Tunnel repair, ideas wanted

[Vmax Al]

So the project sled I am working on (and man what a project it has turned into), '97 SX, has a tunnel that has a 10"x12" hole near the front from studs that were obviously longer than the protectors, see picture.

What would be a good repair?

The previous owner had duct taped a piece of alumninum over the hole to keep the gas tank from falling through but I am thinking I can do a little better than that.

Hate to bail and try to piece this thing out now but not sure I want to drill out and replace every rivet to replace a tunnel either, plus I have to find a tunnel.

Ideas appreciated....

Al

 

[Ding]

I probably have a tunnel that you could use, but really I would just rivet a piece of aluminum over the hole. That section really does very little as far as strength or supporting the gas tank unless the front is falling through.

 

[YamerDown]

^^^ yep. Just rivet the piece you have on. No need for overkill here.

 

[BETHEVIPER]

use polaris style tunnel protectors, they are aluminum, this will help keep your new piece of aluminum you repair the hole with from bowing down again in this trouble area.

 

[Vmax Al]

Thanks for the tips. I was thinking the same thing on structure, I think the pol tunnel protectors or something similar will do what I am looking for.

 

[Madmatt]

Square aluminum tubing

I have used 1"X1"X1/8th wall square aluminum tubing for tunnel protectors for years. Stiffens things up and works very well.

Madmatt