Cut Your Tunnel Without Welding It Back Together

[tmberro]

I'm going to assume the lack of response means no on-snow testing has been completed?

 

[Sheetmetalfab]

I'm going to assume the lack of response means no on-snow testing has been completed?

Your best bet might be to call them?

 

[Chadly]

I wonder when they are going to start shipping them. Anyone get a kit yet? I ordered it back when this was first posted...

 

[Woody1992]

I wonder when they are going to start shipping them. Anyone get a kit yet? I ordered it back when this was first posted...

Will get my kit in 2 weeks in sweden, just worried about the warranty when the 850 engine blows up, maybe it depends on dealer if that will be a problem?

 

[Motorbreath_]

Your best bet might be to call them?

Good luck with that.. These guys are impossible to get in touch with, especially in the winter season.

 

[slash]

Just how much are you cutting off the stock cooler 8" 10" not 15" or 20"
so a good cup or 12 oz coolant ?

 

[BG567]

Got my tunnel mostly finished up. Cut 6” off of my 163 tunnel. Mounted the bumper 1” further in then stock (the kit gives 2 mounting options). Process went relatively smoothly, just be sure to take your time. Definitely stressful to make the cut! My heart was pounding when it came time to chop my 1 year old sled!

Sent from my iPhone using Tapatalk

 

[goridedoo]

Got my tunnel mostly finished up. Cut 6” off of my 163 tunnel. Mounted the bumper 1” further in then stock (the kit gives 2 mounting options). Process went relatively smoothly, just be sure to take your time. Definitely stressful to make the cut! My heart was pounding when it came time to chop my 1 year old sled!

Sent from my iPhone using Tapatalk

Just curious, what did you make the cut with?

 

[BG567]

I used a 5” aluminum zip disk on a grinder. Worked well enough. Ideally an aluminum blade on a circular saw would work better. But those blades are pricy.


Sent from my iPhone using Tapatalk

 

[sno*jet]

Chris buradnt make people do crazy things.

 

[turbo RMK]

I hope that rear support is strong enough because that crossover coolant section imo is what holds everything together back there so when you cut that out and only add a thin plate to cover the hose I’m thinking you lost strength only way I think to add some back is a strong aftermarket bumper

 

[damx]

Imo if you cut the tunnel you need to do something about the bumper. It looks like your bumper and track are almost flush with each other. If your bumper grab handle is on a 45 ish degree angle i think it would work better, your bump is still going to be in the way. Thanks for the pictures though, I'm thinking about the same kit.

 

[Wheel House Motorsports]

I used a 5” aluminum zip disk on a grinder. Worked well enough. Ideally an aluminum blade on a circular saw would work better. But those blades are pricy.


Sent from my iPhone using Tapatalk

Standard demo wood blade rips through aluminum with ease. Cut a lot of aluminum on my regular wood chopsaw with total ease. Same goes for running a sawzall or skill saw thru sheet/extrusions like this.

 

[live2beel]

How do you keep the aluminum shavings out of the radiators and engine?

 

[Wheel House Motorsports]

How do you keep the aluminum shavings out of the radiators and engine?

Lift front of the sled then pump water down through the cooler inlets up in the front. then blast some compressed air down behind it a time or two. comes out pretty nice

 

[BG567]

I hope that rear support is strong enough because that crossover coolant section imo is what holds everything together back there so when you cut that out and only add a thin plate to cover the hose I’m thinking you lost strength only way I think to add some back is a strong aftermarket bumper

With the new rear tunnel cap section that comes with the kit it is very strong. I am impressed. It ties in further down the inside of the tunnel sides, and the hose protector under add another element of strength to the rear.

 

[damx]

BG567 can you post some pictures of the hose protector bracket part installed ?

 

[freerideordie]

I cut 5.5” off my 155. I used the mntk “tunnel shortening kit”. On the first ride in November I noticed the track can hit the crossover guard, I didn’t think much of it. Now after 15hours of riding the track has hit the guard hard enough, and enough times to break the seal on the glue in adapter. Not sure what my plan is now. You would think that mntk would have designed the kit thin enough to clear...


Sent from my iPhone using Tapatalk

 

[freerideordie]

Sent from my iPhone using Tapatalk

 

[Chadly]

They had no testing on the snow with this. They used Polaris' business model and it worked. I own the kit but it will be on the shelf until next year.