Well, an update:
You won't believe how far things have come!
Things I've done:
1) New camoplast plastic skis/carbides.
I had to make my own bushings, brackets, and find my own hardware because I got a deal on them used off another sled. They are in like new condition, except for some scratches and normal light wear - probably used well under 1 season.
2) New, slightly used (no cracks/pullouts/lost lugs) campolast challenger with 191 woodys carbide studs in a v pattern with plastic backers.
3) Rebuilt suspension. Took it out, completely apart, all new bearings, replaced a few wheels, again made my own bushings when needed (some were gone altogether from rubbing!). My torsion springs weren't even resting where they were supposed to due to no maint. and lots of wear.
4) Sanded, fixed the cracks, and painted the hood. Replaced air box cover thing (busted to hell...) with my own plexiglass piece. I used fiberglass to fix the cracks from the inside, epoxy on the out.
5)Rewired still more stuff with melted wires, etc. I also used zip ties to attach them where brackets and holders were supposed to be.
6) Odds and ends - zip tie stitches on the bellypan, sanded and painted pipe, new pressure cap because of overheating issue, replaced some hoses here and there where needed, etc.
I spent 800 on the sled, 10 on the skis (yep...10 dollars), 250 for the track, and 200 or so rebuilding suspension and other junk. Other repairs cost nothing because I already had supplies.
Wow, a total of $1260 for a completely redone sled...(and I'll probably grab a new chain before next season). I'd say worth it to me. I did everything, so there's a sense of pride. I'm sure I could've gotten a newer or faster sled for that though.
I don't have any more pictures on this computer, but I'll upload some soon.
Oh! I almost forgot:
That driveshaft speedo hole is in fact a bushing. It's hardened steel, and the driveshaft is mild steel though, so drilling it out straight was much harder than I initially thought. I used a bone bit in a dremmel to drill out the rest of the broken off speedo key, and used progressively larger bits to drill it out to size. I had the replacement bushing, so at least I knew how big to drill the shaft. It may have been easier if I didn't try drilling it out normally first and knew the technique though.
I learned a hell of alot doing all this and never could have done it without the repair book.
