Our new workhorse has arrived!

After selling our 2014 Gator to a private party, in early April we finalized plans to purchase and modify a 2020 Honda Pioneer 1000 Deluxe side-by-side that now makes its home at the Blue Hills Trail.

Beginning in February, recognizing it was time to replace our Gator, here's the process we followed...

• Researched UTVs that would meet our needs
• Researched industrial strength tracks that would be superior to the Camoplast tracks we've used since 2014
• Inspected and test drove several UTVs
• Visited the nearest Mattracks dealer (Winter, WI) for a first hand look
• Spoke with groomers at ski trails with experience using the Honda Pioneer, and Mattracks.

By late March, we felt the Honda Pioneer 1000 was a good choice for our new UTV. And Mattracks became our choice for a tougher set of tracks. Recognizing the need to pay attention to our space limitations (the doors opening into our storage shed are 83" wide and 83" tall), we...

• Downloaded specs for Mattracks and the Pioneer
• Made multiple careful measurements of the Pioneer
• Realizing the vertical fit would be close, we decided to purchase the Pioneer (with a backup option of modifying the storage shed doors)

Recognizing the current Coronavirus Pandemic has greatly disrupted supply chains and the availability of manufactured items, we felt fortunate to locate a UTV that could fit our needs (a 2020 Pioneer was available at Zacho Sports Center in Chippewa Falls). We made a down payment on the Pioneer. Simultaneously, we ordered the Mattracks from TRACKIT trail grooming located east of Winter, WI (just before a big price increase). Zacho Sports Center did nice work adding a front receiver hitch, interior storage compartments, front and rear LED lights, special dashboard rocker switches to operate our grooming implements, and a second stronger battery to handle the extra electrical load.

Once all the modifications were completed on the Pioneer, we sealed the deal and chose May 12th as the day to transport the Pioneer from Chippewa Falls to Winter (Wisconsin) where the tracks were installed. Then from there to the Blue Hills Trail -- all in the same day. A HUGE THANK YOU to John Waldron for his time and mileage (220 miles that day) as he trailered from Rice Lake to Chippewa Falls to Winter to our trailhead transporting the Pioneer.

Once at the trailhead, we were relieved our new Pioneer fit the vertical opening into the storage shed with about 3 inches to spare! WooHoo!!!

The next major step was to fabricate a special extended rear hitch for towing our grooming implements and trail mower. Bob Wieckowicz (our member with special welding expertise) evaluated the Pioneer, and decided to weld the extended hitch at his shop. The welding and painting was accomplished in a couple days, and the Pioneer returned to the trailhead just before rainy weather moved in. Considering the tight spaces that are present when the cargo bed is tilted, the fabricated hitch and welding support is really quite brilliant! Thanks Bob!

Many thanks to the following members that helped research the new machine and tracks: Sam Behrends, Ron Beebe, Ron Jasperson, Tom Paulsen, and John Waldron. And thanks to Bob Langer for help with trailering as part of the rear hitch fabrication.

And many thanks to our members and donors. The Pioneer + Mattracks is a big investment, we genuinely appreciate your financial support.

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In 2014 we purchased and began using a John Deere Gator with Camoplast tracks to handle the bulk of our ski trail grooming. It also pulls our trail mower through 22 miles of rough trails during the summer.

As a result of a couple major breakdowns involving the Camoplast tracks, we’ve learned to carefully monitor the tightness of the bolt/washer combination that secures the hub bearings and holds the entire track on the Gator axle. Every 50 hours we perform a safety check on the tightness of the 12 mm diameter hub bearing bolts that hold everything together. If we discover a bolt is starting to loosen up, we replace it. However, on two occasions the bolt itself snapped off - requiring a delicate welding operation to mount a nut on the bolt shaft so the bolt could be removed. This happened most recently just one week ago.

The Camoplast tracks that we use are realistically designed for recreational use. However, we demand a lot more of the tracks when pulling heavy grooming implements up hills, down hills, across hills, over bumps and ridges. Even though we’re using new bolts and washers when they need replacement, they still have difficulty withstanding the abuse.

After one of these bolts broke off a week ago, we called Camoplast in Canada and spoke with a very helpful engineering technician. He knew that ski trail groomers in Europe had greatly diminished their problems with bolt breakage through one specific modification of the setup: they substitute a much thicker washer. This makes a lot of sense. We’ve noticed all along that the original washers tend to deform (cup) within the first 100 hours of use - probably allowing the bolt to loosen, perhaps allowing too much play at a point where the mechanical forces are extreme.

So this past week, we tried finding a thicker heavy duty washer by calling Fastenal, and by scouring the internet, and by speaking with representatives from several big online companies that specialize in selling fasteners. Nobody could provide what we were looking for!

Then an AHA! moment. How about trying the machine shop located 3 miles from our trailhead?

CPH Enterprises Inc said “Of course! - WE CAN DO.” They took the original washer, recommended an improved fitment for the bolt, and later that day provided a bid for fabricating the washers we needed. We gave the go ahead, and actually had the opportunity to watch the machining in action.

They used a Waterjet Machine to cut the new thick heavy duty washers. After programming the specs, it cut the washers using water pressure of 50,000 PSI. I’ve never seen anything like it, truly amazing!

Think Global, shop Local.  

The following pictures and video tell the story.

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