Hammerlaris 400 GS

[G-ray]

HH 250 SS with Polaris Scrambler struts and a Polaris 400 2 stroke.

[x-bird]

Hey G-ray, welcome aboard. I don't think i've seen all of those pics of the assembly--maybe just too deep in your thread's pages over on BN. the forklift paint technique is classic though. sure beats flipping these things round on the floor to spray them!

[trailrider198686]

I think you need to start making those and selling them. haha. That buggy is awesome!

[G-ray]

It's been 10 months and I haven't finished this one yet.

[300cpilot]

Yep, I would buy one!

[bear]

Wicked looking buggy, let me know when they go into production!!! lol

[300cpilot]

Ok I have a couple of questions, does this buggy use the polaris gear box or is that the HH gearbox in there? If it is the HH gear box what did you have to do to mate them up to the Polaris? Also how is the ride?

[300cpilot]

One other thing before I start buying things to make something simular, would you sell this beast?

[bear]

I don't know "300', that looks like a labor of love! be hard to put a price on that!

[xlint89]

That's either a "proud poppa" stance in that last photo, or he just shot and killed the thing.

U decide.......

[bear]

Yup1, that is one bad-ss buggy, for sure!!!

[300cpilot]

Yep I am looking for pieces this weekend. I wouldnt sell it either, but had to ask.

[SYCARMS]

Great work G

[bear]

Too bad you don't live closer "300", I was on CL cincy lat night and found a bms 250 for only $1500/obo and a helix 150 for $600/obo, if uncle sam haddened short changed me this year, I'd get them myself and choose which I liked, and sale the others!

[300cpilot]

Funny how you mention Uncle Sam short changing ya! He knocked me down and dug through my pockets this year! Set my project back a long ways.

[Johnny 5]

I like that you had a idea and made it happen. Very nice job and looks like a fun buggy to ride. The 400cc 2 stroke is like a 800cc 4stroke=800cc is like 5.3 150cc motors. Ill bet that has some good roost power.

[G-ray]

Sorry I haven't been around in a while. Been a few updates. First I put some 27s on the back trying to get some more ground clearance.



Worked great...till I found out the HH axles weren't quite strong enough.





Put the 25s back on and tested the roll cage. Passed with flying colors. All it did was scuff the paint.



Made a few mods and went racing in the UTV Rally Raid.





Six 8.2 mile laps completely destroyed the HH rear suspension.





Time for a rework.



To answer some of the questions I have missed, the whole center section of the Polaris quad is in the back. Engine, transmission and frame.



AND...it's not for sale.

[300cpilot]

OK have to know where in the world do you get to race this thing? Or what were the numbers for on it?

[Johnny 5]

I couldn't afford to break that much in one trip. Power is good but parts be breaking. I will stick to my low powered 155cc and 183cc.

Ill bet you had fun and that is what counts.

[G-ray]

UTV Rally Raid, Widrock Park, Oliver Springs, TN



I made it into the video about 3:17

http://www.youtube.com/watch?v=KfNbT...uV5jD7Fs7slwCQ

Here's me coming across the finish line on the first lap.

http://youtu.be/aQeFn0IJmQc

[2SlickNick]

Holy cow!!! on 3 wheels.......

[G-ray]

Here's another vid from back in January.

http://youtu.be/DIzYC8bB_L0

[2SlickNick]

Wow that has to hit at least 60 MPH on the strait aways. Great video.

[SYCARMS]

Great vid and great riding area. Hope to see you again at the Bash.

[bear]

I still can't believe how awesome that thing looks!!!

[G-ray]

Thanks.

I still don't know if I will be able to make it to the Bash. That is the busiest time of the year for my work but if I can get this rear end redone and my schedule permits I'm going to try to make it.

[G-ray]

I have been working on a spool to use with the Arctic Cat suspension and axles I have. I took a ring gear which has the female splines for the axles and cut it in half. Then I got some 1 3/8" 21 spline couplers and used them to make it all fit together.

[SYCARMS]

Lookin good, looks like it will be a lot stronger then the HH setup. Hope to see you at the Bask if possible.

[4pullingGM]

Thats a beast of a buggy thats for sure, nice work sir

[toomanytoys2]

I would call your third video a tree hugger video

Great job,

[Johnny 5]

Your buggy is cool and I look forward to the improvements you will make. I have a lot of ideas but am so tired after work have no energy to fulfill them. Your buggy is inspiring to me thanks for posting the pics.

[SYCARMS]

Careful Johnny 5 your about to tell your age

[bear]

Are you sure you're not a direct desendant of Dr. Frankenstien?! Your fab work blows me away!!!

[G-ray]

Been working on rebuilding after the carnage at the race. Trying to get it done in time for the Bash next week.

