Been there, done that
Changing the front heat exchanger isn't bad, it just takes lots of time and beer. If you cut yours, let me know, I have a couple. I've been toying with the idea of trying what you are doing myself. As a side note, I have been using 1" square by 1/8 wall tubing for tunnel protectors for years. I think they work great. I would have to take a look but I think I have front and rear heat exchanger protectors for your sled. How about $40 shipped? Let me know if you are interested. If so, I'll take some photo's.
Madmatt