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FOUND! Reunited with my '93 MXZ after 30 years

9051 Views 73 Replies 29 Participants Last post by  coyotekiller
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Many of you have seen my earlier post regarding the search for my original '93 MXZ. Thanks to the efforts of a very helpful representative with the Minnesota DNR - who really went above and beyond for my benefit - I was able to make contact with the current owner of my original sled. This was a long-term search, and after months of effort, I was thrilled with the prospect of being able to acquire my original sled and bring it back home after 30 years. My hope is that I'd find it in decent condition, well maintained and garage kept. That was the hope anyway . . .

If I was able to find the sled, the plan was always to make this a restoration project, assuming that after 30 years the sled would likely need some level of work to return it to its former glory. When I first talked to the current owner - who lives in west central Minnesota - and started asking questions, I learned that the sled has been sitting out in the "back 40" for nearly two years. That generate lots of bad visions!

Apparently, the owner's kids were the main riders of the sled during the 20 years that he has owned it. As the story goes, one day two winters ago they were out riding it and ran out of gas. They walked back to their house, and the sled sat right where it stopped. They did prop up the track to get it off the ground, and it was under a small tree. That's where it has been since. Summer and winter - uncovered.

I showed up at the owner's place on July 1st, and we proceeded to take the walk through a couple hundred yards of woods and then another hundred yards of 4-foot-tall grass to get to where the sled was sitting. Finally - I saw it. I knew it would be rough, and it was! Significant front-end damage, sun-baked hood, trashed seat - it was a sad picture. To think that my prized old sled had been treated so poorly was a bummer for sure. I checked the VIN and a couple other details that only I would know about to confirm that this was in fact my original sled. It was.

I told the owner that this sled was really bordering on a salvage deal, but since it was my original sled, and because I worked so hard to find it, I'd still be interested in buying it and bringing it home for further evaluation. I made an offer, he took it, and we spent three hours getting it out of the woods. Quite an operation.

With the sled now in my shop, I'm going to blow it apart (what's left of it!) and really evaluate just what I've got and whether or not it would be advisable to even start a resto project. I've already restored three of these previously, but the starting points on those projects were far beyond what this one is. It would be a challenge for sure - it will take some serious metal fab along with significant resto work on every component. Also, lots of $$$$. So, the bottom-line question is this: how bad do I want my original sled to live on? I can't answer that question just yet. Stay tuned . . . .

Ken
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Thanks REV RUNNER for the info!
Your work looks amazing
Crash34, how many miles on that MXZ? I'm guessing by the look of the track that there's not more than 4000 Miles on it. I think I'm with a couple of others here, it's almost too nice to restore, you have already cleaned it up very well, but it is your machine and your choice. I do agree, a nice restoration is very rewarding when finished. Regarding Fullerton's, I agree with what was said earlier, I've dealt with them as well, both Tracey and Bill, both are fantastic to deal with.
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Crash34, how many miles on that MXZ? I'm guessing by the look of the track that there's not more than 4000 Miles on it. I think I'm with a couple of others here, it's almost too nice to restore, you have already cleaned it up very well, but it is your machine and your choice. I do agree, a nice restoration is very rewarding when finished. Regarding Fullerton's, I agree with what was said earlier, I've dealt with them as well, both Tracey and Bill, both are fantastic to deal with.
Sled has 2600 original miles on it. fella in PA used it for ice fishing
Just completed the restoration on the skid frame for my original '93 MXZ project. Pics show what it was like when I removed it from the sled last summer and post-resto. After 30 years (the last two of that time out in a field), it was rough. Resto project included many NOS parts, including all three shocks, springs, and rails. Media blast/powder coat on all steel parts. All new fasteners. As with any old skid, lots of issues with seized shafts and bearings. Lots of opportunity for using the hydraulic press.

More updates to follow . . . .

