Reply
Go Back   TexasBowhunter.com Community Discussion Forums > Topics > D-I-Y Projects
 
Thread Tools Display Modes
Old 12-03-2018, 03:29 PM   #1
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default 2018 Kawasaki Mule SX Roof Build

I'm about to build a roof for my 2018 Kawasaki Mule SX 4x4 and I figured I'd share my plans for anyone else who might be interested. I plan on using 3/4" treated plywood with several layers of undercoat so I can stand on it to feel feeders. I plan to fasten it to the roll bar with (10) 1 3/4" Stainless Pipe straps with rubber softeners I found on amazon for $12.99 for a 10 pack. I found a 120 watt LED lightbar for $29 on amazon and a 3 switch toggle panel to control the light (2 extra switches in case I add more lights later). I will run a 15 amp fuse between the battery and the switch. If anyone has any advice feel free to chime in.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-03-2018, 05:36 PM   #2
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default

I will post pics of the project as I go along. Ill also include part numbers and pricing for all parts as well as where they were purchased from.
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-04-2018, 03:01 PM   #3
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Undercoat

This is the undercoat I'll be applying to my treated plywood.
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-04-2018, 03:23 PM   #4
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default

sorry the picture did not take. here is the undercoat.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-04-2018, 09:04 PM   #5
savin yours
Pope & Young
 
savin yours's Avatar
 
Join Date: Feb 2007
Location: Texas
Hunt In: Lampasas
Default

In


Sent from my iPhone using Tapatalk
savin yours is offline   Reply With Quote Back To The Top
Old 12-04-2018, 09:28 PM   #6
FLASH_OUTDOORS
Ten Point
 
FLASH_OUTDOORS's Avatar
 
Join Date: Aug 2012
Location: Tomball
Hunt In: Kennard
Default

Don’t use the rubberized undercoating. It won’t hold up with you walking on it. It will also soften in the heat. Get a raptor liner kit on amazon. Or something similar. Cures hard as a rock and stays that way. Also UV resistant. It will be the best $100 you’ve spent. I have some parts on the exterior of my Jeep that I used rubberized undercoating. Never again. After a year it’s chalky and peeling like rubber. The fenders, inner door panels and floor are raptor liner. Good as new and still hard as a rock.


Sent from my iPhone using Tapatalk
FLASH_OUTDOORS is offline   Reply With Quote Back To The Top
Old 12-04-2018, 09:52 PM   #7
TXDraht
Four Point
 
TXDraht's Avatar
 
Join Date: Dec 2014
Location: Naruna, TX
Hunt In: Burnet County
Default

I did something similar. I used two pieces of 3/4” plywood. Used liquid nails and screwed them together. Added a couple of layers of fiberglass around the edges to protect them from tree branches, etc. Applied resin to the top and bottom and then coated with herculiner from Lowes. I attached to the roll bar on the same fashion you described. Before sealing the top I installed all the bolts for the clamps and then applied the resin and liner over them. It’s very sturdy.

Last edited by TXDraht; 12-04-2018 at 09:55 PM.
TXDraht is offline   Reply With Quote Back To The Top
Old 12-07-2018, 06:58 AM   #8
DBilbe
Spike
 
Join Date: Jan 2016
Location: Pinehurst
Hunt In: Milam County
Default

I'm going to do something similar, but I'm going to mount a piece of sheet metal I have on top of the plywood.

I already tried attaching the sheet metal directly to the rollbar with those clamps, but the vibration was too much. Lots of noise on bumpy terrain, and some of the clamp bolts loosened up. I'm hoping the ply will dampen/buffer the vibrations without adding too much weight.
DBilbe is offline   Reply With Quote Back To The Top
Old 12-07-2018, 03:48 PM   #9
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default the plywood

Heres the plywood. I went ahead and beveled the rear corners as well. I thought it looked a little better that way.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-08-2018, 06:02 PM   #10
Traildust
Pope & Young
 
Traildust's Avatar
 
Join Date: Apr 2007
Location: Alvin, Texas
Hunt In: Looking!
Default

Quote:
Originally Posted by FLASH_OUTDOORS View Post
Don’t use the rubberized undercoating. It won’t hold up with you walking on it. It will also soften in the heat. Get a raptor liner kit on amazon. Or something similar. Cures hard as a rock and stays that way. Also UV resistant. It will be the best $100 you’ve spent. I have some parts on the exterior of my Jeep that I used rubberized undercoating. Never again. After a year it’s chalky and peeling like rubber. The fenders, inner door panels and floor are raptor liner. Good as new and still hard as a rock.


