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Discussion Starter #1 (Edited)
Picked this up cheap last fall. Sitting in a field for 8+ years. Started on it last month. Cleaned, rebuilt if needed, and a fresh coat of paint. This will be the 4th sportsman of this body style i have restored. One 335 and the rest were 500’s. I have found on this 6x6 that parts are not that common. With a lot of comparisons, i have also found that Polaris used their brains and built this almost entirely from sportsman/trailblazer/xplorer/scrambler parts. The middle axle and swing arm are from a trailblazer (or other chain drive from that era). The rear axle swing arm is unique, but the chain tensioner is the same as the middle axle which is xplorer/trailblazer as well. Front end is all sportsman/xplorer. I have the service manual for this as well if anyone has questions. This is what it looked like the day i picked it up after a trip to the car wash. Came with all the plastics. Much much more to come.
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This is great! Keep the photos coming. I occasionally see one of these here in Georgia and would like one for my property.
 

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I guess I'm dense, but if you have the transmission out and cleaned up, why not have the hole welded closed instead of using the redneck epoxy repair? Going to a lot of work to redneck a major component.
 

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Discussion Starter #7
Being cast aluminum, I didn’t want to mess with trying to tig weld it. It is a non structural area so i am not worried about it.
 

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Discussion Starter #8
mid axle before and after. Front end all done. Up and running now. Still plenty of work to do, but it sure rips! Somehow, doing a donut on this is way cooler than a 4x4!
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Discussion Starter #12
Today. Led lights on, fixed 4wd and put the bed on. Waiting on the winch relay and light bar. Still need to fix the electric dump bed actuator.
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