So as many of you might already know, I picked up a 2005 M7 with a bent bulkhead. Instead of trying to straighten out what the front of the frame I went ahead and purchased a brand new bulkhead. Once I drilled out what seemed like a million rivets I was finally ready to assemble the sled back together. Instead of leaving the tunnel in the stock form, I purchased a roll of 3M Dinoc Carbon Fiber wrap that I am wrapping the entire sled in. I've already got the tunnel down and I was more than happy with the end result. I was worried about the vinyl wrap peeling later down the road so I did everything I possibly could to prep the aluminum before primering. Sanded down with a rough grit to get good primer adhesion, layed a light layer of Zinc Chromate Primer. This stuff is extremely durable and prevents any type of corrosion or oxidizing occuring in the aluminum. Once that had cure, it was time to go ahead and lay out my wrap. Some patience, a little heat, and a whole lot of squeege'in, I came out with a good result. Once the tunnel was wrapped, I attached my bulkhead to the tunnel. I ended up fabbing my own steering post support brace. There is a plate on the top and a plate on the bottom. I originally was going to use only one plate but after discussing with some of the forum members, I ended up sandwhiching the two together. Shout out BACKCOUNTRY for his input! I had to get a slimmer nut to fit on the bottom of the steering post shaft since the extra aluminum I used ate up some of the threads on the ball joint. After all said and done, the thing is stout as hell and I shouldn't end up with a cracked tunnel at the end of my riding season. More than likely when I get the motor mounted back in Im going to make up a steering hoop brace that should tie everything together and make this steering setup stronger than hell. You can see in the pictures where the existing running boards, there getting cut out, and a set of running boards im buildling will be going in its place. The running boards will be similiar to the open board style that the Airframes are producing. I've got a few little tweaks and ideas Im going to do to try and make the best, strongest, running board I can for this sled. I bought the newer style tunnel from the 09's to replace that bulky snow holding tunnel they had for the 05's. Now this is where I've got a couple questions. I plan on using my existing cooler and flattening it out. I've read that you have to cut part of the cooler tubes in order for this cooler to slide far enough forward that it's not hanging out the back? If I do this, I will have to cut into the cooler tubes where the finned parts are. I am assuming you eithier grind the fins down so that your rubber hose fits over? Or are you welding a new section of pipe onto the ends for your rubber hose to slide over? Second question is more of an opionon, I Havent laid the rear section of carbon fiber wrap on the tunnel. I was looking at it and I was debating whether to run the wrap with the weave in the same direction, or 90 degrees aganist the weave? It kind of breaks it up a little bit and gives it a different look. Anyways thats enough typing for now, let me know what you guys think, I should be getting my boards done this weekend and the thing will really start coming to life!
I am looking for the hardware to fasten to the top of the boards for traction. Ice studs or some other products were the ones I was looking at. I eventually plan to have these powdercoated. One more to go and the hard part will be done!
