggies before, but this is the first 4wd multi-passenger machine that I’ve ever tackled. The drive-train is from a 2009 RZR 800 and the engine is a 2002 Suzuki GSXR 600 street bike. I’ll be running 30" 8 ply tires, 12" ground clearance, and 14" of suspension travel. The frame is completely designed by me in 3d CAD (Sketchup) and will used square tube on the bottom section of the frame and 1.5" round tube for the roll cage.

I bought a cheap powder coating kit, and I’ve been busy coating all my parts!

Plate work cut at Virtucom in Ottawa (Ontario CA)

Suspension parts started

And for your viewing pleasure, a video log showing my work!

Sheet metal thickness for complete body

Hi all,

I am thinking of building a whole body out of aluminum, looking at around 2024t3 in 16g (.0508), do you guys think this is thick enough or should I go thicker? I have the skills as I am a sheet metal mechanic for helicopters just wondering if some of the fab guys on here think it’s enough…I feel like it is as the skin of most helicopter is around .040, this will be completely cosmetics as I will be building around the original floorboard. but they aren’t running getting knocked by branches and such. Any help would be greatly appreciated. Thanks

Sheet metal thickness for complete body

Hi all,

I am thinking of building a whole body out of aluminum, looking at around 2024t3 in 16g (.0508), do you guys think this is thick enough or should I go thicker? I have the skills as I am a sheet metal mechanic for helicopters just wondering if some of the fab guys on here think it’s enough…I feel like it is as the skin of most helicopter is around .040, this will be completely cosmetics as I will be building around the original floorboard. but they aren’t running getting knocked by branches and such. Any help would be greatly appreciated. Thanks

RZR 800s Bed

I have a 2013 800S and was wanting to do a build on it that will get rid of the back plastics because i am tired of them falling off was wondering if anybody has done this before i am wanting to build a cage and try to add the bed delete to it was wondering if anybody had pictures of things they have tried out

RZR 800s Bed

I have a 2013 800S and was wanting to do a build on it that will get rid of the back plastics because i am tired of them falling off was wondering if anybody has done this before i am wanting to build a cage and try to add the bed delete to it was wondering if anybody had pictures of things they have tried out

Mixed 900/1000 Rzr Buggy

I have finally gotten around to starting my Rzr tube chassis. I am going for more of a rock racer/ultra 4 look. I am utilizing most of the parts I already have from my 14 Rzr 900, some new parts and plenty of home made parts. I have HCR 900 long travel suspension, 14 1000 motor and trans, billet 1000 diff (soon to have this anyways), bored throttle body, 1000 billet bored intake manifolds, rolling on 35" BFG tires. I have stretched to around a 93" wheelbase now (actually 4" more with the long travel.) The front suspension is all 1/2" bolts now and the upper a arm is a 2 bolt design like the bottom. I am adding a utv inc 1000 front and rear swaybar. I am trying to come up with some way to easily disconnect them for rock crawling. From the lowest point of my frame to the highest point is 45". That is close to 1" or so above the top of a stock 1000 seat for comparison. I will add more descriptions in future posts. This is just getting up to the point I am currently at.

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Mixed 900/1000 Rzr Buggy

I have finally gotten around to starting my Rzr tube chassis. I am going for more of a rock racer/ultra 4 look. I am utilizing most of the parts I already have from my 14 Rzr 900, some new parts and plenty of home made parts. I have HCR 900 long travel suspension, 14 1000 motor and trans, billet 1000 diff (soon to have this anyways), bored throttle body, 1000 billet bored intake manifolds, rolling on 35" BFG tires. I have stretched to around a 93" wheelbase now (actually 4" more with the long travel.) The front suspension is all 1/2" bolts now and the upper a arm is a 2 bolt design like the bottom. I am adding a utv inc 1000 front and rear swaybar. I am trying to come up with some way to easily disconnect them for rock crawling. From the lowest point of my frame to the highest point is 45". That is close to 1" or so above the top of a stock 1000 seat for comparison. I will add more descriptions in future posts. This is just getting up to the point I am currently at.

