IN THE BEGINNING....
(Nov. 2000)
Here's a brief history of my Trail Boss. I purchased it in November of 2000 for $350. The engine ran fine, but the belt was out of alignment, and the trannys were completely out of adjustment. The belt was smoking at idle and it only went forward, no reverse. The seller pulled out some wrenches and started jacking the adjustment screws in and out. Finally I told him " I'll take it! " just so he wouldn't screw it up any worse than it already was. He claimed that he recently bought it himself, and that the first time he used it, he was fined $150 for driving it on state land. This was where he intended to use it, and since he found out he couldn't, he put it up for sale. In my opinion, he was also selling it because he screwed it all up and couldn't fix it. I had a bad case of 6X6 fever and bought it anyway. The original upper body was long gone, replaced by the wooden one you see in the pictures. (Ugly but functional.) It has a bench seat in front, and a fold up, rear facing seat in the back. Also has a removable tailgate. The craftsmanship was actually very good! I don't think the engine is the original. It is a Rotax 299cc. Everything I've seen says the were originally equipped with a Kohler 20 hp 309cc. When this engine was installed it did not line up properly with the driven clutch. I will need to remove the engine and slot the mounting holes to get it to line up. This should end the smoking belt at idle. The exhaust was also cobbled together poorly, causing some burned plywood and melted plastic where it exited the body. Other than these things, it was in pretty good shape.

REBUILDING STARTS...
(Feb. 2001)
I am currently rebuilding my Trail Boss. It's really more of a rebuild than a restoration. I am not trying to restore it to original or better condition at this time. My goal is just to go thru all the mechanicals and make sure everything is in good shape. At this time, I have everything torn apart except for the right-hand transmission and the engine. These are going to be left alone for now since they seem to be ok.

This is where the project stands as of mid-February.
- The body tub has been stripped and scrubbed.
- I have rebuilt 4 axle assy's so far. New bearings and seals. Two of them also needed sprockets. One axle is bent and needs to be straightened.
- I completely dis-assembled the left-hand tranny because the output shaft seal was leaking. I installed new bronze bushings and seals. Also got a new sprocket for the output shaft. Ready for re-assembly.

This is what still needs to be done.
- Rebuild the last 2 axle assy's.
- Re-install frame and axles, including new chains.
- Re-install motor/tranny sub-frame.
- Replace couplings on drive shaft.
- Fabricate or purchase new upper body.

REBUILDING CONTINUES...
(March 2001)
As of mid March all the axle assemblies are rebuilt and re-installed. I used all new fasteners and cork gaskets. New #50 chain was also installed. Now I need to finish the rebuild of my left-hand tranny. Should have that done soon. My self imposed April 1st dead-line is getting near! The snow has melted and it's getting warmer everyday.
Time to be out riding!

ROLLING ALONG...
(May 2001)
As of May my Boss is now in driveable condition. All axles rebuilt, new chain, motor and trannys re-installed and a new belt. I still don't have an upper body and the exhaust system is cobbled together from the old stuff. Spent some time getting the trannys adjusted and it seems to run good! Needs new seats, exhaust system and upper body to be complete. Having fun driving around the yard. Bought a new 5'x9' trailer to haul it around with.

GONE...
(July 2001)
After great consideration I decided to part out my Trail Boss. This decision was based on the cost of a new body and other needed parts vs. buying another machine that has a complete body and is in running condition. I posted an ad and quickly sold off the entire machine to someone who had a good body but need tranny and tires. Worked out good for both of us. Now all I need is to find another elusive Trail Boss to buy. I ran across a Scrambler for $400 but.........I don't think so.

QUAD CITY...
(Aug. 2001)
My wife and I came to a corporate decision and decided to buy a pair of ATVs rather than another 6x6. This is based on Wisconsin laws that exclude 6x6's from being legal ATVs (what a joke.. huh?). The only place you can really use one is on private property. There are extensive ATV trail sytems in northern Wisconsin where we own a cabin. With the quads, we now spend weekends trail riding. Hopefully someday the state of Wis. will open their eyes and legalize the original and true ATVs (6x6s). In the meantime, if I run across a reasonable, restorable, project 6x6 I may become an owner once again. By the way, what kind of quads did I buy...you ask? I bought 2 brand new Kawasaki Prairie 300 4x4s. Fully automatic 4-wheel drives. I love them. They run and handle great. No problems yet with 150 miles on each.

P.S. The common 6x6 term BOUNCE does not apply. These babies soak up bumpy trails with the greatest of ease. Cadillac smooth!

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