900 KK MC rear tunnel and bumper mod. for summer project

76FOMOCO · Jul 22, 2009

took the O'l cat and put the new 09 M series rear tunnel ends and made a custom cover for the cooler with a (I hate to say this) XP rear bumper and LED tail light. I had the tail light from years past but the total was as follows: tunnel ends 16.00, bumper, 50.00 plate aluminum 13.00 and rear cover 20.00. so total about 100 bucks.

this is what i started with

Layout for the rear

new rear cover and layout for the chop

the chop

and the finished product

1Mike900 · Jul 22, 2009

Beautiful! I am ready to do mine shortly. I like that idea, Inexpensive, Plain and simple, Yet very user friendly!

Mike

Rixster · Jul 22, 2009

I am doing the same thing right now. What gussets did you use? I was going to use the 09 cat gussets but i can figure out how to hook them to the rip rails. I figured I would buy 08 153 rip rails and cut them to length. then the gussets slide right in the end of the rip rails. What did you cut the tunnel with?

76FOMOCO · Jul 22, 2009

I used the 09 cat rear gussets and cut the tunnel with a 1/4 angle air grinder with a cut off wheel. the 09 cat ends will not fit in the 03 rail edges so i had to grind them down to fit and use a towel and a hammer to oblong the rail end to give the gussets more area, and you can't even tell they have been beat to chit with the hammer. LOL. the best way would be to buy the 09 edges and gussets.

mattymac · Jul 22, 2009

turned out sweet!

Rixster · Jul 23, 2009

I am going to buy the 08 rip rails, they are the same as 09 just longer. Then I can cut them to the length I want. I was going to use aluminum tubing for a bumper but I may just spend the 50 and get a XP bumper, that looks great! You are better with a die grinder then I am! Also I am not 100% sure I am going to taper my tunnel that much. I havent decided yet.

sunbather1969 · Jul 23, 2009

just a thought

speaking from experience on same machine plate the rear of the rolled edge only problem ,trust me see the stripe up my seat and the boards if you had them covered and running snow eliminators and you would have minimal snow in there.thats what ill do to mine

Bearcat · Jul 23, 2009

I used -09 gussets too in my CF7 -06. You need to weld them to rolls as they will broke if you do not do that. I broke mine and pal did too. After welding they worked good.

diirtbag · Jul 23, 2009

hey sunbather do you have any more pics of your tunnel mods

sunbather1969 · Jul 23, 2009

yea

send me an email and ill send ya some

1Mike900 · Jul 23, 2009

How much does the original bumper assy weigh? Did you cut the side brackets shorter on the rear exchanger, Or completely off? Do you think it can be riveted back on, Instead of using the original bolts? Or is yours mounted into the bumper assy?

Thanks
Mike

76FOMOCO · Jul 23, 2009

Bearcat said:
I used -09 gussets too in my CF7 -06. You need to weld them to rolls as they will broke if you do not do that. I broke mine and pal did too. After welding they worked good.

Thanks for the input i will have them welded before the season as i did cut a fair amount out of them. I to added a 2"x1/8"x36" inner support to the tunnel to help with the flex and did cut the cooler supports off about 3/4 of the way and added a rivet on the cooler cover to help support it.
I don't think your will loose weight with this mod but will gain the side hill and loose extra flotation under deep powder with the boards tunneling you out.

Nate · Jul 23, 2009

You're still holding onto that thing??

76FOMOCO · Jul 23, 2009

yep, until you have something without a turbo to put the beatin to it or can out climb it for less then 3x the cash stuck with the turd.

Twostroke · Jul 23, 2009

turned out sweet.

Rixster · Jul 24, 2009

Did you build the cover for the heat exchanger or buy it form some where? I have sheets of aluminum that I was going to build them out of but if you can but it somewhere cheap I might do that. ( I am not the greatest fabricator in the world)

KMOD · Jul 24, 2009

Very clean, good job.

76FOMOCO · Aug 9, 2009

ttt for ya tator

Turbotater · Aug 9, 2009

76FOMOCO said:
ttt for ya tator

Sweet!
I'll swing by next time I'm in the area and check it out first hand.
Looks good.

76FOMOCO · Aug 9, 2009

anybody else done something like this? how did it side hill after?

900 KK MC rear tunnel and bumper mod. for summer project

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