What follows are periodic reports as the RXL kit was being made. Many of my plans, prices and features changed as the kit came together. Ignore all pricing in the following unless in matches with the information on the RXL page.

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At this point we are in the middle of fine tuning the RXL graphics. It's not an easy task. We had to adapt the RXL theme to the precise shape of my RXL hood and nose. The various parts of this sticker package are keyed to the mold lines in the hood. Here Cece, my long time sign gal, is in round two of the fine tune process.

Now I told you that I am making changes to the original Polaris RXL graphics and I have but I challenge you and those who screamed "sacrilege" to see what I changed. (Note some elements of what you see in photo will be altered to look more like original). A happy note for you guys who will not use rear bumpers. The tunnel graphics will be made to fit bumper and bumperless Indys. You tell me at order time and we will cut (or not) to fit. Are we easy or what!

Cece gave me an idea of what kit will cost-it will about $249. Mind you this is for nine separate pieces in multiple colors. I will write installation instructions. If you don't have vinyl application experience you should seek the aid of a pro. I may offer this service-we'll see.

~ Phil

RXL Report 3-31-2014-01It has been 56 days since we started the graphics project. I knew it wasn't going to be easy and that's how it turned out. This is the final design. For quality and fit reasons this is not a nuts-on exact RXL copy. [Don't worry about that jag in side stripe. You or you supplier will install graphics after hood and nose are installed and aligned.]

Now I have to modify the hood mold. I discovered I had to add depth to the nose edge to lift hood out of bumper tray by 5/8" or so.

I think we have solved the fastening of the hood front with Dzus fasteners-more on that after I do a search. Hopefully it can be hidden by the wide white strip that borders the hood deck and nose

~ Phil

rxl-indy-hood-tapedI have been silent for the past few months not because I've not been working on the RXL. RXL stuff has been happening. We discovered a problem last winter with the hood and nose. Donny Sayen, my guinea pig, had the first hood/nose on his Indy and discovered the hood/nose contact began wearing away the nose trailing edge. We needed to find a way to keep the nose stationary-bungees couldn't do it. We also had another problem. The hood was a bitch to remove and replace. There was no good way to grab the hood front.

I enlisted the aid of super engineer Rick Jostrom, who also happens to be a TX freak. For months he has been working on a nifty way to solve both problems. Prior to his discovery we kicked around a hinge system but it just couldn't happen primarily because a hinge system would occupy the exhaust space. Whatever we would do I wanted minimal interruption on the hood surface. What it comes down to is a smallish depression in the hood of something like 2" x 1" and ½" deep-minimal. Here's a prototype depression in the hood

rxl-indy-hood-d-ringThe depression will be molded into the hood and makes room for a Duez fastener with a one inch flip up D-ring handle. You might even be able to operate it with gloves on but maybe not. Here is Duez is a quarter turn fastener.

rxl-indy-hood-mountingRick also developed the receptacle for the Duez that mounts to the back side of the internal aluminum bulk head. The mount system has right/left/up/down positioning so you can get a perfect nose/hood fit and lock it in place. This minimal system allows a finger hold to lift the hood and stabilizes it to minimize wear. This nothing little system has cost me over a thousand dollars so you'd better like it or I'm comin' after ya. All our plans are based on a sled bulk head that has not taken a deforming hit. If your aluminum bumper is off--mounting will be more of a challenge. Here is a peek at the Duez mounting system on the aluminum bulk head

rxl-indy-hood-rick-wrenchRick has to finish the part that screws into the mold and finalize the latch pieces but we're close. Here is a photo of Rick, the mad engineer, with one of his precise instruments.

Timing

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This process has thrown off the overall time table and put back production. The upshot is that we'll miss Haydays and the big deal RXL/Indy thing at Waconia. That has been put off until 2016 because none of you will have had enough time to put together a show ready RXL

Technical stuff

It was smart for us to mold two long tabs on the forward edge of the hood. These are deeper than they need be for a reason. The idea is that by grinding way on these tabs you will be able to lower the hood position on a level with the nose. I suspect that grinding will also wind up angled so the hood is able to move forward to kiss fit the nose. Here is visually what I'm talkin' about.

I'll report again when I got something.
~ Phil

Boy this has been a long road but I think I see daylight.

The Duez ¼ turn hood latch kit is done and the first new style hood for Kevin Sondreal is being made. After we pre-fit his hood to proof our work it is into production we will go.

I have contacted the customers who placed early orders to see how many still want to remain on the list. After they have responded, yea or nay, I will take new orders on a first come basis. The following fellows have indicted a burning desire for hood kits so they will get first nod when they confirm; Allen, Swiller and Losvar. (They haven't seen complete pricing yet)

I suspect production rate in the beginning will be something like one per week. That rate may be condensed when every thing starts flowing. Once I pick up a hood kit from the glass maker, I have to take hood to graphics gal to have kit installed (for those of you who are like me and want no part of trying to install those graphics). Others may want graphics separate in the carton for installation later on-no problem. And I have to literally make the carton (ain't no off-the-shelf carton in creation that will take the hood [48 x 41 x 16"]).

To order just mention what you want from the price list and I will follow up with confirmation.

Thanks a ton.
~ Phil

A couple of days ago I got a black hood set and a blue one. The nose on each suffered some minor cracking because they came out of a reverse draft mold-my fault. Luckily the problem is easily solved and my glass man, Tim, is working on it now.

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I dropped the nose and hood on my sled the frantic day before the Waconia meet. I was surprised how well they fit-often horror stories are discovered at this point. I didn't have much time to fiddle with mounting but I do have clues.

  1. You'll have to screw around with the nose mount holes--they are not nuts on with the bulkhead holes. Easily solved with a quarter inch drill.
  2. I noticed with a bit of pressure the left front of the hood seemed to drop below the nose edge. I suspect we'll have to find a way to support that corner in an artificial way. I'm guessing the experience of the first couple of buyers will yield a fix which I'll report to all of you. Surely this will vary from sled to sled depending on how true the bumper extrusions are from stock specs (years of use and impacts with immovable objects).

Two things will happen now. I'll begin making the graphics and orders will be filled. Oh, that blue hood-that is going to Donny Sayen, my Polaris guru and the guy who will finish building my sled. More when I know it. Enjoy photos.

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Thanks
~ Phil

(No, the hood will not be at Waconia--I have no way to protect the loose parts from getting all scratched up.)