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How Cognito Motorsports Builds Their HellraiserXP1k Polaris RZR

Posted in Features on June 29, 2015
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Photographers: Courtesy of Manufacturer

We’ve always been in awe of how Rod Hall could go so fast in a short wheelbase Jeep. It should go without saying that we love to go fast, but we’re also big fans of being in control and for us that means stability. And stability means a wide footprint, or in the case of off road vehicles, a wide and long wheelbase.

Obviously, the guys at Cognito feel the same way. They build some very fast RZR’s for their team guys, but to make sure that the cars are as stable as possible, they start with a 4-seater Polaris RZR HP 1000 and only add 2 seats when they build it.

How they build it is another story. They dismantle it down to the stock frame, cut a bunch of that away, and then build a cage onto what’s remaining. Then they add their long travel suspension systems, a set of internally bypassed FOX shocks, a host of raceworthy parts such as Method Wheels, ITP tires, Rigid Industries lighting and Rugged Radios items.

The Polaris RZR 4 seater is a serious off road vehicle that thanks to its 4wd can go just about anywhere, and do it in style and safety.

The result is the Cognito Motorsports HellraiserXP1k.

Make no mistake; this is a full on racecar that has seen upgrades that Cognito has been learned over the past few seasons of hard racing. They have taken all their experience and put it into the Hellraiser, and we’re going to show you how they build one.

They’ll build you one too if you want, but know that this is a long process (and probably an expensive one) but if you want to go racing, or just have the baddest RZR around, the results are totally worth it.

If you’re interested, contact Cognito at cognitomotorsports.com. We don’t see how you can go wrong.

