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Tunnel Removal???
started by 02XC700SP
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April 21st 2009 at 7:27 PM
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02XC700SP
Starting Member
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26 Posts
Group: Members
Member Since: January 29th 2009
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I am stretching my Edge to 144". I have the snow skirts, bumper, seat and snow flap removed. I am working on drilling out all the rivets to take the stock tunnel out. I have a tunnel from a 144" sled I am trying to make work. What is the best way to take care of the rivets along the top corner of the tunnel? The one side of the rivet is flat and the other doesnt look like a normal rivet and they are very hard. I really cant drill them out.
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Site Supporter
Group: Site Supporters
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April 21st 2009 at 8:02 PM
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McGrail.S
Junior Member
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114 Posts 
Group: Members
Member Since: February 17th 2009
Location: Sutton, Ontario, Canada
Current Sled: 87' Indy trail 500 144"
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Get a grinder then, grind em' out.
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April 21st 2009 at 8:33 PM
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xc600rmk
Friend of Fast
xc600rmk need info on the exciter!!
Updated Last Sunday at 12:00 PM
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2047 Posts 
Group: Members
Member Since: March 27th 2007
Location: Albion, NY, USA
Current Sled: 04 Pro-X 600,98XC600rmk
2008-2009 Miles: 1,700ish
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the easiest way wouldve been to get the tunnel extension and all the stuff to make the 121 a 144.The easiest way to get rivits out of a sled, i drill um thru then hit the tops off with a good chisel and punch the rivit thru with a punch.
*04 Pro-X 600-A few mods,and go-fast parts.......136" x 1.25" this winter
*98 XC600 and some RMK add ons-The sons ride this winter
*98 XCR440 and some SKS add ons------SOLD :-(
*83 Polaris Star 250
*90 Yamaha Exciter---Wanna trade even up for an Indy Trail,Or any Indy of equal Value!!
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April 21st 2009 at 10:50 PM
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erick
Alternate Realities
erick pretty much excited that it's Friday, though there are no plans for the weekend yet!
Updated Yesterday at 11:45 AM
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11495 Posts 
Group: Administrators
Member Since: April 10th 2001
Location: Strathcona, MN, USA
Current Sled: IQr 800 & RMK 800
2008-2009 Miles: 800
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If it is a newer tunnel Polaris uses a self piercing rivet. They have a very hard center and can not be drilled or chiseled. The only way I know to get them out is to grind them off on what ever part you no longer intend to use and drive the remainder out with a punch. Once it is thin enough it should drive out but you need to hold some kind of a block on the side you are driving to or it will deform the aluminum.
We have been using 1/4 inch steel tubular rivets to fasten the parts back together as the holes are slightly larger than 3/16th. They are installed with an air hammer and an anvil that we made to roll the rivet over on h inside and tighten up.
It is all a lot of work but worth it in the end as it looks good and is very strong and sturdy.
Breaking free from the thoughts in my mind
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April 22nd 2009 at 6:51 AM
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02XC700SP
Starting Member
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26 Posts
Group: Members
Member Since: January 29th 2009
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Quote originally posted by erick
If it is a newer tunnel Polaris uses a self piercing rivet. They have a very hard center and can not be drilled or chiseled. The only way I know to get them out is to grind them off on what ever part you no longer intend to use and drive the remainder out with a punch. Once it is thin enough it should drive out but you need to hold some kind of a block on the side you are driving to or it will deform the aluminum.
We have been using 1/4 inch steel tubular rivets to fasten the parts back together as the holes are slightly larger than 3/16th. They are installed with an air hammer and an anvil that we made to roll the rivet over on h inside and tighten up.
It is all a lot of work but worth it in the end as it looks good and is very strong and sturdy.
Those rivets are exactly what you are talking about. The end is rolled over instead of a pin being drawn through to expand it.
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April 23rd 2009 at 5:47 PM
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polaris37
Junior Member
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175 Posts
Group: Members
Member Since: January 13th 2007
Location: NEWFOUNDLAND, Canada
Current Sled: 06-600 fusion 136"track
2008-2009 Miles: 650
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carbide tipped bit works,be careful not to heat bit to much.
2006 600 h.o.fusion-136 x 1 1/4"track extension kit--studded
slp pipe set
v-force 3 reeds
gutted air box and push arm
65g mtx weights and blue/pink primary
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April 24th 2009 at 2:58 AM
[ Modified April 24th 2009 at 3:03 AM
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Do not grind them, I just extended a 02 xc to a 136 and a 02 rmk to a 156. I had the tunnel on the xc off in about 30 min with a few good bits. the rmk took me hours to do, took a while before I got the hang of these rivits. you CAN drill them, drill them from the inside of the tunnel and be sure you have good drill bits and some time on your hands... you dont have to drill all the way threw, just untill the curlled part of the rivit is drilled past, then take a punch and a good sized hammer and pop' em out. easy and looks good.
00 xc/rmk... the new frankinsled.
98 xc 700
79' camaro Z28
77' silverado. old trucks are pimp!
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April 24th 2009 at 6:56 AM
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02XC700SP
Starting Member
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26 Posts
Group: Members
Member Since: January 29th 2009
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Quote originally posted by crdude
Do not grind them, I just extended a 02 xc to a 136 and a 02 rmk to a 156. I had the tunnel on the xc off in about 30 min with a few good bits. the rmk took me hours to do, took a while before I got the hang of these rivits. you CAN drill them, drill them from the inside of the tunnel and be sure you have good drill bits and some time on your hands... you dont have to drill all the way threw, just untill the curlled part of the rivit is drilled past, then take a punch and a good sized hammer and pop' em out. easy and looks good.
What size bit did you use? I was using an 1/8" bit on the other rivets. Should I use a larger bit on these to take the curled part off?
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