The Diablo 500 for the 50th Anniversary Celebration

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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Tue Dec 27, 2016 10:21 pm

The original 500's had a chrome plastic nose cone. The chrome was so poorly applied, it just blew off in the wind and left you with a dull white nose cone. These new chrome nose cones are much better. The nose cone is held in place by two NOS headlight assemblies.

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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 9:57 am

The original handle pins are very shallow on the top and have these wide aluminum press clips under them. I had a pair of the original pins re-chromed along with the half moon handles and had a good pair of original clips.

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The wiring on a 500 or 502 is fairly simple. A new key switch, new light switch and all new wires makes for a clean looking harness.

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Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 10:03 am

The carb I installed is an original Tillotson HR3A that would have been on the 500's. I've started using Tygon fuel line as it is softer and better quality.

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Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Schoobytwo (Bruce)
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 10:06 am

The original Primary Clutch on the 500 would have the three small allen headed screws holding the ramp plate on, so I installed the same clutch on this unit.

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I also installed an original NOS Saylers belt which would have been common in that time.

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Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 10:17 am

As mentioned early on, I found an original windshield bracket for a 500. For many years, we thought the windshield was just a myth as it was only ever seen in the promo-video for the 500. Since then, I have come across two factory brackets both missing the windshield. Bill S from Stone Lake, WI gave me a picture of his Diablo 500 taken back in 1967 and it had a windshield. Nate over in the thumb of Michigan also had a NOS windshield. So that is four that I know of.

I struggled to get someone to make a windshield for me. I tried working with two different companies looking for someone to reproduce this and although both held the pattern and pieces for months, neither completed the project. So buying a piece of windshield material myself, I made my own.

Cutting out the material based on the pattern, I then connected it to a piece of 2" PVC. Using my heat gun, I softened the material and rolled it over the PVC.

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It was a trick to get the windshield in the frame. And then another trick to put on the trim and hold it there, but in the end, I am very happy with what I came up with. To my knowledge, this may very well be the only Diablo 500 in existence that has a factory windshield on it.

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The tractor half of this restoration is complete. On to the ski seater!
Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 8:06 pm

The 500 seaters did not have the grab bar around the back. Some of the early seaters also did not have the support inside the toolbox which meant when you got a couple of people on the seater, it tended to cave in. For this restoration, I chose to use a seater that is original and has the updated internal support.

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Of course, a restoration like this can only have Barrie's authentic maple skis on them. I stained them black and added the Durasurf wear skins under them. The runners are new. I rivet the runners on to the skis and then use elevator bolts to attach the skis to the seater spring.

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Tighten things down, add the wiring and the tail light and we are ready for the seat.

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Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Schoobytwo (Bruce)
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 8:11 pm

I may have told you the story behind this seat, but it is worth repeating.

I lived close to my parents my whole life, so I saw them almost weekly. My father died about 6 years ago and a few years later, my mother passed away. In the process of cleaning out their house that I was born in, I found this original Diablo 500 seat buried in the attic. It was one of the last areas of the house we were cleaning up and to find it was a gift from pops I'm sure. It is my gift to this unique Diablo restoration.

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Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
User avatar
Schoobytwo (Bruce)
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Posts: 1710
Joined: Fri Feb 22, 2008 12:47 am
Location: Sobieski, Wisconsin

Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Schoobytwo (Bruce) » Sat Dec 31, 2016 8:18 pm

Presenting - a restoration of an original 1967 Bolens Diablo Rouge Snowmobile.

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We hope you will all come to the Banquet on Saturday Night to get a look at it, enjoy the presentations, have a great meal and win prizes.

Thank you all for your support through the years.

Bruce
Too many Diablos and parts to count.
Yamaha Apex (it outruns the Diablo for sure)
Yamaha 600 SX
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby Barrie2777 » Mon Jan 02, 2017 8:07 am

Great looking machine Bruce. I like the yellow gas line!!

I had heard that the SAYLERS belt was made for a dealer by the name of SAYLERS. Have you heard this?
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Re: The Diablo 500 for the 50th Anniversary Celebration

Postby husskifan » Mon Jan 02, 2017 9:35 pm

BRUCE GREAT JOB, IT LOOKS LIKE BRAND NEW, AND I AM SURE BETTER THAN NEW.
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