08 dragon needs new tunnel rear section...help!?!?

[Shelfrost]

My buddy has an 08 Dragon 155. Well, it didn't stand up too well to the old M7 162 landing on the back bumper after a jump. I bent the tunnel and coolers almost down to the track. Needless to say, I need to find a replacement section for his sled.

Surely some of you Polaris fellas have replaced just the rear sections of these one-piece tunnel before in order to repair broken tails or extend your track sizes. What has been the best way to go? I see VanAmburg has something available, but I would like to see some other options. I want to fix him up without breaking my bank account or spending 50 hours replacing a tunnel. Thanks in advance for all your help!

 

[rydningen]

If you have bent the tunnel coolers i guess youll have to replace the tunnell.

See if you can get a replacement tunnell from someone which has gone with an aftermarket one like Van Amburg. Doing this does take alot of time, but if you want to make it cheaper than buying an whole new chassis (1000$) I guess you have to be prepared to use some time one it.

 

[Shelfrost]

Well, we've bent the tunnel back up and braced the insides to keep it strong. One little coolant leak that we will weld up and make it rideable for the remainder of the year. I'm still looking for an easier way to fix it up and make it look good. I fully expected some of the Polaris turbo riders to have either ripped the back halves off the tunnels or extended them for a longer track. Hopefully they will have some suggestions. Thanks again!

 

[Shelfrost]

No one has worked on these Dragon tunnels?

 

[dan8485]

Here is the probelm with the dragon tunnel and just replacing parts of it..... The tunnel is a 3 piece set up, 2 side pannels and a top plate which contains the coolers. The pieces are full length and have no breaks in them. Depending on where it is bent you pretty much have to replace the whole entire tunnel or just cut away the portion of the sides and add the VE Tunnel Kit which adds pannels to the sides as well as a bumper and new running boards.

http://vanamburgonline.com/catalog/product_info.php?cPath=70&products_id=341

http://vanamburgonline.com/catalog/product_info.php?cPath=66&products_id=280

Good Luck to you but my guess is you will be replacing a whole tunnel

 

[Arcteryx]

I did the same thing to mine, well landed upside down anyway, but bent the tunnel and coolers in half down to the track. We bent it back up and braced it and it worked well for the rest of the season. I was looking at the various options and Carl's in Boise had a take off that was in great shape. It was only a couple hundred bucks. Was going to buy it but ended up center punching a tree and the sled was a goner.
Anyway, might want to call Carl's and see if they still have it. Might save you some money.

 

[AKSNOWRIDER]

I have reinforced a few tunnels up here, but if it kinks the coolers you are in need of a tunnel..heres a pic of my dragon i just sold...

I just built some of these for the pro 155's..and am gonna start on some for the 163 pro's here shortly..

 

[Shelfrost]

I have reinforced a few tunnels up here, but if it kinks the coolers you are in need of a tunnel..heres a pic of my dragon i just sold...
I just built some of these for the pro 155's..and am gonna start on some for the 163 pro's here shortly..

That looks really good, could you make another for a reasonable price? I would be very interested. We were able to straighten the coolers with just a small leak to be welded up. No worries there.

 

[AKSNOWRIDER]

I just made a set of the sides only (with rear bumper) for a 155 dragon, total cost 450 plus freight without powder coating..I will see if i can find a pic(rear bumper is done similar to a cobe bumper with a lower rod to keep snowflap off the bumper when stuck..........his was without the gas rack.but can do them either way...the rack adds slightly to the price(about 25 due to the extra time on the waterjet to cut it)...these also tie to the bulkhead to make sure the tunnel is stout..frt to rear...

 

[Shelfrost]

How are you tying it into the bulkhead? And a picture of it would be nice. Thanks.

 

[Mag]

These are the tunnel supports designed by Aksnowrider the supports run all the way to the front of the footwells. Thanks again Mike

 

[MORSNO]

Looks great Mag. Mikes fabrication skills are awesome. Did you incorporate the rear bumper into the supports like Mike did on his old Dragon, or is that a seperate bumper? I like how solid his was...I pull sleds occasionally too.

 

[Mag]

Looks great Mag. Mikes fabrication skills are awesome. Did you incorporate the rear bumper into the supports like Mike did on his old Dragon, or is that a seperate bumper? I like how solid his was...I pull sleds occasionally too.

The bumper is part of sides nice and clean, I had bent my tunnel just behind the seat supports, straightened it all out and put these on. I took alot harder hits with it last weekend than I did when it bent and everything held up great!