Sounds like you have quite a set of plans for your projects, and they will be very interesting to follow! I will also start a build thread when I get a little closer to being done with my project. I just hate reading a build thread and then it stops and nothing happens for months, which is kind of where my project would be right now. I figured no one wants to see or hear about all of the sanding, filling, more sanding, more filling I've done on the tunnel plug!
As for what I'm doing to my 2007 Phazer, I am widening it to use a 15 wide track, 153 Arctic Cat float rear skid with 15x155x2.5 Challenger Extreme track, machined various parts out of titanium or high strength aluminum to replace steel, carbon fiber tunnel w/under tunnel exhaust, fixed a lot of the loose steering problems, etc. If I have time yet this summer, I would like to machine a titanium driveshaft and jacksjaft to reduce weight a little more, but I really need to focus on getting the tunnel done.
I have limited experience with carbon fiber work, so I have been learning as I go, and of course making a few mistakes along the way! Luckily, I have a good friend, also a sledder, who has been doing aerospace carbon fiber work for the last 15 years or so, which has been very helpful.
Currently, I am just sanding the tunnel plug to make the finish a little smoother, then I'll wax it up and start laying up a mold over it. Once the mold is done, I will be infusing the actual tunnel in the mold, and praying that everything works out! I was hoping to have it done this season, but recently bought another sled to ride instead, so the mad rush to get it finished is over. Now I'm hoping to be able to do most of the layup work when the weather starts getting warmer.
This has been my first sled project (using my first sled) and there are still a lot of unknowns, but I am confident it will be a very fun sled to ride when it's done! Of course, I also feel like it may never be done, there will always be something else to design and build for it...narrow A-arms, custom spindles, custom turbo setup, more carbon fiber body panels, belt drive...it could be a never ending project! But I am loving it, don't really regret diving in head first, just wish I had a workshop and that I didn't miss out on riding this season! Hopefully next year will make up for it!