View Full Version : Drilling holes running boards?

06-29-2009, 11:08 PM
is it a bad idea? any lost strength? just want better snow evacuation. i got a 99 indy 500 so pretty poor running boards compared to what's out there now

06-30-2009, 05:19 PM

06-30-2009, 08:18 PM
I would think drilling without re-enforcing somehow would be a bad idea. Might cause that tunnel to tweek.

06-30-2009, 10:58 PM
Indy 500, bad idea. I still have that switchback/RMK you wanted for sale.

07-01-2009, 08:06 AM
Rather than just drilling holes, you should look into snow eliminators or better boards for your sled. People seem to like them. They run about $150-$200 for the set.

07-01-2009, 09:46 AM
your heat exchangers are on the bottom side of the running boards on the 500 they should melt off the snow.

07-01-2009, 09:58 AM
If there are exchangers on that sled I would think that snow eliminators would not be efective either.

07-01-2009, 10:22 AM
towards the back of the running board where i don't stand, snow builds up because the heat exchangers don't run all the way back there. polarisrider1 i'm almost about 1/3 of the way there. what are you asking in these summer months for it?

07-01-2009, 05:21 PM

07-01-2009, 09:57 PM
better get that mower out and start knocking on doors olny 5mo left till snow you know you need that rmk

07-02-2009, 12:59 PM
I would be very careful drilling holes in the running boards with you heat exchanger right there. Like mn mxz said - snow eliminators!

07-18-2009, 11:46 AM
Holes will let in snow off the skis,also forget waterskipping will look like Old Faithfull! Poor Devil!

10-15-2009, 11:23 PM
dimple die the holes after you drill them.

10-16-2009, 03:54 PM
This is what I did to my Edge RMK running boards. All you need to do is drill out the dimple from the back side with a step drill to 1/2" diameter. You then need to make a compression tool to the size you want. I used 1" diameter roundstock, drilled a .500" hole in center, machined in a .875 x 45 degree chamfer. Use a 1/2" hardend bolt and nut, the bolt has to have the same angle as what you chamfered on the compression tool. Put the bolt in the drilled holes from the underside, place the compression tool with the chamfer down on the top side of the board. Put on a washer and the nut, tighten down. I used a torque wrench set at 35 pounds so every hole comes out the same. Oil the threads and washer, I went through a couple of bolts and nuts before I put lube on them. This really helped getting snow of the boards. Not as good as the "better boards", but alot better than stock. This is easy once you get started.


10-16-2009, 09:49 PM
Nice job. You must work in a Machine shop.


10-17-2009, 10:00 AM
that is a great job there

10-18-2009, 08:25 PM
indy 500. I hope you don't mind but I am going to do this to the switchback. If all goes well then the RMK gets it next. I already marked out the pattern.

10-21-2009, 08:11 PM

10-22-2009, 12:07 AM
SEE truth made his own dimple die! lol

11-13-2009, 10:36 AM
anyone interested in buying one of these dies, contact me. We are making them and putting them into a kit form with instructions. I am doing 2 sleds this weekend. Currently making a die to do 3/4 holes.

11-13-2009, 10:46 AM
polarisrider1, remember this?

By polarisrider1 on Tuesday, June 30, 2009 - 10:58 pm: Edit Post
Indy 500, bad idea. I still have that switchback/RMK you wanted for sale.


11-13-2009, 02:27 PM

good one indy_500

11-14-2009, 09:59 AM
polaris rider u have mail

11-14-2009, 09:47 PM

FYI.. That 45 degree Chamfer (or extruded portion) adds a fair amount of strength. IF you just drilled the holes, the boards would flex more.. with the addition of the formed metal, this not only hardens the metal some, but the extruded portion adds strength as well!!

Probably wouldn't hurt to use a air ratchet, or 1/4" impact to speed up the process...
Again.. Nice work.. when I saw the pics.. I thought you installed newer Cat boards on that Polaris..

