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Polaris RZR XP Turbo Intercooler, 2016+

Honing the Blade – 2016+ Polaris RZR XP Turbo Performance Intercooler R&D, Part 3- Production Sample

Posted: February 08, 2023

Categories: Polaris RZR XP Turbo Intercooler, 2016+

Blades dull and lose their utility the more they’re used, and the same could be said about Polaris’s flagship side-by-side bearing the RZR name. This specialized tool is designed to slice its way through tough terrain with ease, but it needs the proper tool to maintain its sharpness over time. The torquey turbocharged twin makes this side-by-side a formidable weapon, but its intercooler is the chink in its armor. Well, until now.
As mentioned in our first post,

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Honing the Blade – 2016-2021 Polaris RZR XP Turbo Performance Intercooler R&D, Part 2 – Prototyping

Posted: February 08, 2023

Categories: Polaris RZR XP Turbo Intercooler, 2016+

It takes more than just a whetstone to sharpen a blade properly. Perfecting the edge on any cutting implement comes with the collection of the correct tools on top of sharpening the technique required for an adequately honed blade. However, the Polaris RZR Turbo isn’t just some run-of-the-mill knife. This is an implement designed for precision cuts through the unforgiving wilderness, so naturally, honing this blade requires special care.

Preparation is a critical step in any tool maintenance. In the case of keeping our RZR sharp, our preparation was outlined in our design plans in the previous post, so we’re moving on to honing our technique. While our modeling software combined with our 3d scan arm provide an accurate virtual workspace for our engineering team, nothing quite tops a physical installation on the vehicle. With the help of our bank of 3D printers, Dave is able to churn out a 1-to-1 scale replica of the new design that is fit for installation.

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Honing the Blade - 2016+ Polaris RZR XP Turbo Performance Intercooler R&D, Part 1 - Stock Review and Design Plans

Posted: September 26, 2022

Categories: Polaris RZR XP Turbo Intercooler, 2016+

Much like the sharpened blade that it takes its name from, Polaris's RZR is a purpose-built tool designed specifically for making precise cuts through the rugged wilderness. The 925cc torquey twin paired with forced induction, knobby tires, and long-travel suspension, all placed neatly in a fun-sized chassis makes this side-by-side the ideal specialty tool for off-the-grid excursions. Much like an actual razor, though, this machine needs constant honing to retain its sharp performance, and in this case, our whetstone is the intercooler.
The OEM intercooler is one aspect of this rugged rig that can dull the performance of your turbocharged RZR. Of course, it's not necessarily in terms of cooling power. Still, the high demand for this vehicle across treacherous terrain knocks this intercooler around enough, which can lead to cracks and leaks in the charged air or, worse, the coolant running through the core.

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Polaris RZR XP Turbo Intercooler, 2016+

Honing the Blade – 2016+ Polaris RZR XP Turbo Performance Intercooler R&D, Part 3- Production Sample

Honing the Blade – 2016-2021 Polaris RZR XP Turbo Performance Intercooler R&D, Part 2 – Prototyping

Honing the Blade - 2016+ Polaris RZR XP Turbo Performance Intercooler R&D, Part 1 - Stock Review and Design Plans