With the Cognito suspension and other pieces layed out, this build is really getting underway. With the Cognito suspension and other pieces layed out, this build is really getting underway.
The various stock pieces are removed, including the seats. The various stock pieces are removed, including the seats.
Next to go is the stock cage. Next to go is the stock cage.
Here’s what the stock RZR looks when all the pieces have been removed. The Cognito crew isn’t done yet though. Here’s what the stock RZR looks when all the pieces have been removed. The Cognito crew isn’t done yet though.
Since Cognito (and most other teams/builders) only use the center section, everything else is removed. Since Cognito (and most other teams/builders) only use the center section, everything else is removed.
The center section is placed on a jig, and the Cognito cage begins to take shape. The center section is placed on a jig, and the Cognito cage begins to take shape.
It takes many days to complete the cage building. It takes many days to complete the cage building.
Once all the tack welds are in place and upper TIG wending has taken place, the cage is flipped over and the welding is finished. Once all the tack welds are in place and upper TIG wending has taken place, the cage is flipped over and the welding is finished.
When the final welding is done, the aluminum side panels are formed. This step also requires many days of fitting and trimming. When the final welding is done, the aluminum side panels are formed. This step also requires many days of fitting and trimming.
With the fabrication done, it’s time to put the RZR together. Here, the engine, fuel cell, front differential and other bits are back in place. With the fabrication done, it’s time to put the RZR together. Here, the engine, fuel cell, front differential and other bits are back in place.
The stock wiring harness is put back into place. The stock wiring harness is put back into place.
A Sparks exhaust system is used. Note that the twin mufflers are re-buildable. A Sparks exhaust system is used. Note that the twin mufflers are re-buildable.
The spare tire carrier is installed. Note that the air cleaner element is attached to it. The spare tire carrier is installed. Note that the air cleaner element is attached to it.
Heavy gauge aluminum panels act as a firewall between the cockpit and the engine. Heavy gauge aluminum panels act as a firewall between the cockpit and the engine.
The upper wing is a multi-tasker as not only does it house all the Rigid Industries LED lights, it’s also the intake vent for the engine and belt cooling system. Cognito figured that getting the intakes up and out of the dust as much as possible just made sense. It looks pretty cool too. The upper wing is a multi-tasker as not only does it house all the Rigid Industries LED lights, it’s also the intake vent for the engine and belt cooling system. Cognito figured that getting the intakes up and out of the dust as much as possible just made sense. It looks pretty cool too.
The drive belts get hot, and this heat buildup needs to be addressed.  Cognito routes fresh air from the upper intake, through the belt housing and back out through a UMP scoop. The drive belts get hot, and this heat buildup needs to be addressed. Cognito routes fresh air from the upper intake, through the belt housing and back out through a UMP scoop.
Cognito custom fabricated the dash to hold Auto Meter gauges, the Rugged Radio and the stock speedo. Cognito custom fabricated the dash to hold Auto Meter gauges, the Rugged Radio and the stock speedo.
The stock wiring harness has been modified to include the new gauges and other items. Clean and easy to work on is the key here. The stock wiring harness has been modified to include the new gauges and other items. Clean and easy to work on is the key here.
The last piece of the dash puzzle is the huge Lowrance GPS system. The last piece of the dash puzzle is the huge Lowrance GPS system.
A Rugged Radios MAC4.2 two-person Air Pumper system is bolted in place  against the firewall. A Rugged Radios MAC4.2 two-person Air Pumper system is bolted in place against the firewall.
As with all of the aluminum body panels, the roof section is held in place using Dzus fasteners. As with all of the aluminum body panels, the roof section is held in place using Dzus fasteners.
The 40-inch Rigid Industries E2 LED lightbar is held to the roll cage with quick release pins. The E2 features both Hyperspot and driving LED’s so things are lighted both near and far. The 40-inch Rigid Industries E2 LED lightbar is held to the roll cage with quick release pins. The E2 features both Hyperspot and driving LED’s so things are lighted both near and far.
The heart of the front suspension is Cognito’s Long Travel Upper & Lower Control Arm Kit (#POL-XP1K-FCAK-LT-1). The kit includes ¾-inch Uni-balls, 17-4 SS pins, poly bushings, and other necessary mounting hardware. It comes in a black powder coated finish. A set of Summers Brothers 300M axles are used. The heart of the front suspension is Cognito’s Long Travel Upper & Lower Control Arm Kit (#POL-XP1K-FCAK-LT-1). The kit includes ¾-inch Uni-balls, 17-4 SS pins, poly bushings, and other necessary mounting hardware. It comes in a black powder coated finish. A set of Summers Brothers 300M axles are used.
Keeping the RZR running smoothly is done with FOX Podium Internal Bypass Series shocks. The FOX shocks feature a DSC adjuster, 7-zone compression and 3-zone rebound bypass, dual rate springs, 7/8-inch shafts and a remote reservoir. Keeping the RZR running smoothly is done with FOX Podium Internal Bypass Series shocks. The FOX shocks feature a DSC adjuster, 7-zone compression and 3-zone rebound bypass, dual rate springs, 7/8-inch shafts and a remote reservoir.
For the rear, a set of huge Cognito trailing arms are first installed (Long Travel Trailing Arm Kit: POL-XP1K-TAK-LT-1). They too are powder coated black. For the rear, a set of huge Cognito trailing arms are first installed (Long Travel Trailing Arm Kit: POL-XP1K-TAK-LT-1). They too are powder coated black.
To increase strength, Cognito adds one of their Radius Rod Cages (POL-XP1K-RRCAGE) as well as their Long Travel Radius Rod Kit (POL-XP1K-RRK-LT-1). A Summers Brothers 300M rear axle shaft, which is 4-inches longer than stock length is installed. And a Sway Bar End Link Kit (POL-XP1K-ENDLINKS) connects the stock arm to the new arms. To increase strength, Cognito adds one of their Radius Rod Cages (POL-XP1K-RRCAGE) as well as their Long Travel Radius Rod Kit (POL-XP1K-RRK-LT-1). A Summers Brothers 300M rear axle shaft, which is 4-inches longer than stock length is installed. And a Sway Bar End Link Kit (POL-XP1K-ENDLINKS) connects the stock arm to the new arms.
Topping off the rearend build is another set of the FOX internal bypass/external reservoir shocks. Topping off the rearend build is another set of the FOX internal bypass/external reservoir shocks.
Method Race Wheels has gotten into the UTV end in a big way with their 401 UTV Bead lock. The wheel includes a forged 6061 bead lock ring along with Grade 8 Zinc plated mounting hardware. Mounted to them are ITP Ultracross R Spec tires. They feature a unique, multi-surface, non-directional tread design improves off-road traction and are constructed with an 8-ply radial design. Method Race Wheels has gotten into the UTV end in a big way with their 401 UTV Bead lock. The wheel includes a forged 6061 bead lock ring along with Grade 8 Zinc plated mounting hardware. Mounted to them are ITP Ultracross R Spec tires. They feature a unique, multi-surface, non-directional tread design improves off-road traction and are constructed with an 8-ply radial design.
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