Sent from my iPhone using Tapatalk
Yes....don't use undercoating! Rustoleum Bedliner will work fine. Plywood need to be dry, dry, dry!
Traildust is online now   Reply With Quote Back To The Top
Old 12-10-2018, 08:28 AM   #11
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Truck Liner

Is this the Truck Liner you guys are talking about using in place of the rubberized undercoat?
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-10-2018, 09:14 AM   #12
FLASH_OUTDOORS
Ten Point
 
FLASH_OUTDOORS's Avatar
 
Join Date: Aug 2012
Location: Tomball
Hunt In: Kennard
Default

Quote:
Originally Posted by nokturnal85 View Post
Is this the Truck Liner you guys are talking about using in place of the rubberized undercoat?


That will hold up better than undercoating, but it’s no raptor liner.


Sent from my iPhone using Tapatalk
FLASH_OUTDOORS is offline   Reply With Quote Back To The Top
Old 12-10-2018, 09:43 AM   #13
Bill in San Jose
Pope & Young
 
Bill in San Jose's Avatar
 
Join Date: Oct 2006
Location: San Jose, CA
Hunt In: CA, CO, OR, and TX
Default

It cones in quarts too and probably cheaper to roll than spray. Follow directions and apply where there’s great ventilation- most are horrible with the chemicals that evaporate. Avoid Herculiner.


Sent from my iPhone using Tapatalk
Bill in San Jose is offline   Reply With Quote Back To The Top
Old 12-11-2018, 01:21 PM   #14
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Adjustment to plans

I noticed my original plans were indexed wrong, here is the corrected layout. Also I decided to use truck liner for the top and sides, and rubberized undercoat for the bottom of the roof. I have now applied 2 coats to both top and bottom and there seems to be plenty of "build". I will bolt the roof up tonight and see how it looks. Pics to follow.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-12-2018, 07:36 AM   #15
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default got the basic roof installed.

I got the basic roof installed on the mule. Now the process of dressing it up begins.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-17-2018, 07:28 AM   #16
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default switch box

heres the switch box/enclosure I will be installing under the roof. I will be painting it black and installing a 3 toggle switch panel to control cab lighting and light bars.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-17-2018, 07:29 AM   #17
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Switch Panel!

This is the switch panel I will be installing in the enclosure to control my lights.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-17-2018, 02:45 PM   #18
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Switch enclosure

Heres the switch box put together.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-17-2018, 02:47 PM   #19
sboudreaux
Eight Point
 
sboudreaux's Avatar
 
Join Date: Sep 2014
Location: Helotes
Hunt In: Kimble County
Default

Looks nice!
sboudreaux is offline   Reply With Quote Back To The Top
Old 12-17-2018, 03:57 PM   #20
Bill in San Jose
Pope & Young
 
Bill in San Jose's Avatar
 
Join Date: Oct 2006
Location: San Jose, CA
Hunt In: CA, CO, OR, and TX
Default

Nice! I assume 3x “ignition” was from whatever it was originally intended for?


Sent from my iPhone using Tapatalk
Bill in San Jose is offline   Reply With Quote Back To The Top
Old 12-17-2018, 06:54 PM   #21
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Switch box mounted

Now that the switchbox is in place, the next step will be my "interior" lighting. I will be routing out 2x4s and installing 'recessed' green led light modules.
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-18-2018, 12:08 PM   #22
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Interior Lighting

got my 2x4s setup with green LED lights for the ceiling. These will be fed from a switch on the switchbox and used to light the cab of the mule.
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-19-2018, 02:51 PM   #23
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default roof interior lighting

got the roof interior lighting mounted and now to wire everything up to switches. The next step will be installing a lightbar in the front and flood pods on the rear.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-20-2018, 09:30 AM   #24
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Interior Lighting Pictures

Got the interior lighting wired up. Next up is LED flood light pods for the rear of the roof and a light bar for the front of the mule.
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-21-2018, 02:41 AM   #25
Gulfcoastin
Four Point
 
Join Date: Oct 2015
Default

Looks awesome, great work.
Gulfcoastin is offline   Reply With Quote Back To The Top
Old 12-22-2018, 09:12 AM   #26
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Up to date schematic and wiring diagram

Here is where I am at in a scaled schematic form as well as the current wiring schematic.

