Terry Bopp fabricated a lower...
Terry Bopp fabricated a lower grab bar to create a lower reaching point for picking this Outlander up when it gets stuck.
To build a frame you must first build a jig. This contraption holds the tubing precisely in place to reduce any twisting and bending of the metal while being welded. Metal sometimes seems to have a mind of its own and does some pretty funky stuff when being subjected to the high heat of welding. This is all too familiar to an experienced welder like Bopp and wouldn't be an issue. He began to measure, cut and weld what would soon become a cage to house the powerful 800cc Rotax. As the skeleton began to take shape, its look was unlike anything resembling that created in the Can-Am factory. Once the frame was completed, fabrication shifted toward the fully adjustable A-arms and extended steering stem. Jigs were again built for every product to ensure a tight fit and enable reproductions to be produced as necessary. Replacing damaged components isn't Bopp's strategy; apparently, he is just planning ahead to manufacture replicas for anyone preparing to keep up with Martin.
At first sight of the finished product Martin was thrilled, and if everything bolted together as planned, they will have created the quad of his dreams. Without any hesitation they began the grueling assembly process leaving out needless components, brackets and fasteners. These individual pieces are seemingly light in weight but as they compile their combined mass becomes surprisingly heavy. Strong, light and fast was the goal, and after many sweaty hours behind a wrench, this creation had come to life. Leftover nuts and bolts were stored in a bucket, and Martin claims they weighed in at an astonishing 25 pounds. I was shocked to hear of that weight loss, but the overall weight of the machine completely blew my mind-it had lost an incredible 70 pounds! In my opinion, Jenny Craig's diet plan doesn't stand a chance against this team of fabricators.
To match the quality of the...
To match the quality of the custom chrome-moly frame, Bopp developed fully adjustable A-arms for the Outlander.
Other modifications that were made to the original design included the integration of a large custom-fabricated radiator for higher capacity and better cooling. This is added weight but is highly beneficial when pushing the motor to its limits in a muddy race where airflow is restricted. Other components such as the airbox remained unchanged. Utilizing an exposed filter could have easily eliminated the airbox, but in battles with the elements, Mother Nature usually has the upper hand. Fabricating this type of part from aluminum is an option, but Martin felt it was unnecessary and would only add unwanted weight. A reduction in seat height is another modification that was achieved. Keeping the center of gravity as low as possible would provide better balance and stability to the machine. This mod isn't visually noticeable, but the first test ride would soon reveal the results of the changes.