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Originally, I was going to purchase a custom made transmission and mate it to my CR500 cylindered power plant out of my Pilot for the drive train. After discovering that the transmission would be at least three thousand dollars, the rear drive clutch would be another six hundred (and of course, I'd need a couple of them) and that I'd need a new front clutch too, I decided against it. Besides, I have a transmission already. The weak link on the Pilot's transmission is the CV joints. The material is too hard and a good shock load will break them off right at the point where they go into the transmission. I can live with this, as the parts are fairly inexpensive and easily replaced. I only broke one this year and it was due to being hit. I'll pull out the entire drive train, electrical system, seat, safety harness, shocks, master cylinders, 13 inch rims and what ever else I need from the Pilot for the new chassis. I will end up having custom axles made for the rear end, I'll fabricate new front spindles, rear carriers, front and rear hubs and of course the new chassis and suspension. I'll need to purchase a rack and pinion steering box, a new quick release steering wheel, brake and throttle peddles, heim joints and lots of other parts too. The list grows each time I think about it.

On the fabrication end of things, I am still doing a bit of research. For the spindles and rear carriers, I'm going to use 7075-T5 Aluminum. It is one of the strongest aluminum alloys, yet quite machinable, although not weldable. I originally was going to make these parts out of steel, requiring many of small parts and a bunch of welding, but after looking at three or four different car's rear carriers, I decided that I would be able to make mine out of a single piece of billet aluminum. I'll have a lot of machining to do, but I think it will be worth it in the end. For the hubs that the wheels attach to, I'll use 6061-T6 aluminum. This is easily machined and strong enough for the needed parts. For all other small parts that I'll need to fabricate, I'll use 6061-T6 and some of the 7075-T6 that I have left over also.

For the frame I intend on using 4130 Chromoly tubing. I am still trying to get more information on the welding process for this material, but that's not a problem, as one of my friends is a welder that just happens to work for the Ferrari WSC team based here in Cincinnati. The only material I am not sure of is called "tough enough". It's some sort of chromoly based steel that I was told to use for the front axles.

I've ordered over two hundred feet of tubing in different sizes and thickness, a couple pieces of 7075-T6 Aluminum, a sheet of steel for the building jig and a new custom length set of Custom Axis shocks (from ATV Racing) for the front suspension and I've started prioritizing my parts list.

Sponsors:

ATV Racing - 2030 W. Deer Valley Rd., Phoenix, AZ 85027 Phone: (623) 516-8640 Fax: (623) 516-8726 Talk to Neil or Paul. Too much stuff and help to list here! THANKS GUYS!

Boretech - 5977 Hutchinson Rd., Batavia, OH 45103 Phone: (513) 625-8374 Fax: (513) 625-2836 Talk to Bill Moeller - Extrodinary Cylinder Work & Carbide Bore Process

Bearings Distributors, Inc - 1850 Summit Rd., Cincinnati, OH phone (513) 761-0866 - Bearings & Seals

Borgeson Universal Company, Inc. - 187 Commercial Boulevard, Torrington, CT 06790-3098 Phone: (860) 428-8283 Fax (860) 496-9320 - Steering Universal Joints

Cincinnati Steel Treating Co. - 5701 Mariemont, Ave. Cincinnati, OH 45227 Phone: (513) 271-3173 - Heat Treating

Continental Motorsports - 7535 Easy Street, Mason, OH 45040 Phone: (513) 459-8888 Fax: (513) 459-8863 Talk to Jim or Jerry. Heim Joints, CV's, Steering wheel. Continental is a racing supply house specializing in on road race cars and supplies.

Custom Axis- 2429 South Stockton St. Suite 4, Lodi, CA 95240 Phone: (209) 368-5046 Fax: (209) 368-5119 Talk to Mike Hallock or Doug. Dana is the secretary.

GETECNO srl - Genova, Italia Phone: +39 010 835 60 16 Fax: +39 010 835 66 55 Talk to René Rais - Tie rod ends - Female 12 x 1.25mm LH & RH threads

McMaster-Carr Supply Company - Phone: (330) 995-5500 Fax: (330) 995-9600 AMAZING assortment of industrial supplies. I used them mainly for fasteners.

Metal Supermarkets - 4766 Dues Drive, Unit C, Cincinnati, OH, 45246 Phone: (513) 942-8222 or (513) 602-0141 Fax: (513) 942-8299 Talk to Brian Naber. My supply house for all my metal tubing and aluminum.

Pro Tools - 11313 Thonotosassa Rd Thonotosassa, FL 33592 Phone: (813) 986-9000 Fax: (813) 986-5607 sales@pro-tool.com - Tube Bender

Slater Brothers - PO Box 1 Mica, WA 99023, Phone: (509) 924-5131 Talk to Roger Slater - Brembo Brake Calipers

Smith Electrochemical Co. 5936 Carthage Court, Cincinnati, OH Phone: (513) 351-7227 - Anodizing

Sway-A-Way - 20755 Marilla St., Chastworth, CA 91311 Phone: (818) 700-9712

W.H. Engineering - Earls Racing Products - 3725 Patch Street Stevens Point, Wisconsin 54481 Phone: (715) 342-1934 Fax: (715) 342-1935 Talk to Dick Walkush - Brake Fuel and Radiator Lines & Fittings