DISCLAIMER: I am in no way an electrician or draftsman, so these schematics do NOT follow any standard at all whatsoever! These are meant to only give a better idea of what I have done.
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-23-2018, 03:16 PM   #27
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Light Bar

Got the Light bar mounted and wired up. Boy is that sucker bright! Now for the last chapter of this story, ordering and installing some 18 watt LED 4" flood pods behind the cab.
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-28-2018, 12:05 PM   #28
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default UPDATE Power failure and remedy

Well unfortunately my 4 year old son decided to turn on the cab lighting to my mule and I never noticed it until my buggy would not start. Turned out that my stock battery died. I have since decided to install an auxiliary battery to power my accessories. I will be running an Interstate SRM-24 Deep cycle battery under the seat where the optional storage bin goes as it fits perfectly (with a little maneuvering) for my auxillary. It is rated at 75 AH and seeing as my accessories together only draw around 14 amps max, I should be able to run everything for around 2.5 hours and still not drop below the 50% recommended threshold of the battery. I will keep the auxiliary charged with a maintainer/trickle charger and am looking into possibly installing some sort of solar charger to make it virtually maintenance free. I replaced the stock dead battery with an Interstate IB14A-A2 and boy what a difference in starting. I will also be installing a dual volt meter that fits in a rocker switch spot on the dash as well as a kill switch so it (the digital volt meter) doesn't become a drain on either the main or auxiliary circuit. I will post pictures of the project as soon as it is completed.
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-28-2018, 12:14 PM   #29
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Pics

Here are some Pictures of the auxiliary battery and the light bar powered by it. If you look back at the previous picture of the lightbar I posted and compare it to the current output of the lightbar you will notice a considerable difference.
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-30-2018, 03:42 PM   #30
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Voltmeter install

At this point I have routed out the switch slots for the voltmeter and voltmeter on off switch, as you can see from the pictures. Access to the rear of the switch panel in the dash is easily made by removing the "Rubber Plug" in the storage compartment in front of the mule. This voltmeter will give me a constant digital readout of my auxiliary and main battery voltage which in turn will allow me to know when the auxiliary battery needs to be charged as well as what state my main battery is in. It will also allow me to see in real time the output of my "stator" on my main battery. The voltmeter will be controlled by a 3-way off-off-on switch that will work by breaking the positive leads from each battery. This is done to eliminate any kind of draw on either battery from the voltmeter as well as a way to simply shut the voltmeter off when not in use. simple 22 awg stranded wire will be plenty for the voltmeter as it does not draw a load other than a signal to read out battery voltage levels. I used an 1/8" drill bit to put holes in all four corners of the switch cutouts and then a dremel tool with a cutting wheel to cut out for each switch. I will upload a picture once the switches are installed showing the voltmeter working.
Attached Images
      
nokturnal85 is offline   Reply With Quote Back To The Top
Old 12-31-2018, 12:36 PM   #31
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Auxiliary/Main battery wiring diagram

Here is a basic wiring diagram for what I have done. Again, as previously stated these are rough diagrams and as anyone can easily tell I am in no way an electrician nor electrical engineer. lol
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-01-2019, 08:01 AM   #32
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Voltmeter installed

I got the voltmeter installed and I must say it offers a bit of peace of mind being able to see the voltage of each battery. From the voltmeter I can see the output of my stator as well as the charge level each battery has upon starting. When the deep cycle's voltage drops to 12.2 volts it is time to put it on the charger. I will still be looking into a solar trickle charger for the auxiliary battery. Any advice on the solar would be greatly appreciated. My next step and final step for this roof build will be to finally order and install some 18 watt 4" flood LED pods to put behind the cab. These will not only allow me to see better behind me at night in the mule but will also aid in backing up my 16' lowboy at night in the dark piney woods of East Texas.
Attached Images
   
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-02-2019, 11:58 AM   #33
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default As Promised here is the breakdown of cost

I stated in my very first post on this project that I would include how much everything cost and where I procured my items from. As far as nuts and bolts go I had a stock pile of carriage bolts and nylon lock nuts I was sitting on so those will not be included in this breakdown. Also this breakdown will include the adding of the auxiliary battery system as it was necessary to run everything on the roof.

Roof Build Cost Sheet

Item Where Purchased Price
Nilight 22” Lightbar Amazon 29.83
8x6x4 switch box enclosure Amazon 12.99
3 toggle switch panel Amazon 19.99
Nilight 4” Flood Pods (2) Amazon 14.57
(10) SS pipe straps Amazon 12.99
(2) Truck bed liner spray Lowe’s 24.98
(2) rubberized undercoat spray Amazon 12.98
Green LED modules (10) Amazon 12.98
48x48x ¾ treated plywood Lowe’s 18.00
Treated 2x4x8 Lowe’s 4.17
Mounting brackets for 2x4’s Lowe’s 6.00
Dual Volt meter Amazon 11.18
On off switch for volt meter Amazon 9.99
SRM-24 Deep Cycle Battery Interstate Battery 129.99

Total Roof Build $320.64


I will post pics of the buggy complete this weekend hopefully!
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-02-2019, 01:26 PM   #34
twosixteens
Ten Point
 
twosixteens's Avatar
 
Join Date: Aug 2013
Location: North Texas
Hunt In: Young County Mostly
Default

How do you like your Mule SX I have been looking at them but don’t know anyone who owns one?
twosixteens is online now   Reply With Quote Back To The Top
Old 01-02-2019, 01:39 PM   #35
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default I love it.

