[david.saterstad]

So... how hard is it to swap out the tunnel/Chassis on a 1995 Vmax 600? My chassis has a cracked frame on the belt side just behind the motor mount. I found a tunnel & Chassis for $99 that I was thinking of buying. But, what kind of project am I looking at?

 

[snowdad4]

hard, no. time consuming yes. your biggest expense will be purchasing rivets, the hardest part is removing existing rivets. there are several different sizes of rivets involved. if you dont have an air riveter, get one! dont even consider picking up rivets at the hardware store, they wont hold. look for stayvex or cherry, or buy oem so you get the correct sizes for the application.

 

[david.saterstad]

Good info snowdad! I just have a hand riveter so I'll pick up an air. What's the best way to remove the old rivets?

 

[snowdad4]

depending on the rivets and accessibility, i use a punch to drive out the centers and then drill out the remaining. some you will have to flat out grind off and then punch through, others chisel off and then punch. after about the first 50 or 60, you will get the hang of it. and then your about halfway there.

 

[david.saterstad]

That doesn't sound too bad. I think it's time for a dremel. Thanks for the help.