11-15-2009, 06:42 PM
You want mail. go to profile. Indy 500, your switchy was my practice sled. 24 holes per side. Did 2 sleds this weekend. You need to do this young man. I am having many dies made. this is a great idea. I did 24 holes in an hr. total of 96 holes in the switchy. p.s. this sled started 2nd pull. NOT for sale! pauly, no air ratchet. Holes will not be uniformed. I used a torque wrench and I have the mystery torque spec. that works. spent 3 days on perfecting this whole thing. Not as earlier posted. contact me if you are interested.

11-17-2009, 02:51 PM
<font color="ff0000">I have made and done the same thing, great idea.
I have also been roped into doing other peoples sleds now. I threaded the inside of my die 1/2-20 UNF and milled 3/4&#34; 6 pt. on the top side. As if welding the nut to the die. Boards look factory !</font>

11-18-2009, 03:13 PM
indy 500, you ready to start drilling holes?

11-18-2009, 04:35 PM
i can&#39;t, i got heat exchangers right under my running boards. Or else, I wouldn&#39;t done it already

11-18-2009, 05:34 PM
Oh thats right you are pre Edge chassis. The switch is getting a second round of more holes yet. They look cool and actually add strength.

11-19-2009, 06:28 PM
getsome, we tried the threaded die. It did not work as well since we are torqueing each hole to be consistant. much easiler to torque from the top side. Also bolt spins against bottom of running boards and die needs to be held steady when threaded. Also what do you do if the grade 8 bolt binds in the die. Real hard to remove from running board. I have done massive amounts of testing and what I offer works very well so far. Our dies are made out of hardened steel and tough enough to drill thru let along tap threads into. Are we riding Halfway to Chaplau this yr.?

11-23-2009, 11:02 AM
I&#39;d like to see some pics with more holes than I put in, would like to put in more, concerned about strength. I have a previous post with pics up above, curious to see what others are doing. I have another sled to do, may want to try a different pattern.

11-23-2009, 07:39 PM
Did this one yesterday. added lots of strength. http://www.johndee.com/discuss/clipart/your_image.gif

11-23-2009, 07:44 PM

11-23-2009, 07:49 PM
here we go again, resize, wrong this and that. hope this works. http://www.johndee.com/discuss/messages/6/120619.jpg

11-23-2009, 07:50 PM

11-23-2009, 08:21 PM
indy 500 check out what I did to your sled!

11-23-2009, 09:08 PM
<font color="ff0000">here&#39;s my Switchy so far, going to drill out the 3 rear brace holes on each side also</font>

11-23-2009, 09:16 PM
polarisrider, looks great tho! i found an 05 600 switchy 45 minutes away from me with 1200 miles. but bent handlebars and cracked console so i figured rolled over? but everything under the hood was 100%. o yea, did i mention it was $2500?

11-23-2009, 09:17 PM
so how do you guys get the metal raised for grip? i don&#39;t understand all these technical terms

11-23-2009, 10:11 PM
getsome, that is the same pattern that I did on an IQ chassis today. Note, you can add 1 more hole to the inner row closest to the front. The spot is not dimpled but you can drill it anyways. Takes you 1 hole closer to the front. Take a pic. of the back holes that you do on the double thickness area for me.

11-24-2009, 11:57 AM
Indy 500, look at the pictures I posted above on Oct.16. The second and third pictures are of the dimple die, turned up so you can see the chamfer, the bolt with matching angle that mates with the dimple die, and the nut. The last picture is of the dimple die with chamfer down, there is a 1/2 inch hole drilled through the board. The bolt is inserted through the hole from the bottom, through the dimple die, and thread on the nut. Tighten/Torque the nut and bolt to around 30 lbs. The angle on the bolt head porces the aluminum up into the dimple die creating the raised &#34;cone&#34; gripper. When finished, the holes end up about 5/8 inch in diameter. It&#39;s a very simple process. Hope this helps.

