My (new) RZR build

[LargeOrangeFont]

Had my 2016 XP41K that I recently sold. Bought this 2019 XP Turbo a few days later. Long term goals for this car are to to use at home to do a little of everything - Rides with neighbors and friends, a little Rock crawling, some open desert run I g, drop kids off at school and running around town, etc.

Since I basically had this same car previously, the idea is to keep costs down and just to what works with a couple additions to my old setup.

It had 400 miles on it when I picked it up. It came with the cage, 32” wheels and tires, a set of 6’ 5150 whips and PRP 5 point harnesses. Other than that it was a bone stock machine.

Here is what we started with

First upgrades were comms and a GPS. The 2019 and up has a much better dash layout that the previous RZRs. My previous car had a 5” GPS mounted low on the dash. Good for not getting lost, but bad for following a route for hundreds of miles.

Surprisingly there are not too many GPS mount options for this car/ dash layout. So I got a 9” Lowrance GPS and figured I’d give it a go and make it fit. While I was in there I put in your fairly standard Rugged Radios intercom and hacked 25 watt waterproof radio.

Radio and Intercom

Time to start cutting…

Mockup

Comms in

All electronics in

Repurposed the factory storage box lid into an access cover.

 

[LargeOrangeFont]

In the spirit of the build, I’m trying not to buy an aftermarket steering wheel for this one. I didn’t have a panel mount PTT button in stock, and Rugged didn’t have any when they were in town. So I tried mounting the driver PTT behind the wheel with industrial Velcro for a cleaner look

Headset jacks flush mounted in the center console

 

[LargeOrangeFont]

I happened to find a single amber Baja Designs cube light on eBay for about half price, so I picked that up as a chase light. I made a simple tab to mount it off of the whip mount. This ended up being a little simpler and easier to mount than the Chinese chase bar I ran before. I’m trying to keep as much rear view visibility as I can.

I also mounted my antenna on the roof a few inches over .

I ended up getting a work light lens for this light. This driving light lens here was blinding directly behind the car .

 

[LargeOrangeFont]

Now for a performance upgrade. Ordered some springs from Shock Therapy at UTV takeover.

Before - stock collapsed springs - remember these have 400 miles on them!

Good springs

You can see my preload collar tool there in the first pic. If you have Walker shocks, make one of these out of a cheap screwdriver if you adjust your ride height. Makes life way easier.

 

[LargeOrangeFont]

The wiring job that came on the car was actually decent, and I deemed it not worth ripping it out and changing. I wish they had put in a bigger fuse box, but I was able to make it all work.

Under hood wiring is done. I still need to remount the horn, and am adding some dust lights for the front on a new bumper. I’m waiting on the bumper, but the wires for the light have all been ran.

 

[LargeOrangeFont]

Waiting for parts I ordered a new tool bag to consolidate multiple tool rolls into one.
I’m very impressed with this Rhino USA tool roll!

I was able to get all the tools I carry into this single roll.

Rhino USA Tool Bag Roll - Heavy Duty Canvas Organizer Pouch for Tools - Ultimate Travel Tool Storage Kit for UTV, Car, Truck, 4x4 Offroad - Upgraded with Labeled & Removable Pouches - Secured for Life https://a.co/d/4XIG5zz

 

[Badchoices03]

Nice! Clean work as usual

 

[LargeOrangeFont]

Next up is some billet radius rods and rear sway bar gussets.

 

[DWC]

Nice work sir. I gotta reroute the radio connections. They end up in the middle of my back half the time.

 

[LargeOrangeFont]

Nice work sir. I gotta reroute the radio connections. They end up in the middle of my back half the time.

Thanks! Let me know.. we can do it over a few beers..

 

[DWC]

Thanks! Let me know.. we can do it over a few beers..

Sounds perfect.

 

[LargeOrangeFont]

Where we stand today - bumpers removed, shorter 2 foot 5150 whips installed that clear the garage door.

A windsheild I designed in CAD - (Cardboard Aided Design) is in progress this afternoon. @dspracing was kind enough to help out here with a frame that will get me started.

 

[DLC]

Looking good!
I like the color & the style / look of the cage!

windshield needs more work! Hard to see thru that!

lol

sorry couldn’t resist….

 

[DLC]

Can you add the clear Fangs? Instead of the blue


what about a Street Legal kit - turn signals.

 

[riverroyal]

looks good

 

[LargeOrangeFont]

looks good
View attachment 1170266

See, I haven’t missed anything.

 

[F.U.IRS]

I like that tool bag, going to have to get one.

 

[DLC]

I like that tool bag, going to have to get one.

Tool bag is AWESOME!

 

[LargeOrangeFont]

I like that tool bag, going to have to get one.

If you don’t listen to anything else I ever say.. get the tool bag.

 

[LargeOrangeFont]

Can you add the clear Fangs? Instead of the blue


what about a Street Legal kit - turn signals.

