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Building the "Mini Sno Kat" 

The project started with installing the track system on my Polaris 800 RZR, it was a simple install that took about 2 hours in all, one time install for the mounting brackets.



The side gaurds were removed from the RZR so the door posts could be attached to the frame work underneath.  The door posts are secured to the top of the aluminum cab.  Notches were cut in the plastic so the guards could be re-attached.  The Alum top was fabricated several years ago for this very project.

The door has a Jeep style paddle latch for opening the door with an inside release, this keeps the project "factory" looking.  The hinges I fabricated from flat steel, steel tubing and pins.  They are "lift off" type so the doors can be removed easy.

The door posts have angles built in to move the door away from the inside so there is more room for your arm, but still keeping it inline with the body.

Two filler panels were cut, one for the rear and the other for the front of the door posts.  I made templates out of paper so the fit would be almost perfect before cutting the aluminum.  The top of each panel has a steel re enforcing strap pop riveted on, this will be used later for attaching the snaps to for the soft side panel.

The driver side door is done differnt than the passenger side, passenger side has the fuel tank and you have to work around that for the rear door post.  Drivers side door posts can be put directly to the frame, 1" square tubing.  The passenger side rear post is 1" square tube above the fuel tank, but from the frame up it has a piece of 1 1/4" flat that is welded to the square tube so it can pass by the fuel tank.  The flat section is then attached to the frame with two 1/4" bolts.  There is just enough room to remove the filler cap on the fuel tank.  Once all bolts are tightened the door posts are very rigid, turns into a mini roll cage.

 



Here is the left side door with hardware attached and both coats of paint.  Bottom is coated with rocker panel and matte black paint.  Top is a special color match to the Polaris Red color, both sides are painted the same.



Painted side panels and top filler strip.




Drivers side with door and side fillers installed.

 
Finished project


 


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