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Old 01-17-2013, 08:35 AM   #1 (permalink)
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1999 xc500

i recently bought a sled with a long track mod on it. it came with a part of tunnel from a different polaris snowmobile and i need to put it on the snowmobile to extend the tunnel any ideas on how to do this without welding it on?
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Old 01-17-2013, 09:24 AM   #2 (permalink)
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Could someone please help with this issue it is very important to me
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Old 01-17-2013, 10:34 AM   #3 (permalink)
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Post some pictures of the tunnel extension and of your tunnel, maybe someone will have some ideas. Having never extended a tunnel, I'm not sure of what I would do. If it's something that you can take off the existing bumper and attach the other one using rivets, it will look more factory. If not, riveting braces to the existing tunnel may be an option, just make sure not to poke holes in the heat exchanger or cooling system...
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Old 01-17-2013, 11:42 AM   #4 (permalink)
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Ill post pictures tonight and i was thinking 4 small bolts through the side of the tunnel to hold it together
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Old 01-17-2013, 02:18 PM   #5 (permalink)
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Bolts work, but rivets seldom fall out
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Old 01-17-2013, 04:44 PM   #6 (permalink)
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this is the part im trying to put on
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1999 xc500-dsc_0178.jpg   1999 xc500-dsc_0175.jpg   1999 xc500-dsc_0176.jpg   1999 xc500-dsc_0177.jpg  
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Old 01-17-2013, 07:54 PM   #7 (permalink)
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i was thinking about welding it but that might cause some damage to the heat exchangers
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Old 01-17-2013, 08:08 PM   #8 (permalink)
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Line it all up like you want it, overlap the edges enough so you can drill holes and rivet it.
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Old 01-17-2013, 08:11 PM   #9 (permalink)
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lol thats what im thinking except use bolts instead of rivits
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