Yes I can put in the fang lights that can flash orange and hook up to a street legal kit. I haven’t researched the blinker kits too much, but the car comes “blinker ready”

 

[Havasu blue label]

Cool looking for one myself

 

[LargeOrangeFont]

Cool looking for one myself

Lots of deals on garage queens out there. The people that bought pre Covid can afford to deal.

 

[Englewood]

If you don’t listen to anything else I ever say.. get the tool bag.

I use the same roll up bag. Holds a ton of stuff and is easy to stash in small places.

 

[badgas]

Lots of deals on garage queens out there. The people that bought pre Covid can afford to deal.

Where are you looking ?

 

[LargeOrangeFont]

Where are you looking ?

Str8up, Craigslist, FB marketplace. I found this one on Str8up.

 

[LargeOrangeFont]

Making progress on the windshield frame.

 

[LargeOrangeFont]

Found some brand new big bore 2.5” front shocks on n EBay for half price! I can’t believe it, these never come up for sale.

These 2.5” shocks are the shocks Walker Evan’s originally speced out for this platform, and Polaris bean counters elected to go 2” front shocks.

I am going to try a little different setup on this car than my old one. I will be having the valving reworked but I am converting the stock shocks to double adjustable units (high and low speed compression) from the factory stock single adjustment.

Here is the difference in size from the OE front shocks to the 2.5” units.. this is from my old car.

 

[F.U.IRS]

If you don’t listen to anything else I ever say.. get the tool bag.

I listened to you once before and it got me out of my Rice Rd. speeding ticket

 

[RVRKID]

Looks good, I am thinking of a single Amber as a "chase light" also. You need to get some of these for the seat belts:

Harness Bezels (XP 1000 & 2015+ RZR 900) (Blue, Orange, Black, Red, Li

Aluminum Harness Bezels (all colors) (1 kit = 2 harness bezels) Seal out the dust after installing aftermarket harnesses in you XP 1000 or 2015 RZR 900. Our harness bezels fit the console opening in the RZR eliminating dust and debris from entering the cockpit. Works with 2" or 3" lap belts. Kit...

innerdemonmotorsports.com

 

[LargeOrangeFont]

Yesterday I got the rear mostly dialed in. Installed LM UTV radius rods and a Cognito radius rod cage. Should be pretty bulletproof now

Got my front light bar mount on this afternoon. It is a Madigan mini front bumper and a Baja Designs 10” light bar.

The windshield frame is out getting made into 1 piece again.

 

[LargeOrangeFont]

Cheap RZR storage trick -

Get yourself an 8 gallon Action Packer, a couple of those screw in bed hooks, 9 5/8” of 1/8 thick 1.5”x1.5” aluminum L and an 8 foot infinite loop strap and you have yourself a secure dry storage box for tools, and room for a 24 pack AO cooler..

Just measure, drill and bolt the L bracket to the engine cover.

 

[Socalx09]

Yesterday I got the rear mostly dialed in. Installed LM UTV radius rods and a Cognito radius rod cage. Should be pretty bulletproof now
View attachment 1171290

Got my front light bar mount on this afternoon. It is a Madigan mini front bumper and a Baja Designs 10” light bar.

The windshield frame is out getting made into 1 piece again.

View attachment 1171289

For the radius rods and rod plate… are the stock ones junk? That’s basically the only thing we haven’t touched yet on the turbo s we got. We carry spare axels and tie rods in the trailer.

 

[LargeOrangeFont]

For the radius rods and rod plate… are the stock ones junk? That’s basically the only thing we haven’t touched yet on the turbo s we got. We carry spare axels and tie rods in the trailer.

On the later cars and the Turbo S they aren’t junk, but they aren’t great. The early ones 2014-2017.5 were junk.

If you do nothing else, get a radius rod “cage” instead of the single plate. It will shore up the mounting points to the chassis. S3, Cognito and a few others make them. It ties all 4 rods together in double shear.

 

[LargeOrangeFont]

Ran the car today with the family and put about 35 miles on it to check everything out. Ran pretty well overall.

Car needs the shocks reworked, but we already knew that. Also the seats need to be lowered in front, wife noticed the tractor-like stock seating position right away. I forgot how much that sucked lol.

I need to make a couple more small adjustments and need to swap the 3 inch harnesses in the back to 2 inch units for the kids.

I need a windsheild quick.

 

[Bowtiepower00]

Looking good. How do you like the RT320’s?

 

[Socalx09]

On the later cars and the Turbo S they aren’t junk, but they aren’t great. The early ones 2014-2017.5 were junk.

If you do nothing else, get a radius rod “cage” instead of the single plate. It will shore up the mounting points to the chassis. S3, Cognito and a few others make them. It ties all 4 rods together in double shear.

Thank you! We really had no knowledge on these. Will be looking for some Black Friday sales on these. Will definitely get the rod cage first.

