Z400 Frame Gusset Kit by Bare Performance - Project QuadSport Z400 ATV
The Z400 frame has
excellent geometry for the ATV racer but notoriously has a serious
problem with strength. The typical recreational rider will probably
never see this problem, however if you race your LTZ or subject it
to severe use such as jumping, you will quickly find there are a
number of weak points in the frame. Inspecting Project Z400 after
the BITD Parker 250, we could see that the frame was starting to
stress-crack near the upper shock mounts on the front
suspension.
We started looking into getting
our frame gusseted and found a number of places that were doing
this, but it would require us shipping the frame to them and being
without it for as long as eight weeks. We were not excited about
the extended down-time.
Then we
discovered a company selling a gusset kit at a VERY reasonable
price. Bare Performance in Muncie, Indiana, is offering a
13-piece gusset kit for $68.95. This kit covers all the major weak
points in Z400 frame.
We had access to a
local shop that could sandblast, weld, and powdercoat, so we
ordered the gusset kit from Bare Performance. (If you don't have a
local shop, Bare performance can also weld and powder coat your
frame for $449.95.)
What you will get is a
bunch of small pieces of metal and a diagram like the one here,
showing where all the pieces should go.
Installation
We stripped down
our Z400 to the frame. This took us about four hours, including
time to carefully ziplock and label all the bolts and parts so we
would know where they went when reassembly time came. Next we took
the bare frame, the gusset kit, and our sub-frame to Kni-Co brand
new manufacturing facility in Wallowa, Oregon. Their specialty is
custom metal sheepherder's stoves, but they also manufacture a
number of other pieces and have their own in-house powdercoating
equipment.
Kni-Co first sandblasted the frame then inspected
it for cracks. As we suspected, the frame was nearly cracked
through behind the upper right shock mount, but no other major
cracks were found. Kni-Co carefully tig-welded and repaired that
crack. With the repair made they welded in all of the gusset pieces
per the diagram. Most of the gussets fit nicely, but a few had to
have modifications before they could be welded in place, as they
did not quite fit.
Kni-Co did a great job welding the Z400 frame,
making sure to apply the right amount heat so that the frame was
not damaged.
After all the gussets were
welded in place Kni-Co then re-sandblasted everything so that it
was ready to be powder coated. Sandblasting is the most
time-consuming and labor-intensive part of the whole
process.
Kni-Co can powder coat many
different colors or can attempt to match a color. We chose to use
the same color as our Holz front A-arms which are Cardinal BL01. We
plan to also have our rear swing arm done in this same
color.
Summary
We received our frame and sub-frame nicely shrink wrapped.
Kni-Co did an excellent job. If you don't have a local shop, we
recommend you call Rob Burns for a quote on your job. The
complete job cost us about $300, including the gusset kit from
Bare Performance. Down time was about two weeks but could
have been less. Bare Performance provides an excellent gusset kit
for only the money. A couple days reassembling and Project Z400
will be ready for a local hare scrambles event and a complete
season of racing.
Then we
discovered a company selling a gusset kit at a VERY reasonable
price. Bare Performance in Muncie, Indiana, is offering a
13-piece gusset kit for $68.95. This kit covers all the major weak
points in Z400 frame.
We had access to a
local shop that could sandblast, weld, and powdercoat, so we
ordered the gusset kit from Bare Performance. (If you don't have a
local shop, Bare performance can also weld and powder coat your
frame for $449.95.)
What you will get is a
bunch of small pieces of metal and a diagram like the one here,
showing where all the pieces should go.
Installation
We stripped down
our Z400 to the frame. This took us about four hours, including
time to carefully ziplock and label all the bolts and parts so we
would know where they went when reassembly time came. Next we took
the bare frame, the gusset kit, and our sub-frame to Kni-Co brand
new manufacturing facility in Wallowa, Oregon. Their specialty is
custom metal sheepherder's stoves, but they also manufacture a
number of other pieces and have their own in-house powdercoating
equipment.
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This is the gusset on the front upper shock
mount.
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The shows the gussets applied to both upper shock
mounts.
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This is the gusset near the front A-arm.
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Gussets are applied to the steering stem and gas
tank mount. Make sure your tank clears these. We actually had to
modify the one on the right to clear our Clarke tank.
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Gussets behind the A-arm mounting location.
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Gussets near the motor mounts.
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With the frame upside-down you can see the gussets
applied to the bottom.
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Shrink-wrapped frame and sub-frame
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Project Z400 partially assembled
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Suggestions, comments, products you would like to see tested and installed on Project Quadsport Z400? Please let us know via Email.
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Contact Information |
Kni-Co Manufacturing
Phone: (541) 886-8055
Fax: (541) 886-6305
www.kni-co.com
Bare Performance
Phone:(765) 744-0320
Muncie, Indiana
sales@bareperformance.com
www.bareperformance.com
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