EDU: How to 09+ tunnel bumper conversion photo fortress (The cheap way)
- Thread starter Carbon77
- Start date
So I got my parts in the mail today:
Got the fastrax end cap set
Got the angle iron set in the tunnel bracket, these rivets are a pain in tha *** because they are at such an angle, I had to drill most of them from the tunnel.
And ran into another problem mockin up the bumper.
As you can tell, the bumper is set at the stock angle for the 09's and such right now, which is not really going to work, because of the excess I have left over from the 05-08 tunnel, In order to maintain strength, I think I'm going to have to cut some slots out of the stock flap, since it is much wider than the 05-08 flap in order to put the bumper down on the tunnel. Yeah it sucks having the bumper this low, and I cant tie the fastrax end peice in with it. I think that will have to work the best for me.
As you can see the flap is in the way, I think if I cut out 2" slots from each side, it should be fine.
Great leason for all. I'm glad you swallowed your pride and posted up the issue for everyone to learn from. Big props goes out to you man.
Looks like it should be a solid setup and cutting a little off the flap is not going to hurt it. Like said above, wires match. I just updated my 06 and wish I would have done it right when I bought it 2 years ago.
Looks like it should be a solid setup and cutting a little off the flap is not going to hurt it. Like said above, wires match. I just updated my 06 and wish I would have done it right when I bought it 2 years ago.
I'm trying to keep as much strength as possible by keeping the bottom half of the bumper on.
W
W A O
Well-known member
With alum when you cut it at close to right angles that roundrd area you left helps out a ton, you could even cut it on more of a strait angle but just stay back a half an inch on both sides and just round that little bit thats left. the two strait edges when they meet just want to rip apart.
A little more of the round edge like you did is even better but you can cut it closer if you chose. The second time around is a dam good job and you should be proud of that job done right.
The other guys were not picking on you just trying to help, well ok maybe a little.. Did my rear bumper this way but with BDX side gussets and still holding great after 4 years.. Good job thanks for the post.
A little more of the round edge like you did is even better but you can cut it closer if you chose. The second time around is a dam good job and you should be proud of that job done right.
The other guys were not picking on you just trying to help, well ok maybe a little.. Did my rear bumper this way but with BDX side gussets and still holding great after 4 years.. Good job thanks for the post.
Got the 09 tailight wired up last night.
Yellow-Yellow
Red - Blue
Brown - Black
Also notice i used heat shrink tubing around it to keep the water out, also used electrical tape over that.
Got the flap mounted, and ready to put the bumper on tonight. I used all stainless steel rivets and luckily our shop had one of these: http://www.amazon.com/Marson-39010-BIG-DADDY-Riveter/dp/B000HAWKTM it was a life saver because those stainless rivets are a mother to break with a hand riveter.
Yellow-Yellow
Red - Blue
Brown - Black
Also notice i used heat shrink tubing around it to keep the water out, also used electrical tape over that.
Got the flap mounted, and ready to put the bumper on tonight. I used all stainless steel rivets and luckily our shop had one of these: http://www.amazon.com/Marson-39010-BIG-DADDY-Riveter/dp/B000HAWKTM it was a life saver because those stainless rivets are a mother to break with a hand riveter.
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What year is your sled? The tail light wires on my 06 M7 were exactly the same as the '09 LED wires.
I will have an air rivet gun before I ever tackle another tunnel. I did about half of mine with a hand one; ended up finishing it at a buddy's with an air gun and wow I would have saved a lot of time if I just did the entire project there.
I will have an air rivet gun before I ever tackle another tunnel. I did about half of mine with a hand one; ended up finishing it at a buddy's with an air gun and wow I would have saved a lot of time if I just did the entire project there.
Critics???
There is a difference between being a critic and knowing the possible results, enough said.
Thanks for adding the extra info so others can learn from the experience.
It is an 05, So my wires must be different. Yeah, the bigger riveter has worked good, but an air riveter would be really nice.
Used Cleco fasteners to Set the bumper and marked out where all the previous holes are with tape so I'd miss them. Also used the rivet holes for the cooler to mount the top of the flap.
Threw the sled on its side to finish out the rivets on both sides.
Finished product:
I'm happy with the way it turned out, if I would have done this over, I probably would have gotten VE bumper honestly for the extra $$$ so it could tie in the sides with 3/16ths aluminum and be stouter than this, Or gotten a close out peice made custom that would go over the full height of the back under the flap and cooler. I think for what it is though the tunnel will be stout enough to hold a set of skis, or whatever else I throw on it. I'll get her tested out tomorrow and see how it all works.
Threw the sled on its side to finish out the rivets on both sides.
Finished product:
I'm happy with the way it turned out, if I would have done this over, I probably would have gotten VE bumper honestly for the extra $$$ so it could tie in the sides with 3/16ths aluminum and be stouter than this, Or gotten a close out peice made custom that would go over the full height of the back under the flap and cooler. I think for what it is though the tunnel will be stout enough to hold a set of skis, or whatever else I throw on it. I'll get her tested out tomorrow and see how it all works.
looks better but still a little leary of the bumper not going far enough forward, should work for a while though.
I give you props for keeping us informed dude, that took some balls.
Did you happen to install fishplates on the inside of the tunnel extending the area of strength at the tunnel seem? It helps spread out the forces/energy that the short bumper won't do.
When you get your hookers/ skis/ gas/ bails of cocaine on there again, I'm sure you'll keep an eye on it. I feel that A long VE bumper will solve this problem, it adds strength to not only one of the bends in the tunnel but to both. The angle you put in only ads strength to one bend--- the bottom side of the tunnel where the forces are not directly pounding on.
When building structures, you don't support a secondary beam and wait for the primary beam to sag into it...
Again, mad props for keeping us informed. This is just my opinion...
Did you happen to install fishplates on the inside of the tunnel extending the area of strength at the tunnel seem? It helps spread out the forces/energy that the short bumper won't do.
When you get your hookers/ skis/ gas/ bails of cocaine on there again, I'm sure you'll keep an eye on it. I feel that A long VE bumper will solve this problem, it adds strength to not only one of the bends in the tunnel but to both. The angle you put in only ads strength to one bend--- the bottom side of the tunnel where the forces are not directly pounding on.
When building structures, you don't support a secondary beam and wait for the primary beam to sag into it...
Again, mad props for keeping us informed. This is just my opinion...
DP2826: Is yours a 153? My bumper cannot go any farther forward otherwise there would be no room for my hands to get inbetween the flap.
I have not gotten the plates underneath yet. I'm still in the process of building the ski rack for it, and with bolting those onto the tunnel I will add 3/8ths plates on the underneath. Took it for a 30 mile ride yesterday, No problems But did not haul any Skis.
Thanks, I figured someone else can learn from my costly mistake too.
I have not gotten the plates underneath yet. I'm still in the process of building the ski rack for it, and with bolting those onto the tunnel I will add 3/8ths plates on the underneath. Took it for a 30 mile ride yesterday, No problems But did not haul any Skis.
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