G2 XT bumper end cap saver. - Outlander discussion - can-am ATV Forums - can-amtalk.com

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G2 XT bumper end cap saver.

Ozy Max OZY ARMOUR

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#1 ozymax

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Posted 07 March 2013 - 02:40 AM

The very first problem I spotted on my new bike was the stupid design of the XT bumper end caps. They are just waiting to get ripped off by a tree.

On my very first ride I managed to remove one of them and I was trying to avoid doing that. :huh:

Anyway, I've come up with a possible way of still keeping the cap but hopefully stopping them from getting ripped off so easily.

 

I took some measurements and cut out four plates on my CNC router. They took a couple of goes till I managed to match the profile of the end cap. The plate is made of 10mm HDPE and once it's bolted in place, it is extremely ridgid.

Here's what I came up with.

 

As you can see, the plate has a 5mm deep trench for the end cap's edge to sit in. That way nothing can get in behind the cap to rip it off.

The centre hole has to be drilled through the bumpers end plate. Once all the holes lined up, the bolts are tightened and extra long screws are fixed into the end cap.

Unfortunatly the XT bars have to be removed for this to happen, but all up it took me approx 40mins to fit all four and that was taking it easy.

See what you think. Any comments welcome.

:beerchug1:

 

Brackets and caps.jpg

 

Plate.jpg

 

Front 01.jpg

 

There is about 10mm gap between the guard and the back of the plate once the bumper is adjusted properly.

 

Front 02.jpg

 

 

 

 


Edited by ozymax, 30 March 2013 - 01:36 AM.


#2 ozymax

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Posted 07 March 2013 - 02:42 AM

Here's what the rear ones look like.

The plates are the same front and back, but there's a left and right plate.

 

Rear 01.jpg

 

Rear 02.jpg

 



#3 rocketdog471

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Posted 07 March 2013 - 04:33 AM

Oz did you add a bolt I thought there were only two that held it on?


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#4 ozymax

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Posted 07 March 2013 - 04:42 AM

Oz did you add a bolt I thought there were only two that held it on?

The end cap is originally held on by 2x screws.

The 3x bolts that hold the plate on are all additional fixings, 2x of which go through original hexagonal holes in the bumper plate. The centre one gets a hole drilled in the plate.

The 2x new screws go through the plates and back into the caps original mounting towers. In the second pic, you can see the 2x outermost holes which coincided with a 4mm hole in the backing plate.

Make sence?


Edited by ozymax, 07 March 2013 - 04:49 AM.


#5 rocketdog471

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Posted 07 March 2013 - 06:02 AM

3 always better than 2, you are the man :D


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#6 Bi66badjohn

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Posted 07 March 2013 - 08:22 AM

Good job!



#7 Hanes Inspector.

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Posted 07 March 2013 - 11:58 AM

Looks good. Wish someone on this side of the pond would develop something similar I have lost or partially snapped three so far on my 2012. Then you also lose the "screws" that BRP wants $6.00 CDN EACH for



#8 stovepiper

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Posted 07 March 2013 - 02:17 PM

I'll take two sets. How much?



#9 ozymax

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Posted 07 March 2013 - 05:56 PM

I'd be more than happy to produce some for people.

I would like $40Au for a set of 4 inc hardware,

Postage would be extra, based on where they are going.

PM me if you're interested in some and I'll machine up a batch.

:beerchug1:


Edited by ozymax, 28 March 2013 - 05:31 AM.


#10 Gene P

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Posted 07 March 2013 - 07:15 PM

Nice work , Oz .

Nothing better than adding your own personal touch to a brand new machine  :thumbs:


  


 
              
 

 

#11 styk

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Posted 07 March 2013 - 11:55 PM

I assume the 2013 models are the same.

#12 ozymax

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Posted 08 March 2013 - 12:12 AM

I assume the 2013 models are the same.

Pretty sure it is. You can check by using my photos as a guide.



#13 MX-Z Man

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Posted 08 March 2013 - 12:01 PM

Looks good. Wish someone on this side of the pond would develop something similar I have lost or partially snapped three so far on my 2012. Then you also lose the "screws" that BRP wants $6.00 CDN EACH for

Agreed. Ozymax, if you don't mind I think I'll try to copy your idea for mine. I lost my first on in the first 50 miles. (I guess that means I'm riding it right)

 

I have some UHMW plate in my garage, looks like a good weekend project. I PROMISE you're will be much nicer than mine. :lol:



#14 ozymax

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Posted 08 March 2013 - 06:01 PM

Agreed. Ozymax, if you don't mind I think I'll try to copy your idea for mine. I lost my first on in the first 50 miles. (I guess that means I'm riding it right)

 

I have some UHMW plate in my garage, looks like a good weekend project. I PROMISE you're will be much nicer than mine. :lol:

All good ideas are meant to be copied. :P

Post up some pics so we all get to see yours. Now the pressures on. :D

I wish you luck.



#15 JaxMax

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Posted 09 March 2013 - 08:22 PM

Very impressive work there Ozy.  Looks like just the ticket.  Can am should take notice and do something like that.


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#16 Albe215

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Posted 09 March 2013 - 10:00 PM

Great work Ozy!

#17 justjustin

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Posted 17 March 2013 - 09:38 AM

Wow, looks great Ozy, I guess if I ever get a G2 Max (still loving the 2010), I'll be copying some of your work again!

 

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#18 MX-Z Man

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Posted 20 March 2013 - 04:46 PM

All good ideas are meant to be copied. :P
Post up some pics so we all get to see yours. Now the pressures on. :D
I wish you luck.

I'm off the hook for a little while. Turns out I didn't have any black material left.

#19 black1000xt

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Posted 15 May 2013 - 12:53 PM

I bought a set of these and wow!  What a difference.  I was losing or at least pulling a cap off everytime I took the Outty out.  We ride some very tight trails here and those stupid caps would always catch on something.  Thanks Ozy Max, they fit like a glove and the installation was easy.



#20 ozymax

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Posted 19 May 2013 - 08:17 PM

I bought a set of these and wow!  What a difference.  I was losing or at least pulling a cap off everytime I took the Outty out.  We ride some very tight trails here and those stupid caps would always catch on something.  Thanks Ozy Max, they fit like a glove and the installation was easy.

Cool.

That's great to hear.

Now the only caps you'll find out on the trails will be from someone else's machine.

:beerchug1:







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