[SYCARMS]

Looking good, hell I'm not in much better shape. My 150 engine is still out of the buggy and I haven't even started the Challenger since the last bash. Nothing like a last minute crunch.

[G-ray]

Nothing like a deadline to get stuff done.

[SYCARMS]

And if you haven't figured it out yet, the older you get the shorter the days are. I swear my day is only about 10 hours long. but still can't wait

[x-bird]

looking good to go Gray. Isn't it painful tearing it down for paint when you know you could just connect everything and run her? You need to give some thought about running that in the 7-miler in September. SxS class along with my little beastie against the expensive factory toys (if any of them even come back after the beatdown they took on the short course LOL).

[Johnny 5]

Very nice work g ray. Looks like you have a few tricks up your sleeve when it comes to fabrication work. Do you bend your own pipes?

[300cpilot]

You know you have inspired me enough to look for a scrambler! Found one today but they wanted $2500 for it. I want to race there too! Any buggy that can bring its self home on three wheels is incredible!

[G-ray]

The new rear end worked flawlessly. Found the next weakest link. I went from 24s to 25s on the front and I guess it was too much for the Polaris spindles. I broke one Friday and the other one Saturday. I did drive it a couple miles back to the campground with the front wheel missing the first time. I also found out running it in the race with the pipe blown out partially melted the piston and my compression was down to 105 psi. I have some newer model struts on the way that will hopefully be an upgrade and some wheels with less offset to the outside. I will have to give up a slight amount of turning radius to keep them from rubbing but it will be worth it if they don't break. Engine upgrades are in the works.

Oh yea, almost forgot. I managed to do a full frontal endo at St. Joe. All the way over and back on the wheels. It bent the top bar on the right side down maybe 1/8" so after three rollovers with very minimal damage I can say the cage has been thoroughly tested and approved.

[toomanytoys2]

G-ray,

A couple of questions for you on your build. Looking at how you mounted the engine / trans, it looks like You used the main Polaris frame and cut the front and back off of it. Then welded some brackets to the frame and bolted it to the buggy frame. Is this correct? I am looking at building something similar (at least in the back) and this looks like a pretty slick way to go. Any issues or things to look out for.

It also looks like you are running the stock Polaris rear brake. Is this the only rear brake that you are using, or are you running brakes at the wheels also? If you are just using the Polaris brake, how well does it work on your taller tires?

Thanks for the help

[G-ray]

That is exactly how I mounted the engine. The Polaris uses a separate engine and transmission, this was the easiest way to keep everything lined up. I have it on a pivot at the front and the back will move up and down to adjust the chain tension. The original Polaris rear brake on the output shaft is the only one I have. The HH had one brake on the spool in the middle and it wouldn't fit after the swap. The Polaris brake works fine. The donor was an xplorer so it had 25" tires to begin with. The only issue I had with the brake was the regular sintered metallic brake pads wouldn't last because of the heat from stopping the extra weight. I found some EBC carbon pads that have held up well.

[toomanytoys2]

Yes I noticed that Polaris went to great lengths to insure that the transmission lined up with the engine. They even have a special tool for checking this, which I have ordered. Do you have a close up shot on how you adjust the engine for belt tension? I plan on doing something very similar to what you have done. However, I will be using a Trail boss 250 and it will connect to a Joyner mid axle, then from there CVs.

Its good to hear that the Polaris brake has good stopping power. The Joyner hubs that I plan on using do have brakes, but it would be a lot more complicated to hook up.

Thanks G-ray

[G-ray]

See if you can read this. I'm not used to this forum yet.

[G-ray]

That looks like it turned out ok. It's straight out of the Polaris service manual. Basically you just have to get the shafts 10" apart. You need the tool to get the offset and the angle right and then add or remove shims from the secondary to get the belt tension right. A few 3/8" fender washers on the motor mounts is all you need to get the center to center distance and the offset right.

[toomanytoys2]

My Bad

I meant to say do you have a close up on how you adjust the drive chain. I was going to toss my rear brake, but from what I have seen of your videos, if it will stop you, it will stop me.

[G-ray]

No problem.

Front of the cradle bolts on here and pivots.



This is the adjustment.



This is about the best pic I have of it out of the buggy

[toomanytoys2]

Thanks G-ray,

You have a very clean setup there. Where to put the mid axle really had me stumped for awhile. The brain said it had to behind the engine, I never thought to put it below. I know that it raises the CG, but since it is a 2 stroke, it is not so predominate. Right now my main hold back is trying to find used / worn out Joyner CVs. I need the ends off of the CVs to convert over to VW CVs. Then my axle lengths are almost endless.

I am trying to look at my build as a whole and not try to just do a section at a time. So once I can get an idea of the rear end width, it will give me ideas on what I can do with the front end. If you know anyone with bad Joyner CVs, could you point them my way.

Thanks again G-ray