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HMF Zombie Apocalyptic RZR

The origin of the Blackout system came from HMF’s own mastermind, Hans Luenger. His idea for an apocalyptic survival machine became reality, like something spawned out of an action movie. Luenger stripped an already modified 2014 Polaris RZR 1000 and created the ultimate camping and survival machine. This beast has it all, including gun and knife mounts, truck tires, custom racks, a rear camera, an insane amount of performance parts and of course a Blacked Out HMF Dual Full Exhaust. This machine is something that you’ll have to see to believe, tricked out with more accessories than you could imagine. When the Blacked out new exhaust system grabbed everyone’s attention and we started getting calls, we knew we had to make it available to everyone. This is the exhaust setup for any person or application, even an apocalyptic one.

Thus the Blackout was born.

See the full gallery on Facebook here

(2) 10W SOLAR PANELS
Mounted on the roof of the RZR are two solar panels that are able to charge the extra batteries in as little as 5 hours.

MAXXIS BIG HORN TRUCK TIRES
Since terrain will vary, Maxxis Big Horn truck tires were mounted on 15” OMF 0 offset rims, creating a wheel base 5” wider than the stock.

LOW LEVEL FRONT RACK
The custom front rack is designed to carry any type of survival gear you may need. When it’s empty, the rack can fold up in front of the windshield for access to the extra batteries and provide a protective cage barrier from, well, zombies.

LET THERE BE LIGHT
The front holds two BajaDesigns HID lights that cut right through the dark of the night. One is a pencil beam light and the other is a spot. Sunglasses not included.

HMF / IQ CUSTOM BUMPER
Integrated to the frame is a custom HMF/IQ Front Bumper that adds rigidity to the front end and holds the winch, light, and skid plate.

SUPERWINCH MOUNTED
A 4,500 lb SuperWinch is fitted on the bumper with a synthetic rope that adds to the arsenal of uses for this thing.

WALKER EVANS CUSTOM SHOCKS
All of the weight embraced from the custom front rack and bumper needed some support, so a set of Walker Evans 2.5 shocks are used on the front.

HI-LIFT JACK STAND
Take the jack Hi-Lift develops for the Jeep, shrink it down, and you have their UTV jack stand, mounted on the side for easy access.

HMF/IQ NERF BARS
The custom HMF/IQ Nerf Bars help protect the machine from debris going in the back drive line and can be used to pivot around trees in tight situations.

MASTER CRAFT 3G SEATS
With their own build in suspension system, these MasterCraft race seats add lateral support and comfort.

MOUNTED .45 HOLSTER ON DOOR
On the inside of the driver side door you will find a holster for a .45 caliber pistol that fits the classic 1911.

MOUNTED TOMAHAWK
Mounted on the ceiling you’ll conveniently find an United Cultry M48 Hawk for quick, easy access.

UMP AIR FILTER
In any survival situation, adapting can be the key to survival. The UMP Air Filter was installed to accommodate for dusty conditions that can bog a vehicle down.

HMF DUAL EXHAUST: BLACKOUT EDITION
The Polaris RZR XP 1000 HMF Dual Full System is available in the Performance Series. The Dual Full System picks up 4HP at high RPM and 2lb TQ at the wheels. The exhaust also picked up more power when we installed the HMF Quiet Cores. Additionally, the aluminum shells and stainless head pipe weigh substantially less than the stock exhaust.

SPARE TIRE/TABLE
Fold down spare tire that doubles as a small table that could be used for all sorts of tasks.

ROOF RACK
The custom built roof rack holds all of your camping supplies. It’s even large enough to take a nap on, inv the event you need to be up high.

BACK STORAGE
Back storage compartment houses a 1000 Watt generator, 5 gallon water tank, and backpacks with survival gear

REAR CAMERA
The rear camera is on the back for a complete 360 surveillance system with a Pyle LCD Screen mounted on the interior.