Originally posted by 76FOMOCO, reposted with permission:
O.K. I have had a bunch of questions on how to chop your tunnel down and what parts to get. So I put it all together in a step by step format along with all the parts needed from each manufacturer with part number and approximate prices. This is not an easy project so if your low on mechanical ability call your buddies with the skills and have them come over and help. This is for a 162” you can order the shorter versions of the parts if needed. I do sell the tunnel cap only and don’t make money off them so this is for the love of the cat and I only take pay pal or a POSTAL M.O.
1. Remove rear bumper, tail flap, rear tail light and seat but leave rear cooler attached and hanging by the hoses.
2. find location for the gussets I used the 4th rivet from the tunnel joint.
3, install the 16” splice for the tunnel cap using the 5 holes holding the rear exchanger in place and tape the rear cap in place and prop the gusset in place, place the rear bumper in line with the rear cap and the gussets.
4, chalk a line below the rear bumper with a pencil and cover with blue true tape above the cut line
5 at the location the bumper is to meet the gusset 45* change drill a 3/8” hole to keep the tunnel from cracking and help make the direction change.
6 drill out the lower cooler line rivets holding the tunnel coolers and about 5 rivets into the rear suspension bracket.(run new tail light wire before you rivet it) Rivet the rear inner supports into place
7 cut rails, cooler support and tunnel to match the rear bumper and gussets, make sure the tunnel is flush with the bottom of the rear bumper. (I used a ¼ cut off air grinder)
8 drill holes for the rear bumper and rear cooler cover mount tail light and rear flap and bumper.
Cat parts
5606-594 Gusset, Tunnel Roll – Right 9.00
5606-595 Gusset, Tunnel Roll – Left 9.00
5606-490 Roll, Tunnel – Right 32.00
5606-491 Roll, Tunnel – Left 32.00
Ski doo parts
518325375 Rear Bumper, 163" 40.00
(Used because it is the right width, and cheap)
Along with 6 metric screws from the hardware store 1.00 or order them from doo for 12.00
Tail light
http://www.bluhmenterprises.com/prod...category_id=87 20.00-40.00
Home depot support
2”x36”x1/8” total of 2 needed 8.00
Rear tunnel cap with 17” flat splice
35.00
And you will need a bunch of rivets too.
Original post removed at request of 76FOMOCO
O.K. I have had a bunch of questions on how to chop your tunnel down and what parts to get. So I put it all together in a step by step format along with all the parts needed from each manufacturer with part number and approximate prices. This is not an easy project so if your low on mechanical ability call your buddies with the skills and have them come over and help. This is for a 162” you can order the shorter versions of the parts if needed. I do sell the tunnel cap only and don’t make money off them so this is for the love of the cat and I only take pay pal or a POSTAL M.O.
1. Remove rear bumper, tail flap, rear tail light and seat but leave rear cooler attached and hanging by the hoses.
2. find location for the gussets I used the 4th rivet from the tunnel joint.
3, install the 16” splice for the tunnel cap using the 5 holes holding the rear exchanger in place and tape the rear cap in place and prop the gusset in place, place the rear bumper in line with the rear cap and the gussets.
4, chalk a line below the rear bumper with a pencil and cover with blue true tape above the cut line
5 at the location the bumper is to meet the gusset 45* change drill a 3/8” hole to keep the tunnel from cracking and help make the direction change.
6 drill out the lower cooler line rivets holding the tunnel coolers and about 5 rivets into the rear suspension bracket.(run new tail light wire before you rivet it) Rivet the rear inner supports into place
7 cut rails, cooler support and tunnel to match the rear bumper and gussets, make sure the tunnel is flush with the bottom of the rear bumper. (I used a ¼ cut off air grinder)
8 drill holes for the rear bumper and rear cooler cover mount tail light and rear flap and bumper.
Cat parts
5606-594 Gusset, Tunnel Roll – Right 9.00
5606-595 Gusset, Tunnel Roll – Left 9.00
5606-490 Roll, Tunnel – Right 32.00
5606-491 Roll, Tunnel – Left 32.00
Ski doo parts
518325375 Rear Bumper, 163" 40.00
(Used because it is the right width, and cheap)
Along with 6 metric screws from the hardware store 1.00 or order them from doo for 12.00
Tail light
http://www.bluhmenterprises.com/prod...category_id=87 20.00-40.00
Home depot support
2”x36”x1/8” total of 2 needed 8.00
Rear tunnel cap with 17” flat splice
35.00
And you will need a bunch of rivets too.
Original post removed at request of 76FOMOCO
.Well it bent down after 10 hrs of hard labor when I sat on it.So technically it didn't fall off just looks like it ready to.It picked up fine guess more rivets and duct tape is needed ,.Will weld the coolers together in morning and rivet some flat bar on the inside and hopefully that'll fix it.And add a ton of rivets.
the basher cat was being born.Stock Cat bumpers are bolted to the cooler and the rivets never fell out of it then so should be ok now.
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