Bent tunnel help...repair or replace?

[dmaxd2500]

Hey guys I need some input as to what u think I should do with this tunnel. Is it worth trying to straighten and install new braces or should I just start over. The other side is bent too but not quite as bad. The kicker is, the bulk is bent also. Where the two halves come together right under the exhaust pipe its splayed open so I'm not sure what to do. I can get a new tunnel bulkhead chaincase assembly all pre-assembled from polaris for $2000. Any input is appreciated.

 

[freak485]

how did you do that? I would think replace maybe someone has a idea to brace it but looks like a good one.

 

[dmaxd2500]

Big rock sticking out of a creek bed, just under the snow. It hit dead center at the front of the bulkhead, right between the lower a-arm mounts. I'll get a couple more pics up tomorrow. Funny thing is I rode it for 3 months like that last season and didn't even know it till I went to put my airframes on. No noticeable performance or handling problems but I'm sure none of the drivetrain bearings were very happy. I'm leaning towards replace but if anyone has any good repair ideas I'm listening. Thanks.

 

[4Z]

Depends on your acceptance level. You could pound the buh-jesus out of to make it as flat as possible. Then put some kind of homemade patch over it or buy an over-lay from VEI or Fire-n-Ice. Or, pony up and buy the chassis from Poo... I don't see any other options....

 

[skibreeze]

Insurance, buy back, and do a new tunnel.

 

[dmaxd2500]

Well I'm not opposed to pounding the buh-jesus out of it but I'm afraid i'll never get it straight enough for my liking and it will never be quite right. On the other hand if I put a new one on it'll probly get f'd up on the first ride anyways so idk...that's my luck. I guess that's what insurance is for right.

 

[skibreeze]

Yup, I totaled out an 11 Doo and came out smelling like a rose.

 

[dmaxd2500]

I did get an insurance check to fix it without totaling it so I have the funds set aside to fix it right. Originally I was gonna save a few bucks and repair it and run it another season but when I got the skid and track out of the way today I realized the damage was more extensive than it looks from the outside, as is usually the case. The scale is almost tipped toward replace. Any solid arguments for repair out there?

 

[Sheetmetalfab]

......

Go aftermarket.
Add polaris bulkhead parts.
Stronger end result.

 

[mountainhorse]

Get a new one... brace as best as possible if you repeat often the situation that caused this.


.

 

[AKSNOWRIDER]

Actually..its a pretty easy fix...basically you put pressure on it exactly opposite of the way the damage was done(I lift them from the rear bumper, stack weight on the tunnel) then slowly work the damage out..its not about smacking it with the biggest BFH you have..its about slowly working the damage out with as little stretching as possible.. (I leave the sled as assembled as possible to unkink it).. using body hammers and dollies and working the creases out slowly in exact reverse order as how they got put in..it may even take using a portapower, or tying the sled down and pulling on it.. when done right..you will have a hard time telling it was buckled..with that said, you can go visit your local bodyshop and find the oldest grey haired guy they have and ask if he knows how to straighten sheetmetal without bondo..that's the guy you want to unbuckle the tunnel(in the old days that is how they fixed dents and it is an ART when done right).... If you search YZ400ez on here he has a thread showing fixing a bad bent bulkhead..there are several places making brace kits, Fastrax, me and a few others..For anyone who risk hitting things, its a good idea to do before you whack something.........Good luck...Mike

 

[dmaxd2500]

I've looked at aftermarket but there's nothing I've found that's really blowin my skirt up.

MH-I try not to make it a habit but you know, sh** happens when you party naked!

 

[dmaxd2500]

Thanks Mike, much appreciated. I fully understand the logic and theory behind what you're saying but I am by no means an artist and I just don't think it would turn out well if I tried to do it myself(although I don't really have much to lose). I can turn wrenches with the best of them but when it comes to body work I just don't have the touch. Finding an old or 'good' bodyman may be an option but I don't know any so I'd have to go hunting. Too bad you're up in the wild country or I'd just have you do it for me.....

 

[sledhead_79]

How deep are your pockets? Have you looked at van amburg? I would say replace, are you going to have the time to repair and get it straightened out enough to keep drive bearings happy. If I recall, the more metal is bent and straightened, the weaker it becomes.

 

[sledhead_79]

I am new to these Pro's, so is this bent tunnel issue something that is from '11-'13? I just looked at my '14 and there is a brace on the outside of both sides of the tunnel.

 

[AKSNOWRIDER]

Thanks Mike, much appreciated. I fully understand the logic and theory behind what you're saying but I am by no means an artist and I just don't think it would turn out well if I tried to do it myself(although I don't really have much to lose). I can turn wrenches with the best of them but when it comes to body work I just don't have the touch. Finding an old or 'good' bodyman may be an option but I don't know any so I'd have to go hunting. Too bad you're up in the wild country or I'd just have you do it for me.....

Read thru this thread..I like to unkink them in one piece..but you might do it this way instead....
http://www.snowest.com/forum/showthread.php?t=304993

How deep are your pockets? Have you looked at van amburg? I would say replace, are you going to have the time to repair and get it straightened out enough to keep drive bearings happy. If I recall, the more metal is bent and straightened, the weaker it becomes.

Actually, where they bend is behind where the driveshaft goes thru..so alignment isn't an issue( of course, yes it does need to be straightened right), and strength wise..once its straight you install a brace kit..and it will be way stronger then it was stock.....

I am new to these Pro's, so is this bent tunnel issue something that is from '11-'13? I just looked at my '14 and there is a brace on the outside of both sides of the tunnel.

its a issue with all pro's if you hit things..other wise its not an issue(hit anything hard enough on a ski/a-arm/bulkhead or tail land it hard and you can kink it right behind the driveshaft).. I recommend to anyone who is jumping/ hits things(trees/rocks) to add a brace kit before hand..I make one, but others do as well..now with that said I haven't seen a aftermarket tunnel yet for the pro that makes it any stronger at the bulkhead then what a stocker is..so regardless of what tunnel you need to make sure it beefs up the bulkhead joint......... oh, and while I haven't looked at a 14 close yet..I am sure it is the same as the earlier sleds.......Mike

 

[AKSNOWRIDER]

Go aftermarket.
Add polaris bulkhead parts.
Stronger end result.

Not really..when Mark did his van amberg(of course van amberg may brace the joint now), he ended up making his own bulkhead braces to make sure his didn't bend down the road...... I love some of the aftermarket tunnels, but I wouldn't install any tunnel on a pro without making sure I braced the bulkhead joint..
Mark(snodawg on here)...http://www.snowest.com/forum/showthread.php?t=318305

 

[Dirty Steve]

Isn't someone on here parting out a 2014 Pro? Might want to check out the SwapMeet.

 

[wjl]

Yes
Here bought some parts from him very easy to deal with. He may have one from the 13s he parted out last year.
http://www.snowest.com/forum/showthread.php?t=354228

 

[tinkerjohnson]

Tunnel

I would try to straighten it there have been a lot of guys have this same thing happen and like mike says the damage is behind the driveshaft so mis alignment is prob not an issue. Also he makes a really good kit for this and from the ones I have looked at they cover more area than most and are very well made they will cover all the damage area and tie more of the tunnel into the repair to make it even stronger. I bought his for my sled I'm going to install them now before it gets bent so I can hopefully keep this from happening. Good luck with your sled and wanna say thanks to mike for the quality kit he makes for this repair