Its a great buggy. It is narrow enough that I can usually go around washouts, although it goes through them just as well. I have rode with guys running polaris rangers and my mule sx seems to float over the mudholes they have trouble in, I'm guessing because it's so light. Top speed is 25 mph so if you're looking for a speed demon then keep looking. It has plenty of power and the fuel economy is amazing. You can ride 3 deep in a pinch but it is only designed for 2. Overall I'd say if you are looking for workhorse that will get the job done and that is all you are after, you can't beat the SX.
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-03-2019, 03:00 PM   #36
Bill in San Jose
Pope & Young
 
Bill in San Jose's Avatar
 
Join Date: Oct 2006
Location: San Jose, CA
Hunt In: CA, CO, OR, and TX
Default

What is the width? National Forests trails are restricted to 50” I think. If you’re not hunting the NF’s it doesn’t matter.


Sent from my iPhone using Tapatalk
Bill in San Jose is offline   Reply With Quote Back To The Top
Old 01-03-2019, 03:24 PM   #37
LCall47
Spike
 
Join Date: Dec 2017
Default

Nice build guys
LCall47 is offline   Reply With Quote Back To The Top
Old 01-04-2019, 03:22 PM   #38
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Width

I built the roof to be as wide as the outer edges of the rollbar which happens to be the widest part of the buggy. So, to answer your question it is 47".
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-05-2019, 04:17 PM   #39
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Well that's a wrap

Got the roof finished! That feels good to say finally. Here are some pics of the completed project. The rear lights turned out impressively bright and will certainly make backing in my 16 foot trailer a breeze in the pitch black night of the piney woods!
Attached Images
  
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-05-2019, 04:20 PM   #40
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Here's the whole buggy

Heres a pic of the whole buggy in the daylight.
Attached Images
 
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-05-2019, 07:31 PM   #41
ETX-Deerslayer
Ten Point
 
ETX-Deerslayer's Avatar
 
Join Date: Oct 2012
Location: Mertzon
Hunt In: Irion County, Gregg, Bowie, Cass, Upshur counties TX and Arkansas
Default

Nice project. Turned out great.
ETX-Deerslayer is online now   Reply With Quote Back To The Top
Old 01-06-2019, 03:21 PM   #42
nokturnal85
Four Point
 
nokturnal85's Avatar
 
Join Date: May 2016
Location: Nederland
Hunt In: East Texas
Default Thanks

Here are some pictures of the lights at night in action. Pictures don't really do it justice as they look darker in these photos, but it gives a general idea.
Attached Images
   
nokturnal85 is offline   Reply With Quote Back To The Top
Old 01-07-2019, 12:59 AM   #43
Gulfcoastin
Four Point
 
Join Date: Oct 2015
Default

Very cool, I like it. Good work.
Gulfcoastin is offline   Reply With Quote Back To The Top
Old 01-07-2019, 09:27 AM   #44
Daniel32
Ten Point
 
Daniel32's Avatar
 
Join Date: Aug 2009
Location: Victoria, TX
Hunt In: Victoria & Kinney County
Default

turned out great!!
Daniel32 is offline   Reply With Quote Back To The Top
Old 01-09-2019, 11:42 AM   #45
OrangeBlood
Ten Point
 
OrangeBlood's Avatar
 
Join Date: Feb 2010
Location: Princeton, TX
Hunt In: where the deer are
Default

Turned out nice, that light bar is really bright. I'll probably be doing something similar to this in the near future, minus the roof. I'm not electrically inclined so it could get interesting. Thanks for the inspiration.
OrangeBlood is offline   Reply With Quote Back To The Top
Old 01-11-2019, 01:19 PM   #46
Dray188
Nubbin' Buck
 
Dray188's Avatar
 
Join Date: Jan 2019
Location: Sulphur Springs
Default

I built one for my 09 rhino so that it covers my kids! 4x8 sheet metal with expanded metal sides then all sprayed with Line-x



Sent from my iPhone using Tapatalk
Dray188 is offline   Reply With Quote Back To The Top
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -5. The time now is 05:47 PM.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
Copyright 1999-2012, TexasBowhunter.com