Z400 Frame Gusset Kit by Bare Performance - Project QuadSport Z400 ATV - - ATV at Off-Road.com

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Z400 Frame Gusset Kit by Bare Performance - Project QuadSport Z400 ATV

Publish date: Mar 1, 2004
By: Dean Waters
Source: ATV at Off-Road.com

The Z400 frame has excellent geometry for the ATV racer but notoriously has a serious problem with strength. The typical recreational rider will probably never see this problem, however if you race your LTZ or subject it to severe use such as jumping, you will quickly find there are a number of weak points in the frame. Inspecting Project Z400 after the BITD Parker 250, we could see that the frame was starting to stress-crack near the upper shock mounts on the front suspension. We started looking into getting our frame gusseted and found a number of places that were doing this, but it would require us shipping the frame to them and being without it for as long as eight weeks. We were not excited about the extended down-time.

Then we discovered a company selling a gusset kit at a VERY reasonable price. Bare Performance in Muncie, Indiana, is offering a 13-piece gusset kit for $68.95. This kit covers all the major weak points in Z400 frame. We had access to a local shop that could sandblast, weld, and powdercoat, so we ordered the gusset kit from Bare Performance. (If you don't have a local shop, Bare performance can also weld and powder coat your frame for $449.95.) What you will get is a bunch of small pieces of metal and a diagram like the one here, showing where all the pieces should go. Installation We stripped down our Z400 to the frame. This took us about four hours, including time to carefully ziplock and label all the bolts and parts so we would know where they went when reassembly time came. Next we took the bare frame, the gusset kit, and our sub-frame to Kni-Co brand new manufacturing facility in Wallowa, Oregon. Their specialty is custom metal sheepherder's stoves, but they also manufacture a number of other pieces and have their own in-house powdercoating equipment.


This is the gusset on the front upper shock mount.	The shows the gussets applied to both upper shock mounts.

Kni-Co first sandblasted the frame then inspected it for cracks. As we suspected, the frame was nearly cracked through behind the upper right shock mount, but no other major cracks were found. Kni-Co carefully tig-welded and repaired that crack. With the repair made they welded in all of the gusset pieces per the diagram. Most of the gussets fit nicely, but a few had to have modifications before they could be welded in place, as they did not quite fit.


This is the gusset near the front A-arm.	Gussets are applied to the steering stem and gas tank mount. Make sure your tank clears these. We actually had to modify the one on the right to clear our Clarke tank.


Gussets behind the A-arm mounting location.	Gussets near the motor mounts.

With the frame upside-down you can see the gussets applied to the bottom.

Kni-Co did a great job welding the Z400 frame, making sure to apply the right amount heat so that the frame was not damaged. After all the gussets were welded in place Kni-Co then re-sandblasted everything so that it was ready to be powder coated. Sandblasting is the most time-consuming and labor-intensive part of the whole process. Kni-Co can powder coat many different colors or can attempt to match a color. We chose to use the same color as our Holz front A-arms which are Cardinal BL01. We plan to also have our rear swing arm done in this same color. Summary We received our frame and sub-frame nicely shrink wrapped. Kni-Co did an excellent job. If you don't have a local shop, we recommend you call Rob Burns for a quote on your job. The complete job cost us about $300, including the gusset kit from Bare Performance. Down time was about two weeks but could have been less. Bare Performance provides an excellent gusset kit for only the money. A couple days reassembling and Project Z400 will be ready for a local hare scrambles event and a complete season of racing.