tunnel replacement

J

jordan

New member
Joined
Dec 18, 2008
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173
Age
38
Location
saskatchewan
hey guys bent my tunnel today bad! now i was wondering how big of a job it is to change it out and what does a tunnel go for and should i go factory or aftermarket
 
I would try to fix if possible. The vin is stamped on the tunnel so if you get a new one you will have to reregister it. But if you have to replace it punch out the mandrels before you drill out the rivets, also use yamaha rivets when you put it back together (i think one of the guys on this site sells them). good luck
 
Fabcraft makes a very nice tunnel for our sleds. They are available in 121" to 166". I don't know how much a Yamaha tunnel is, but the fabcraft is $900US for a standard tunnel, and $1350 for a tunnel built with running board coolers, and a U-shaped cooler in the rear already installed. I still might pick one up next year for my 144" SRX build.

http://www.fabcraft.com/partlist2.php
 

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ok thanks i dunno if i want to spend that much on it but i just pulled it pretty much straight and i was thinking of getting a metal shop to make me up some aluminum reinforcements to rivet along the side
 
If you can straighten it well enough (measure it, don't just eye it) then reinforce it, it is way easier than replacing the tunnel.

To replace a ProAction chassis tunnel you will need to pull the engine jackshaft, driveshaft, chaincase, gas tank, belly pan, and heat exchangers. Drill out a couple hundred rivets and you are there. Depends on what you consider a big job.
 
yeah its not bent where anything important mounts its bent aout 4-6 inches back from the rear skid mount so i got it relatively straight for now i gotta do the precision work yet
 
What Happened?

Jordon - What happenened? Inquiring minds need to know. Did you go off a jump - sled stood straight up - you said holy shit and let go - and the sled landed on the tail. Seen it three or four times now. Please do tell.
 
A good easy way to get it pretty straight is to use a car's screw type jack, with planks or something on either end...so you twisy the jack, and it slowy presses outwards, but not causing a new dent or bulge...

From there maybe a hammer and...anvil? the metal piece on the other side..whatever they call that
 
Heres what mine looked like, before and after.
 

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Just finished putting a new viper tunnel onto my 02 SRX... Happened to catch a culvert going up side of highway. Stoped the sled dead but I continued on... Needless to say there was a ton of damage. The nice thing about swaping out the tunnel is you get to know every inch of your sled and as it goes back together it gets to look like new again! (Degreased / Polished)
Replacing tunnel is not a bad job if you have 1) Time, 2) Heated Shop, 3) Air Chisel, 4) Air Riviter.
I have been taking pics as I go and will post in working log once parts get back from powder coat. Good luck with yours!
 
you gotter mac big jump+stupidity=f'ed up tunnel but its lookin alright now the good thing is it didnt hurt the coollers at all
 
well a friend of ine owns a welding shop and he does aluminum work so he is building me to aluminum plate/reinforcements to go on each side of the tunnel then i think i may decal them to make them look a little better
 
oh and in case anyone wants to know a new rear section of tunnel i imagine thats belly pan back is 1080.00 dollars canadian from yamaha not cheap
 
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