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So when you're done with this, do you think you'll be able to ride it? I'd probably put it in a glass case on a shelf. Please take that as a compliment.
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Great question - my current plan is to ride it under "controlled conditions". We'll see if I still feel that way when the project is complete . . . . .
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Back to work on the '93 MXZ project. Chaincase, countershaft, drive axle all installed. Thanks to one of my donor sleds, this build will have electric start, so I fabricated a custom carrier in the OEM location for the EarthX lightweight battery.

Front suspension installed. Note from photos the custom-fabricated UHMW bushings for the radius rods to replace the OEM rubber-mounted units. I salvaged the hollow tubes from the OEM bushings and re-used them as the pivot tubes for the UHMW bushings. The UHMW's will provide smooth pivot performance and offer long-term wear resistance.

With the original polymer ski bottoms essentially extinct, I'm converting to current-gen Pilot X skis. These are a great retrofit option for the F-2000 platform. As shown in the photos, no modifications are required to the spindle or the ski to make this happen. A 12mm to 10mm reducing sleeve inside the spindle, a couple aluminum spacers on each side of the spindle, and a slight mod to the OEM rubber ski stopper is all that's required. Very clean and easy.

More updates to follow . . .
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Moving toward completion of the rolling chassis. Next will be working on adding fuel tank cover, seat, handlebars, and all electrical. Hood restoration will follow . . .
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The chassis rebuild process in now underway - in my basement shop! Too cold here in northern MN to be working in the garage . . .

Anyway - starting with the tunnel, I've attached the four skid frame support brackets, the rear close-off panel, the rear bumper, and new side tunnel decals. As mentioned earlier, I will be using various threaded fasteners for reassembly of the entire chassis as opposed to the pop rivets used at the factory. The type of threaded fastener used depends on the function of a particular component and its location on the chassis. As a note, to accommodate the M5 fasteners being used for the majority of reassembly, the existing factory rivet holes in the tunnel and support components were slightly enlarged.

For attaching the rear tunnel close-off panel, I'm using M5 high-strength hex flange cap screws and M5 high-strength flange locknuts on the sides where there are no clearance issues with other components. For the top of the close-off panel - which was riveted from the factory - I'm using M5 extreme low profile TORX drive machine screws (see pic) and M5 high-strength flange locknuts. The extreme low profile M5 screws are essentially the same height as the factory rivets, which make them perfect for use in places where the profile is critical. For anyone working on a restoration project and is looking for an alternative to factory spec pop rivets, consider using these fasteners if a low head profile is required.

For fastening the skid frame support/reinforcement brackets to the tunnel, I'm using black anodized countersunk washers and high-strength M5 flat head machine screws on the outside and securing with M5 high-strength flange locknuts on the inside (see pics). The countersunk washers are 3/4" OD which provides for a much broader surface area of support around the head of the machine screws. The countersunk washers/flathead screw combo also provides for a nice custom look.

Next step is attaching the various brackets and components to the bulkhead . . . .

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Where did you source these ultra low profile fasteners and washers? These are amazing looking.

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Thanks for the reply Labradorboy.

One of the custom fasteners I'm using on this build is a countersunk washer designed to be compatible with 5mm flat head machine screws (first photo). The washers are black anodized aluminum and are about 3/4" OD. I used these on the side of the tunnel and to secure the bellypan to the chassis. Very nice parts. While they look great, they also provide function as the large OD spreads out the holding force over a larger area than small-headed rivets (or other fasteners). These washers are sourced from Pro-Bolt (www.probolt-usa.com). The ones I used are part number LWAC5BK.

Additional custom fasteners that I'm using are Extreme Low Profile, TORX drive, black nickel plated 5mm screws (second photo). These are manufactured by NBK America LLC (www.nbk1560.com). I used these as removable replacements for the stock rivets on the top of the tunnel and other select areas of the chassis where head profile is critical. I used both 12mm length (part number SET-M 5-12-BNI) and 16mm length (part number SET-M 5-16-BNI). Needed two length options based on the particular location on the chassis. These are really cool fasteners and were part of my overall chassis restoration that now features true "bolt-together" design.



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Those do look elegant. Are they just nyloc nutted on the backside?
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