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PolarisRich 09-22-2007 10:08 PM

How to Build A Track Cutting Tool
5 Attachment(s)
Some of you may never have a need to use one of these
cutters but if you ever do, here what they look like....

Attachment 978

My story....

I had a 1995 Polaris XCR 600, I bought it used and it came
with a 1.25" Challenger full length paddel track. I kind of
figured that it was too much track for our area of riding.
The sled ran great with ton's of traction but when I got
into the deep snow the sled would bogg down. I lowered
the suspension into to lower mounting holes wich helped
some but it did not get rid of the bogg completly.
I realized that the track was filling the tunnel with too
much snow, causing the bogg.
My options were, to buy a new track and try to sell the
Challenger(The track was brand new with only a few
hours on it.) Or try to cutt it down to 1".

Now I had gotten some ideas from fellow sledders,
of course none of them good ones.
One said "try a grinder" no thanks! Another said
"use a propane torch and a sharp knife" again No thanks!
So I came up with this handy tool! You couldent belive
how easy it was and it only took about 5 minutes to do
the entire track.

Here's how its made..

I used a piece of nylon but you could use whatever you
have around like wood or steel.

Drill and tapp two holes in one end of the block far enough
apart to accomidate a standard razor blade. Then cut
out a semi-circle between the two holes you just made.
Attachment 979
Now add washer's above the razor blade untill you have
reached the dypth of lug you want on your track.
Attachment 980
In my case I wanted the depth of my track to be 1"
Attachment 981
Now place the cutter over the track lugso that the bolts
are touching the bottom of the track.

Attachment 982
Now slowly pull twardy yourself while keeping a downward
pressure on the tool.
This will cut off the remainder of the track that you don't
want leaving you with the lug hight that you require.
For me it left a 1" lugHere's a tip- Change the blade every
15-20 cuts, it makes life allot easer.

rickfly 02-07-2011 01:24 PM

if you spritz the cutter with water or wd40 it will breeze through and likely cut all the lugs way easier

blue avenger 02-07-2011 01:47 PM

Nice idea! But, pull towards you? That's safe for some, but not accident pron wolfie LOL

DirtylilWolfess 02-13-2011 04:29 PM

BA, fuck you :)

I may use this tip if I find a stellar deal on a track that's too big for the Wolfsled.

blue avenger 02-13-2011 05:00 PM

:) there are some 2" tracks out in utah that have some torn lugs that might be good projects. Lugs would be stiffer and thicker after cutting.

Indy_500 03-19-2011 12:33 AM


Originally Posted by blue avenger (Post 111467)
:) there are some 2" tracks out in utah that have some torn lugs that might be good projects. Lugs would be stiffer and thicker after cutting.

hot knife

Slamdry 03-29-2011 09:25 AM

should you torch the end of the lug to re-seal them? or just roll with it??
i feel i may turn mine into a 1.5" to lighten the rotating mass a little bit, and get rid of the rolled over tips that i have.

Slamdry 08-12-2011 01:24 PM

somoen want to answer my question about tourching he lug after i cut it?? going to be doing htis in a few weeks here...

Powersledder 08-12-2011 01:35 PM

You should be able to answer it after you try it out.

Slamdry 08-14-2011 08:16 PM


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