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How Aftermarket Polaris RZR Parts And Accessories Are Made

Mar 22nd 2022

When you’re in the market for a new aftermarket Polaris RZR part or accessory, build material and quality are usually the first things that come to mind.

After all, our UTV is responsible for our safety and enjoyment while off-roading, right? So it stands to say that we as consumers may want to know a thing or two about the most common parts manufacturing processes.

Today we will specifically cover the process of creating Polaris RZR parts out of Cast Aluminum, Billet Aluminum and Forged Aluminum.

Cast Aluminum Polaris RZR Parts

To make cast aluminum parts, such as a cast aluminum Polaris RZR Clutches, things need to get hot.

Aluminum ore is melted down into shippable-sized blocks and sent to manufacturing plants. At this point, the aluminum is melted down once again, and carefully poured into moulds. The moulds are shaped like the part that the final product will become, and the molten aluminum is left to cool completely until it's solid.

The process makes it easy to make Polaris RZR clutch kits like the Polaris RZR XP 1000 S4 Recoil Clutch Kit by Aftermarket Assassins, which is a direct replacement for the stock unit.

What's great about cast aluminum parts, is that they’re decently strong and durable while being very inexpensive compared to other methods. One downside, however, has to do with the melting process…

Melting down aluminum multiple times changes its structure. It also tends to increase the likelihood of introducing impurities into the final product. This is one reason why cast aluminum may not be as dependable as our next option:

Billet Aluminum Polaris RZR Parts

The process of creating billet aluminum parts -- such as Polaris RZR Portal Gear Lifts -- differs from the casting process in that no additional melting of material is required.

A specific type of CNC machine is used to precision mill solid aluminum to the manufacturer's exact specifications. These specs are put into a computer, which follows them to the letter. This process is highly accurate, making it perfect for situations with little to no margin of error. The results in a super strong, reliable, and even aesthetically pleasing with smooth, rounded edges and a chrome-like shine.

As far as downsides go, the top of the list would have to be the fact that whoever is in charge of designing the part itself, and programming its specifications into the computer running the CNC, will decide the strength and fitment of the part. Consequently, operator error can sometimes adversely affect the final product.

All that is to say, billet aluminum parts are stronger than cast, more reliable, and customizable during the design process as long as the design is within the CNC’s capabilities. So parts like the Polaris RZR Limited Edition 8" Portal Gear Lifts by Super ATV look great, work great, and will last you longer than the alternatives!

Forged Aluminum Polaris RZR Parts

Finding forged aluminum parts is becoming easier as they become more widely available.

Although the process is different from casting or billet machining, the forging process can actually result in even stronger parts and accessories. The same grade of aluminum is used as in casting and billet machining. But instead of melting or machining, the aluminum is forced into place using a large and incredibly strong hydraulic press.

This process is so effective because unlike billet or cast aluminum, the general structure of the metal is not compromised. It isn’t melted down, and it isn’t carved or cut into. With more of the original grain and structure remaining, the strength of forged aluminum parts becomes extremely difficult to beat.

Popular forged aluminum parts you may be familiar with are Polaris RZR wheels. Wheels such as the Polaris RZR Grenade Beadlock Forged Wheels by KMC are made using the forging process, ensuring extreme strength and reliability on any trail or rock crawling adventure you set out on.

Unlike billet and casting, however, the forging process does limit what types of parts can be made.

Billet machining and aluminum casting allows for a higher level of precision that some parts may require.

So Which Process is Best?

Now that you know how each process works, and what their strengths and weaknesses are, how will you know which part to go with?

Cast aluminum parts are lower in cost and readily available for nearly anything you’re trying to replace, while billet aluminum parts are stronger, more reliable, and better looking. Forged aluminum parts can provide unmatched strength, but they are few and far between and hard to find sometimes.

At the end of the day, you will still need to research the parts that you’re interested in. Read reviews, check online forums and see what experiences others have had. If you go with a solid company like SeizmikModQuad, or Rough Country, you'll be in good hands. But if you simply choose a no-name brand, be weary, as you might get a part that is inferior or made with the wrong material for the job.

All of the aforementioned methods can produce extremely strong and reliable parts, and if you don't feel like doing your homework, just know that anything you get from Everything Polaris RZR will be of the highest quality!