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  1. #1
    Derwood98's Avatar
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    2001 Polaris Pro 1200 - Triple Pipe Project

    And so the build begins. I purchased a set of triple pipes last summer and I am finally getting ready to start on my spring project. I will document all the information here like I did with my Pro 785 build. Hopefully it will be a source of good information for someone doing this or as just general information.

    Here's the link to my 785 build for reference:

    http://www.greenhulk.net/forums/show...ight=derwood98

    To start, I purchased these pipes used in excellent condition. However, since I can never seem to leave well enough alone and I am a little OCD, I have decided to strip and powder coat them in the same color as my Pro 785 pipes. That way I will literally have a matching set. Here are some pictures of what I am starting with.









    I will be showing the progression as I move forward. I have since already sourced all new silicone tubes from McMaster-Carr along with all new stainless steel t-clamps and stainless steel crush clamps for the 3/8" water lines. I also purchased all new stainless steel hardware that was missing for the project according to the installation instructions in addition to all new O-rings. Here is a list of the items I got from McMaster-Carr. Keep in mind I always order one or two spares just in case, the other few misc. items I sourced from my local hardware store. (Marine epoxy and a few misc. metric bolts and washers.)

    (6) 5204K16 T-Bolt Clamp 4-9/32 to 4-19/32
    (6) 5204K14 T-Bolt Clamp 3-9/32 to 3-19/32
    (8 ) 5204K12 T-Bolt Clamp 2-5/16 to 2-5/8
    (1) 52545K54 Hose Clamp - Crush Style 33/64 to 5/8
    (1) 52545K51 Hose Clamp - Crush Style 27/64 to 17/32
    (1) 52545K27 Hose Clamp - Crush Style 11/32 to 13/32
    (2) 5296K421 2" ID Silicone Hose
    (1) 5296K631 4" ID Silicone Hose
    (2) 5296K481 3" ID Silicone Hose
    (1) 9452K49 Buna-N O-Ring (For the manifolds)
    (1) 90715A145 3/8 SS Nylon Locking Hex Nuts
    (1) 90107A051 3/8 SS Flat Washer



    Next step, strip the pipes and get them ready for powder coating. If anyone has any spare Lord mounts they can sell or a one piece head that will accept factory domes, please PM me. Also, if anyone can identify which pipes go to which cylinder, that would be helpful too. I would like to mark them before I get them powder coated.

    I am currently working on a copy of the OEM hood mount. Hopefully that works out. More to come...

    BTW, I have been trying to upload the installation instructions, but not having any success. If you need a copy, please PM me.
    Last edited by Derwood98; 03-10-2013 at 07:10 PM.


  2. #2
    Connecticut CrazyA's Avatar
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    Quote Originally Posted by Derwood98 View Post
    Also, if anyone can identify which pipes go to which cylinder, that would be helpful too. I would like to mark them before I get them powder coated.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  4. #3
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    You should be able to get lord mounts from McMaster as well. Instead of the one piece head cover, I wonder if you can use a brace between cylinders like on the 700s?

  5. #4
    Derwood98's Avatar
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    Look what landed at my door step...




    This is the Polaris factory hood modification for triple pipes for the Polaris 1200. Not crazy about the design, but I don't have my ski in front of me so I am being proactive and copying their design. I currently have bids out to copy these parts. The trickiest part was the SS square u-bolt as it's a custom made part. I did find someone to make it for me so now I am waiting for the production cost of the replication of the brackets. Should know in a few days to a week. What a PITA!!!

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    If you want to have more than one set made, let me know. I would be interested in buying one as well

  7. #6
    Derwood98's Avatar
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    I am actually looking at getting 10 sets made...

  8. #7
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    Quote Originally Posted by Derwood98 View Post
    I am actually looking at getting 10 sets made...
    I only need one

  9. #8
    Derwood98's Avatar
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    Quote Originally Posted by BryanP View Post
    Quote Originally Posted by Derwood98 View Post
    I am actually looking at getting 10 sets made...
    I only need one
    I suspect someone else will need a set made...

  10. #9
    Derwood98's Avatar
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    The special stainless U-bolts will cost me $15 per each to have them made and I am looking into what it will cost to make copies of the brackets. The u-bolts were a SOB to locate at a reasonable price. True to fashion, Polaris must have had a run of these made for them. Does anyone have some of these laying around?

    Last edited by Derwood98; 03-13-2013 at 07:06 AM. Reason: Spelling / Added To

  11. #10
    Connecticut CrazyA's Avatar
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    What are the measurements on those U-Bolts? I think we can find them cheaper than that.

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