Project Race RZR


In early 2011 James Schofield, BTF VP, raced the side-by-side class at the ECORS race in Auburn, AL.  He was driving
a borrowed Polaris RZR S from Octane Racing.  Unfortunately, the rear axle shafts broke half-way through the race, but that still gave him and everyone at the shop enough time to get hooked.  So right then plans began to build the BTF Race RZR.  A few weeks later we picked up a brand new Polaris RZR 900 XP and began work. 
First order of business was to begin the tear-down and nearly disassemble the entire RZR down to a bare chassis. After we had a huge pile of plastic and parts lying in the corner, roll-cage work commenced. We pulled the factory cage and cage mounts and started from scratch. We wanted a strong design to be able to hold up to a high-
speed crash and keep the driver safe, yet still have a bit of BTF style.  The cage was made out of 1.5” .120 wall DOM tubing, all TIG welded.  We chose TIG welding for many reasons, the main benefit being to ability to weld in all positions, horizontal, vertical, overhead, etc. with no splatter or spark.  In addition to the clean look of TIG, this made it the perfect choice for our roll cage.  We tied it in to the chassis at as many points as we could, and also ran tubing out to just behind the plastics to avoid damaging during those “rubbin is racin’” moments.  We dropped a full size Mastercraft seat in with custom seat mounts to mount 2” lower than stock.
A very common issue for RZRs has been front A-arm failures not just during racing, but even trail riding. 
We decided to avoid ever having this issue in the future and make our own suspension arms.  Since this is such a common problem we took the time to build a jig for the arms as we made them for ours, so to be able to produce them for the public.  We will also have front and rear A-arms for the 800 RZR S available as well.  Once we finished fabbing the arms, we bolted in a set of Walker Evans Racing coilovers front and rear.
For tires and wheels we chose the Goodyear Wrangler MTRs around Walker Evans Racing beadlocks.  This light-weight setup will hopefully help us off the line.
Since the first race we planned to attend was a day/night race, lighting was going to be required.  The guys at Baja Designs hooked us up with the new Stealth XPG LED Light Bar.  We went with the 30 LED bar which is more light output than 3 high power HIDs.