BEER MOD's Z1 Turbo RZR build

[Beer Mod]

Ok guys and gals here is the full build from start to finish! I decided to post this build of my personal rzr because of how popular this swap has become. I often get tons of questions about the swap when I'm out. I love that! So here is everyone's chance to ask me any questions you have.

[Beer Mod]

I will be doing this swap at my house with limited tool and limited funds! With a lot of back and forth conversations with Jason @ Hawk I feel I am ready. My background as a fabricator has led me to build Ultra4 cars among other buggies and trail rigs. My wife and I have jumped into the SXS world head first! We love the dunes, but also like rock crawling. I plan to build a motor that not only hauls ass, but will handle trail rides with the family also. First things first. we needed a donor sled and after a few months we found a 2012 SnoPro with 41hrs on it!! Jackpot!!

[Beer Mod]

Next on the list was to get the rzr off to Polaris for its first service and a full inspection of the motor. Once the motor came back legit it was time to pull it to sell. At this point the rzr is stripped down fairly good.

One question I get asked a lot is "how much did you sell the stock 1K motor for?" In short I sold the motor with 40hrs for $4,000$

[Beer Mod]

Motor is out. It's a lot easier than I thought to pull it :)

[Beer Mod]

Slow going progress. Pulling a sled motor is defiantly more of a pain in the ass than I thought it would be haha

[Beer Mod]

More

[Beer Mod]

Motor is out!

[Beer Mod]

Ok so this is a two part build. I will cover part one so everyone understands what it takes to make around 300hp. Later I will cover part two of my build.

Phase one part list
Jason@hawk install kit
3 stage flash 200hp/265hp/315hp
Stage 3 water/meth Snow Performance
30x11x3 intercooler
Rage 8 clutch
Scatter shield
External oil cooler
Walbro 255lph pump
BOV (evolution)
Fluidine radiator
4 bar map
ARP head studs
Billet motor mounts

[Beer Mod]

Little comparison for you guys!

[Beer Mod]

With both the rzr and cat harnesses pulled I thought I'd snap a shot. The rzr harness is on the left

[Beer Mod]

So here is a word of advise. I built my own Z1 harness that took me at least 40hrs to do. So I would recommend calling Jason Hawk and having him do it for you. The price he charges is well worth it

[Beer Mod]

The stock Polaris gear case is fairly strong, the major weak link are the bearings. I pulled the case apart and added the 7 much needed Japanese bearings and put it back together. Start to finish under 4hrs

[Beer Mod]

Sway bar dropped to clear the turbo

[Beer Mod]

Jason @ Hawk makes such a great kit! This is such an easy install for the DIY type of guy. Jason has thought of everything making it so simple for everyone.

I decided to go my own route on all the plumbing. I wanted full SS braided lines with AN fittings. This is a big extra cost ($1000) ish. IMO well worth it

[Beer Mod]

Time for some ARP head studs. This is all you need to do to internally to make 325-350hp and over 30psi of boost. These motors are already stout from the factory.

[Beer Mod]

Glassworks dash just thrown on for mockup. This is a very nice piece, following the body lines almost perfectly. I will go into more detail later on the placement of the rivets, gauges and what not.

This is not a must have item. I have seen a lot of stock dash swaps look great.

[Beer Mod]

All this power demands a solid cage. I opted for a TMW V4 with a 8" drop

[Beer Mod]

So the V4 is a 8 in drop and since I'm a big fan if low and wide I decided to order it and make it work at all costs. I'm 6' 1" so I went into this knowing it would be a bit of a challenge to fit under so much drop. First thing I did was contact PRP about there GT/SE seat. They clam roughly a 1.5" drop over stock seat. Next I purchased UTV inc drop brackets that they claim 1.25-1.50" drop over factory. So having done all this I threw the seats in the rzr and checked it out. Over all it was a massive improvement over stock but I wasn't quite satisfied. I took them back out and tore them down to the prp rails that mount to the utv inc plate. I then took a inch out of the prp seat rail as well as extending the slide mount for the hardware on the plate. What I ended up with was another 1" down and a full inch back! Total drop = 4" from my stock seats with no bottoming out

[Beer Mod]

In an effort to keep the rear cage as clean as possible I moved the oil cooler to the front of the rzr.

[Beer Mod]

Dash started. 3 of 5 gauges are in and most of the toggle switches. Also installed a self amplified 10" sub behind the dash.

[Beer Mod]

Built custom intercooler mounts of the cage.

[Beer Mod]

Motor is installed and the STM Clutches are in place. I went with the Rage 8 for its easy tuning and massive horsepower rating.

[Beer Mod]

Last bit of wiring going in!

