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Bent Tunnel Pics

4Z

Well-known member
Lifetime Membership
Good grief, I know the tunnels were light.... Maybe I am the only one?

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Your not the only one. Talking to a friend on the weekend, he said he would like to buy a pro but said it wouldn't last a season. I believe him. These guys aren't abusive, they just ride em hard. Light? yes, durable? no.
 
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Ouch man. Mine looks like that, but not near as bad. Same with my buddies 13. Mine can probably be straightened which is the plan for this summer. Definitely a weak spot on these sleds. Any companies make a brace for that area?
 
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Yikes!

Mine did the same thing from a very minor hit. I took it all apart and put in KMOD/Fire-n-ice gussets. They are .100" 7075-t6 aluminum that are an exact match to the existing pieces. I recommend them...
 
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Not NEARLY as bad as yours. Mine came out very easy - Bolted in the driveshaft and front cross shaft of the suspension and then pressed the tunnel back out with a porta-power. Clamp, drill, and rivet new pieces on. I'll post another picture of the finished product when I get home tonight.
 
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4Z you should have another talk with those contacts of yours. I personally see a real market for the Carbon Fiber tunnel panels like they used to produce. They could just remove the rivets and glue from the tweaked aluminum and replace with the Carbon Fiber skins. Just as light and even if they went twice as thick or more in the needed areas it would still be lighter. Just a thought, that is the direction I'm headed in but too many other irons in the fire to be a timely fix for your sled.
 
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When FTX built that Rush into a mountain sled, the carbon fiber tunnel sides/running boards went past the footwell connecting the chassis together MUCH better than the factory has done..

Honestly I can't believe Polaris didn't do the same thing. It's so easy and obvious that that little piece of material adds a TON of rigidity to the chassis.

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Here is mine..Pics are from How badly it was bent and the process of straightening it out, to the final result of making it better and A LOT more rigid than ever before. These tunnels are weak and the stock bracing is no stronger than an aluminum can.. Can't say it was an easy fix, but wasnt too bad.. Just have to strip it down a bit.. Then get the Bracing from AKSNOWRIDER to ensure it doesnt happen again. I also used Lords when putting it all back together.


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yup same thing happend to my sled after an small inpact on the left ski.
and my friend got the same dent after an hit with a rock....
Need to brace it but ho sells kits for it ???
 
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KMOD/Fire n Ice

Here is the outcome. I haven't installed the mag side yet. The PTO side overlays over the existing plate and goes to about the center line of the driveshaft and jackshaft. The mag side replaces the OEM plate. Mine wasn't bent and I didn't feel like ungluing my chaincase just to fix something that wasn't broke.

Sorry about the rotation. I'm having a heck of a time uploading pictures to SnoWest with my new Mac... They show up correctly rotated for me:face-icon-small-con
 
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Ouch man. Mine looks like that, but not near as bad. Same with my buddies 13. Mine can probably be straightened which is the plan for this summer. Definitely a weak spot on these sleds. Any companies make a brace for that area?

Pretty sure K-MOD, makes a brace for that area.
 
I'm having a heck of a time uploading pictures to SnoWest with my new Mac...

LOL... once you go Mac, you never go back....

Thanks to all so far. I think Tory is right, the best/strongest approach is like what FTX was doing back in '11 with that Rush conversion. Triangulating that horizontal plane and incorporating a QD/Chaincase cup would be serving more than one purpose.

Thank you Tory for the engineering solution!!! This is the path I will travel...
 
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