Thread: Polaris 800 Crew Restoration

Well here we are again, another good piece of equipment but the environment it was stored and used in is eating it up. It's mine now so let the games begin.



I was fabricating all the accessories for a couple of these units. I'm washing it up in this picture. Funny the seats are out here because they are the reason for this post. I made the aluminum roof and bed cover. The bed cover is on struts so when you unlatch it the struts hold it open while you access the inside.



This is another 800 Crew they had. Anyway I took care of their equipment over the years and a lot of times when they upgrade I get the older used stuff. We had a lot of fun pre Chronic Waste days.



I didn't think to take pictures at the start like usual. Trying to figure out why the 2 seats were curled up had my brain engaged fully. Once studying on the seats I realized the seat coverings had actually shrunk so bad it was curling the plastic base up cutting it off was the only thing I could do.



The seat still flipped over I have already cut the cover off and used the heat gun to start straightening the plastic base.



If you compare the first 2 pictures to the last you will see the plastic base is crowned all the way around. The last picture I have worked the crown down in the center area and partially around the perimeter. This is as far as I have gotten so far. The seat bases need to be molded back first. A 4-way stretch Marine seat vinyl is on order so I have time to finish molding & remove all the staples before the material arrives. I have a complete replacement exhaust system on the way too. The Shift Lever going into the transmission was almost frozen up so I spend a hour freeing it up, rigging a temp seat, and placing it near the shop for more work.