[Beer Mod]

Bed is on
Intercooler is sprayed
Cage is done

[Beer Mod]

So at this point the swap is almost done. I took it out for a 29psi test run. Wow!!!! I've never been in anything so fast in my live. Acceleration is faster than my 2010 BMW M3! No joke

[Beer Mod]

So to round off the machine I decided to go into the suspension. Now most of you know I run HCR long arm so I'll keep it brief.

It's easy to over look the suspension, but I felt with the amount of power this motor makes it was a must to do something. I wanted the lightest, strongest and best looking kit I could afford. HCR Elite kit fit the bill.

I added NXS hubs bringing the total weight gained over stock @ 10lbs!!!

[Beer Mod]

Amazing TIG welded kit!

[Beer Mod]

I wanted to go all out so I ordered the 2.5" internal bypass King shock upgrade in the front. I also ordered them in black with the remote fin cooled external reservoir.

[Beer Mod]

Install on the full kit including all of the welding on the frame stiffening kit was just under 8 hrs

[Beer Mod]

More

[Beer Mod]

....

[Beer Mod]

Ok so now on to Phase two!!!

I've been talking to Mark @ Queen racing for months. Today we came up with a plan and a Goal of 400hp. I want to have a dune machine that runs for years not hours. So with that said we now have a plan set in motion. I currently have a Turbo Tech STG III turbo that we plan to push around 40psi with.


Stock turbo vs the stgIII

[Beer Mod]

As it sits the RZR will beat 400hp sand rails. I want the RZR to pull the front end off the ground while destroying big boy rails!!!

https://m.youtube.com/watch?v=XAoiqa3Uu2c

https://m.youtube.com/watch?v=SWy6upPij6Y

[Beer Mod]

Hope you all enjoy!

Please look for the updates of Phase II

[CrazyCooter]

Thanks for sharing your build with us Josh.

I have always wondered what was involved with these high end SXS projects that you see in the magazines.

[gridman]

Sweet, that little strip has brokin many egos over the years your car runs great

[Beer Mod]

Thanks for sharing your build with us Josh.

I have always wondered what was involved with these high end SXS projects that you see in the magazines.

You bet! I look forward to hearing everyone's feedback :)

[Beer Mod]

Sweet, that little strip has brokin many egos over the years your car runs great

Thank you sir. It's a great spot for traction :)

[Beach Leo]

Great Write up Josh on Your Z-1 Build, Looking forward to phase II,

Its Cool as Hell watching Your Car Spank them sand Rails

Thank-You for taking the Time in posting this Build Thread

Just wondering How many Total Hours you figure you have on Complete Build?

[Beer Mod]

To be honest I never kept track of my hours. Most of the time it was after work or weekend hours. If I was to guess I would say 200-300 hours :)

[LBR]

To be honest I never kept track of my hours. Most of the time it was after work or weekend hours. If I was to guess I would say 200-300 hours :)
That's realistic numbers. It took me 2 months for my swap, after work and on weekends, and I would guess maybe 200 hours by myself.

[Beer Mod]

Ya that's by myself.

[Beach Leo]

Hey Bro

You got it to 400HP Yet?

I know you are not content with just 300HP lol

Give us all an Up-Date

[Beer Mod]

Motor is coming out in the next week. Once it's out I'll have it built and balanced with a race head. With the GTX turbo I have it will run 45psi all day laying down 450-475hp before NOS :) this will be the end of my trail machine tho so the plan it to buy a XPT4 for the trails with my 33" BFG's on it

[EPL]

Looking forward to seeing the progress .

[neil11975]

Can't wait to see it Josh, and take a ride in it.


Sent from my iPad using Tapatalk

[Beer Mod]

Sorry for the lack of updates guys. Trying to keep this build a little more hush hush than normal. I will say that I'm working very closely with Glenn Hall and I will have dyno video when the time comes. Thanks to brittney @HCR I have prototype RCV axles in the works now to hold the power. I will be posting pictures and info for you all on that as well.

[EPL]

Any updates , pictures of the rebuild Josh ??

[Beer Mod]

Any updates , pictures of the rebuild Josh ??

No sorry guys. With the new baby and the death of my father in law, life has been a whirlwind. I can see the light at the end of the tunnel but this project has taken a back seat for now....

[Desert900]

Congrats on the baby, sincere condolences on your father-in-law and kudos on an impressive build.

[Beer Mod]

Thank you :)

[Beer Mod]

So after many long hours and a great build it's time to get this rzr project back on track!!! I want to give a big thanks to Glen Hall he is the Z1 guru. I will do a full write up with lots of pictures here soon enough. For now I need to get this new motor swapped and dyno tested. I won't say what's been done to the motor, nor will I make BIG HP claims but I will say that the boost is going to be high 40+psi and I ain't running the stock snail :)

Sorry for all the delays guys. My beautiful new baby girl took all of my time :)