11-24-2009, 02:53 PM

11-24-2009, 04:53 PM
can i take off my heat exchangers, drill holes, and put the heat exchangers back on? the exchangers r riveted in.

11-24-2009, 05:16 PM

11-24-2009, 05:29 PM
but why?

11-24-2009, 05:41 PM
i want more grip. what would be a disadvantage of taking the heat exchanger off? i know the hole won&#39;t get rid of snow but i just need more grip badly

11-24-2009, 09:53 PM
indy 500, you need the heat exchangers to cool the engine. They must be put back on and all air burped out of the system to work correctly. I could do the whole removal and reinstall and bleeding lines for you way faster than I can type it for you. lol

11-25-2009, 07:22 AM
<font color="ff0000"> Indy, I just remembered that Polaris indeed does make the slip on Aluminum rail covers. Prolly difficult to find , but not impossible and would work great for your application. cross reference many models same as yours for tunnel up to 2000. Best bet to post in WTB. I made my own &#34;fishbone&#34; tunnel braces before from diamond plate alum. with boot grips on them. good luck.</font>

11-27-2009, 11:30 AM
I have more holes to drill today. It is addictive.

11-29-2009, 07:35 PM
Indy 500, the switchy got 72 holes per side. I will post pic. when I retrieve camera. I did every dimple. You can grate cheese with boards now. &#40;left camera and cell phone at the cabin 110 miles Nort. eh! or Nord for some&#41;.LOL

11-30-2009, 06:19 PM
still drilling! http://www.johndee.com/discuss/messages/6/121268.jpg

11-30-2009, 06:21 PM
still drilling! http://www.johndee.com/discuss/clipart/your_image.gif

11-30-2009, 06:56 PM
i made my own die kit for 2 dollars and it looks decent i dont need it to be perfect it gets the job done

11-30-2009, 08:40 PM
polarisrider1, my sister saw that pic and she asked why i was looking at cheese graders! lmao

12-01-2009, 12:38 AM
ttallin, how many will you make me for $2? Supply me the same hardware too. I am buying. Send pics. except mine need to be perfect if you want me to buy. Perfect is not much to ask since I offer to do volume buying from you. I will send specs. of metal hardness requirements. Send pics of your product. Thank you. Oh! and about shipping. Is that included?

12-01-2009, 11:42 AM
Polarisrider1, I&#39;d like to see your metal hardness requirements. Are you using the Brinell or Rockwell scale. It&#39;s pretty hard to find steel round stock that is harder than aluminum. This is a great idea that you came up with, thank you for sharing it with us. It is a very labor intensive project makeing a dimple die, and hardened bolts aren&#39;t cheap these days.

12-01-2009, 03:32 PM
truthrider, we are recycling 4x4 jack shafts for the dies. Very hard steel but not brittle. We did use Rockwell scale to find the round stock to use. These dies may be way over built but I do not want any to fail or mess up a fellow sledders running boards. We get our fasteners from Select Fasteners. Fastenal was not on top of what I wanted. I have my brother who owns &#34;Pirate Salvage Inc.&#34; A snowmobile salvage and vintage sled business, making them for me in his machine shop. So far all happy users. I will ask him the rockwell scale reading for hardness. I was wondering why the first 10 made all had a little indentation on them and he said, &#34;Hardness testing&#34;. so I said, &#34;Okay&#34;. lol I always just used a file for that.

12-01-2009, 09:16 PM
We made a few sets &#40;125-150 sets&#41; cost about 7 bucks a set. H.T. to 56-58 r/c

12-02-2009, 03:17 PM
i dont think i will make them to sell cuz you are doing that alredy dont want to copy you polarisrider, and i did this so i dident have to spend the 22$ that you want for the little kit plus the 22 for the step bit. ill send u a pic of my running boards so u can see them they dont look that bad. i mean i dont need my <font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font> to look the best. im a broke azz dude just trying to do some cheap mods to my sled whatever. i dont want u to be upset over this.

