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Old 12-04-2017, 12:32 PM
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Default Cracked rear tunnel

Iv got a 163 thats got a crack in the rear of the tunnel where theres a factory drilled hole in the rolled edge at the end of the inside bracing. Its being brought to a local welding shop to be welded, sled is still under warranty but not putting any faith into polaris to repair it.
Im looking for info on a good bracing kit that i could put on the side ,perhaps with the rolled lower edge to reenforce the tunnel and cover up the repair after welding.
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Old 12-04-2017, 12:47 PM
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Any pictures of it?

Might go with a BM Fab rear bumper- they extend down to rolled edge and all the way forward to running board support.


The welder needs to be really careful with the amount of heat used-- you don't want to weaken the tunnel around the weld.
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Old 12-04-2017, 01:44 PM
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I like the Mountain Armour rear bumper (made here in Wyoming) and have it on 4 sleds now and really does good job of tunnel braceing!
gtwitch in wyoming
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Old 12-04-2017, 05:21 PM
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How big a tunnel bag is on it, how many lbs of stuff is in it, and how far behind the seat brace/rear suspension mounting bolt is it?

Pix will tell a story for sure.
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Old 12-04-2017, 07:40 PM
snobyrd snobyrd is online now
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How big a tunnel bag is on it, how many lbs of stuff is in it, and how far behind the seat brace/rear suspension mounting bolt is it?

Pix will tell a story for sure.
no storage bag or jerry can. The crack started in the rivet hole on the curl where the last inside brace stops.
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Old 12-04-2017, 08:19 PM
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VanAmburg will make a full length custom tunnel brace/bumper combo. Nice piece and very solid.
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Old 12-05-2017, 02:22 AM
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Originally Posted by Murph View Post
Any pictures of it?

.....

The welder needs to be really careful with the amount of heat used-- you don't want to weaken the tunnel around the weld.
Polaris and most manufactures use 5052 aluminum for the formed portions of the tunnel which is not a heat treated nor a heat treatable alloy. Welding will not effect it's strength (positively or negatively).

Depending on what direction and how far the crack has propagated, I'd consider stop drilling it and calling it good. As running a weld over the top of the crack will do nothing beneficial other than lighten your wallet and give you a false sense of security. If the crack is not stop drilled and 100 percent fused back together, it has a good chance of coming back.
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Old 12-05-2017, 11:14 AM
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Quote:
Originally Posted by LoudHandle View Post
Polaris and most manufactures use 5052 aluminum for the formed portions of the tunnel which is not a heat treated nor a heat treatable alloy. Welding will not effect it's strength (positively or negatively).

Depending on what direction and how far the crack has propagated, I'd consider stop drilling it and calling it good. As running a weld over the top of the crack will do nothing beneficial other than lighten your wallet and give you a false sense of security. If the crack is not stop drilled and 100 percent fused back together, it has a good chance of coming back.
Awesome--thanks for the info!
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Old 12-05-2017, 12:08 PM
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The crack is being welded today, its mostly for lipstick, we're putting a vanamburg product on it to cover up the repair and strengthened up the sides. We get stuck alot and i guess the constant lifting on the bumper has taken its toll. Moving foward, we need to buy rear tunnel stiffeners to avoid this issue.
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Old 12-05-2017, 01:03 PM
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Quote:
Originally Posted by LoudHandle View Post
Polaris and most manufactures use 5052 aluminum for the formed portions of the tunnel which is not a heat treated nor a heat treatable alloy. Welding will not effect it's strength (positively or negatively).

Depending on what direction and how far the crack has propagated, I'd consider stop drilling it and calling it good. As running a weld over the top of the crack will do nothing beneficial other than lighten your wallet and give you a false sense of security. If the crack is not stop drilled and 100 percent fused back together, it has a good chance of coming back.
All good info except the bolded statement.

How does strain hardened aluminum not get its base strength reduced due to welding? Weldability shouldn't be confused with post weld strength.
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Old 12-05-2017, 02:53 PM
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Old 12-08-2017, 02:24 AM
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Old 12-08-2017, 08:43 AM
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Old 12-08-2017, 10:18 AM
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Old 12-12-2017, 06:35 PM
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