considering making my own aluminum CV guards. Thoughts/Suggestions?

[redneckff42]

Tore 2 rear CV boots on my '02 Sportsman 500 H.O. in one afternoon of riding. It is especially annoying as my first machine, a '98 Sportsman 500, has U-jointed driveshafts in back, and rides on that suffer none of the check-every-half-hour shenanigans.
So, I guess I gotta armor up at least the rear CVs. Thinking about making my own aluminum guards as they seem to be a pretty simple design. Also would theoretically be cheap as my dad is an industrial glazing manager and my brother does welding/metal fabrication.
At this point all I think I need are dimensions from a commercially produced product, so I can transfer them as accurately as possible to flat stock.
Can anyone offer more insight and/or suggestions?

[swampdonkey1982]

I like to mock things up with cardboard and tape. That usually gives me a good idea about dimensions, angles, ect. Might be your best bet if you can't find any factory specs on em.

[polman500]

I too use the cardboard mock up method and it works very well if you take your time and double check all measures and angles.

[POLARIS13]

i took the guards off, covered the face of them with duck tape, then i cut around the tape so it was exactly the same size as the plastics. I peeled that off and transfered it to card board. I did this to all 4. I got bored one day and designed them in Autodesk Inventor (a CAD program) and printed them off with rounded edges and strail lines. I cut them out and put them on my aluminum sheet. It worked wonderfully! i have pictures and stuff but have to get then on here still.

[redneckff42]

Thanks guys! I'll definitely use the cardboard mock-up.
Also, a clarification. I have the standard full length heavy plastic cv guards on the front and the small half arm ones on the rear.
I never have an issue with the front since all the sticks fly up behind that point. The rears are ok for what they are I guess since they are tough, but they obviously can't provide all around protection which is what I need.
Sooo what I really meant is an A-arm guard. Not sure why I said cv guard, gotta love brain farts lol.
Anyway, what thickness would you recommend for the aluminum. I was thinking 1/8"-3/16"?

[POLARIS13]

Im using 1/8.....its plenty thick

[SMP63]

You need to make them like a-arm skid plates, also need to have protection form stuff coming up through the bottom of the a-arms. Polaris13 I like what you did, they look good but you have no more protection than the stock plastic guards. The guards I bought from Thor are 3/16" aluminum & fit, easy to put on, well worth the money.

[POLARIS13]

i ride in stuff that is more sandy (rivers) and muddy and i didnt want them packing in and me taking them off every time to clean. I dont have too much of a problem with stuff comming up and slicing them so thats what i did....


ALSO on the cost side of things....i got a good deal on that sheet of aluminum...its actually bigger but the guy took it down to like 4sq. feet and discounted it also, i got it for 20 bucks....I cut out my set, and have traced 3 more full sets on them that im going to do for my buddys. charge them 20 bucks a set or so and make 3 times my money for some simple fab. I saw some sets online for 129ish i think.....not my idea of cheap for what im getting.

[SMP63]

Originally Posted by POLARIS13

i ride in stuff that is more sandy (rivers) and muddy and i didnt want them packing in and me taking them off every time to clean. I dont have too much of a problem with stuff comming up and slicing them so thats what i did....

Come ride in Florida brother!!!!!!!!!!! I don't take them off to clean them. I drive thru water just deep enough to go over them, drive foward & then back up a couple times & their clean. Sand, gumbo-clay-limerock mud, just that easy. Didn't think I needed them either until I got a small hole in one of the creases on the boot that was hard to see, trashed the cv joint. Took the dealer awhile to find it,didn't see it till they had the whole axil out. Lucky for me still under 6 month warranty & after much lobbying from dealer got it replaced for free!!! It's up to you bro but they don't give them cv joints away.

[POLARIS13]

Originally Posted by SMP63

Come ride in Florida brother!!!!!!!!!!! I don't take them off to clean them. I drive thru water just deep enough to go over them, drive foward & then back up a couple times & their clean. Sand, gombo-clay-limerock mud, just that easy. Didn't think I needed them either until I got a small hole in one of the creases on the boot that was hard to see, trashed the cv joint. Took the dealer awhile to find it,didn't see it till they had the whole axil out. Lucky for me still under 6 month warranty & after much lobbying from dealer got it replaced for free!!! It's up to you bro but they don't give them cv joints away.

I hear ya....but i check mine alot. My cousin didnt check his for awhile and the internals were gone in the cv joint.....i think they were like 150-180...i cant remember!