 

[LargeOrangeFont]

Thank you! We really had no knowledge on these. Will be looking for some Black Friday sales on these. Will definitely get the rod cage first.

No problem! Just run the stock rods until they start to get sloppy, then upgrade the rods.

 

[Boatymcboatface]

For the radius rods and rod plate… are the stock ones junk? That’s basically the only thing we haven’t touched yet on the turbo s we got. We carry spare axels and tie rods in the trailer.

According to the coupe dealers I talked to about the turbo s was just replace upgrade as parts break or wear out. It’s a pretty durable car right off the floor.

 

[Boatymcboatface]

Cheap RZR storage trick -

Get yourself an 8 gallon Action Packer, a couple of those screw in bed hooks, 9 5/8” of 1/8 thick 1.5”x1.5” aluminum L and an 8 foot infinite loop strap and you have yourself a secure dry storage box for tools, and room for a 24 pack AO cooler..

Just measure, drill and bolt the L bracket to the engine cover.

View attachment 1171369 View attachment 1171368 View attachment 1171370

I’m going to be doing something similar to this soon thanks for the tip!

 

[t&y]

It's been crazy watching these cars grow over the years. I still remember them clogging up trails and getting turtled on basic obstacles back before they really took off. Now they are very capable, and the modifications are endless. Living in a state where you could actually use these daily I'd be all over it. Cool build.

 

[LargeOrangeFont]

Windsheild frame is done. I had a local shop weld it back together. I think I will end up using this frame as a template, but this one will do the job for now! Getting glass in it tomorrow night.

Budget upgrade to make the stock front seats more comfortable - lowering seat bases. Driver seat is stock, passenger seat is lowered 2 inches and reclined 5 degrees. Much more comfortable. With proper suspension and lowered seats, I don’t feel like I need aftermarket seats in these cars.

 

[RiverCruiser]

Windsheild frame is done. I had a local shop weld it back together. I think I will end up using this frame as a template, but this one will do the job for now! Getting glass in it tomorrow night.
View attachment 1172964

Budget upgrade to make the stock front seats more comfortable - lowering seat bases. Driver seat is stock, passenger seat is lowered 2 inches and reclined 5 degrees. Much more comfortable. With proper suspension and lowered seats, I don’t feel like I need aftermarket seats in these cars.

How did you lower them?

 

[LargeOrangeFont]

How did you lower them?

I used these. These allow use of the factory slider. I’m actually going to delete the slider to mount the seat with less play.

Seat Lowering Bases

These seat lowering bases are : -Easier to Install-Uses Stock Slider-Slider Plate integrated -Harness 5th Point Mount -Lowers 2” -Reclines 5.2 degrees

landwfab.com

 

[Flatsix66]

Do you carry a spare tire/wheel or plug and fill?

 

[LargeOrangeFont]

Do you carry a spare tire/wheel or plug and fill?

Yes. I have an el cheapo compact 12v inflator in my tool kit as an emergency backup, and a plug kit. On longer drives I will take my 18v Ryobi inflator or my 12v Milwaukee inflator because they are much faster.

I also carry a spare usually. My spare tire carrier I ordered 3 weeks ago.. and it will finally be here tomorrow.

If your cage will work with this spare tire carrier, it is among the best out there, and the cheapest. It needs a little hand fitting when assembling it, but it is solid and the latch does not fail.

Polaris RZR XP 1000 Turbo Spare Tire Mount 2014-2021

Polaris RZR XP 1000 Turbo Spare Tire Mount

www.utvkingz.com

 

[throttle]

Looks like you been busy. Nicely done.

 

[DWC]

Budget upgrade to make the stock front seats more comfortable - lowering seat bases. Driver seat is stock, passenger seat is lowered 2 inches and reclined 5 degrees. Much more comfortable. With proper suspension and lowered seats, I don’t feel like I need aftermarket seats in these cars.
View attachment 1172965

Weird. I put spacers in the can am front seat to see better. Must be the car
Car is looking damn good.

 

[Bpracing1127]

Windsheild frame is done. I had a local shop weld it back together. I think I will end up using this frame as a template, but this one will do the job for now! Getting glass in it tomorrow night.
View attachment 1172964

Budget upgrade to make the stock front seats more comfortable - lowering seat bases. Driver seat is stock, passenger seat is lowered 2 inches and reclined 5 degrees. Much more comfortable. With proper suspension and lowered seats, I don’t feel like I need aftermarket seats in these cars.
View attachment 1172965

The new bases comfy? I liked them alot in the rzr

 

[LargeOrangeFont]

The new bases comfy? I liked them alot in the rzr

Yea. I’m going to delete the sliders though. After that I don’t think the seats will move at all. The base has no slop at all now, it’s all in the slider.

 

[Sherpa]

LargeOrangeMazda? might be my eyes.... nice build on your rzr..