12-02-2009, 09:46 PM
30 bux is a pretty frickin cheap investment!<font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font> Polaris rider, I sent you an email concerning these dies, would ask you here but it seems to be getting kinda deep. LOL

12-02-2009, 10:06 PM
reaper969x- I did not recieve. I sent you an email to address in profile.

12-02-2009, 10:47 PM
We talked it over today and didn&#39;t get some time logged to the job.So that puts the cost to just shy of 9 bucks.With you making,selling them for $22 that is reasonable.I would use a step drill ground with a 1/4&#34;O.D. pilot 3/8&#34; long to 1/2&#34;O.D &#40;1/2&#34; colbalt stub drill&#41;just because it is cheaper than the step bit you are using.If some of you guys are like me and drop the son of a gun on the floor then you can resharpen the pilot on a bench grinder like most drill bits.either way buy polarisriders kit or make your own,use it on your own sleds it works,you are done.&#40;put it where you can&#39;t find it to do your next sled or your buddies then buy another&#41;LOL keep smiling,think snow,

12-03-2009, 03:50 AM
Thank you Dale 58, I also have step bits that I have done over 400 plus 1/2&#34; holes with and still haven&#39;t sharpened yet. at $10 ea. if you buy a kit. These bits sell for $38.00 ea. at ACE Hardware and the same at Lowes. I have the Kit, bit and delivery at $38.00. I bought a very large amount of these bits to supply my web site tool store. They are not moving so fast there and they work great for this application. Yes it is going on 4 am. I am working on a torque dampening/stop to add to or replace the wimpy stock devices. I find that the 800, 900,1000 class twins twist way to much on the motor mounts and cause belt clutch alignment issues. I feel that $150 dollar drive belts is insane. This tool will add to belt life, crank life and motor mount life big time. SLP has a few designs out. Mine will be less than 1/2 the price and will be far easier to install.

12-06-2009, 06:59 PM

Those running boards look really nice. Are you building and selling these kits? If you are send me a PM I would like to do that to my sled. It looks like it turned out really nice.

12-06-2009, 07:02 PM
polarisrider1, my new sled doesn't have heat exchangers under the running boards :) i'll maybe do it next year to the boards, i don't have any money left over

12-06-2009, 09:09 PM
Indy 500 aka 700, Do you have a birthday coming up? Oh I found 3 gallons of Polaris Blue cap oil I was going to give you, but I forgot you use that "Other" brand. I do take paypal for the dies.

12-06-2009, 09:21 PM
polarisrider1, i'm running arctic blue in my indy 500. Me and my dad are going to run either polaris or amsoil in the 700's. I'll let you know

12-06-2009, 09:37 PM
I like the hole kit BD extrem was doing one a few yrs back that was like 2x3 and as over $250 bucks I went with the jig saw and no sno from CPC and still droped over a hondo

12-06-2009, 09:40 PM
oh and if you f up and land on your knee it really sucks hard about 5/8 high jagged alloy snowpants don't help hope that never happens again

12-06-2009, 10:26 PM
ezra- I found this site that carries knee pads for you. www.tiletools4less.com at least a dozen versions of them. lol

12-09-2009, 10:05 PM
indy 500 looks like a lot of snow on your boards? Glad to see you got to ride today.

12-09-2009, 10:09 PM
Best thing on the market!


12-09-2009, 10:16 PM
zaskar they look pricey.

12-09-2009, 10:19 PM
better boards are nice but for the M they have no style up the tunnel just a straight line about 1 in high. did not think that gave very much support for the board only having 1 in up tunnel after cutting so much material out of the running board

12-10-2009, 01:57 PM
yea polarisrider1, my boards were full of snow, i kept kicking the crap outta them!

10-24-2010, 05:34 PM
Making dimple dies again. any one interested email me.