straightening a tunnel

dnale

dnale

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Joined
Jun 11, 2003
Messages
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Location
South Lyon, Michigan
Ok the time has come for me to fix my sled. I need to straighten the rear of my tunnel. I landed the sled on the rear bumper and it kinked both sides where the bumper attaches. I pulled everything off and the heat exchanger is fine. Right now I just need to know how to get this tunnel back in shape. I have a hammer and dollies but haven't tried them. I've put my channel locks on there and tried to pull it back some it but it hasn't helped much. I'm open to anyone's input.

Thanks.
D
 
I used to do that all the time with my 78 Exciter 440.Sometimes with 2 people on board.Used to jump driveways and would land on the tail end with my passenger sliding right off.Never ever had damage with the old beast.I guess they don't make as strong as they used to...lol.Good luck with your fabrication there.
 
I was thinking of making some wood jigs to pound in to spread things back out once I started. First thing is I think I need to drop my skid out for more room.
 
Getting some pics of the damage will give the guys on here a better way of approaching the tunnel fix.It might not look pretty when it is done,but it will be functional at least.Changing the whole tunnel would be a real challenging job.How much damage you think there is in$$$$$.Wouldn't insurance help you out at all?
 
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I have fixed a few kinked and bent tunnels, you have to remove the heat exchangers, bumpers, tunnel cap ends, whatever is attached to the tunnel in the damaged area. Then using a large 6x6 for a base, place the 6x6 under the damage, place another peice of 2x8 or something over the top and beat it with a heavy hammer or sledge, by striking the wood and not the tunnel itself it wont make stretch marks in the aluminum and will get it flattened back out.

Also a tip to get the rolled edge of a running board straight again is to insert a small steel rod into the rear and drive it thru the kink, it straightens them right out. For some really badly kinked ones I used aluminum solid rod and drove it in and left it in to gain back the strength of the roll/support to running board, you cant tell they are fixed if you take your time and remove all the parts attached. make sure you repair the parts to be reattached if they are bent or they will pull your newly straightend tunnel back when you repop rivet them in.
 
The rolled edge of the foot board isn't bent at all. It's right at the rear of the tunnel. I was able to pick up all of the pieces pretty cheaply and I dind't want to deal with insurance. They would have totalled it out, I know. I could have gone through the whole deal of buying it back and such but then it would be a salvage title. Probably this weekend I'll have the photos taken.
 
Tunnel

Yamahowie had the same problem. The rear of the tunnel was bent up on his viper. He ended geting a whole new tunnel and replacing it. Talk to him if you want.
 
Do you have any pics for us to see...is your suspension still in one piece.How hard did you come down on it anyways.As long as you didn`t bend your rear axle or damage any of the rear wheels,or twist the rails.Make sure you check all that to.
 
No pics yet. It's buried under camping gear right now. Probably first of next week after our Memorial Day holiday. I didn't notice anything bent/broken in the suspension.
 
dnale said:
Then you'd have to change registration etc.... The numbers are on the tunnel.
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i wouldnt see how it would really matter. people change to aftermarket tunnels. me, personaly, never heard of anyone having to change the registration, but not positive on that :dunno:
 
The tail of the tunnel has no function except to hold the bumper and the snow flap on, and possibly a rear cooler if so equipped. Take it from someone who has changed a few tunnels . . . Only do that if you really have to. Simply straighten what you can or add a modified extension to the current tunnel. if it is bad enough. If you simply straighten it, it will bend easier next time.
Now if you are a sled modder that changes tunnels all the time, and are set up to do it, then it would be no big deal. I am guessing you are no, hence this post.
 
fasttoys17 said:
i wouldnt see how it would really matter. people change to aftermarket tunnels. me, personaly, never heard of anyone having to change the registration, but not positive on that :dunno:
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The VIN is stamped into the tunnel. At least in Michigan the authorities like the numbers on the registration to match the numbers on the sled. Otherwise they like to impound the sled until they can determine if it is stolen or not.

That said, I know of a large number of sleds whose numbers don't match the registrations. Personally I don't like to risk losing the sled.
 
I wrecked a sled and replaced the tunnel. New ones come with out numbers and you stamp your old numbers on, so no need for new title if going that way. If I was buying a used tunnel I would sand off the numbers and stamp new ones on to match my old numbers. Just a suggestion, not legal advice.
 
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