Stretching the phazer to 136 - tunnel extension questions

[DigitalFusion]

Hey all,

I just ordered up a 136" freeride (they found a few left!). The stock rear bumper on my phazer is pretty chewed up, so I'd like to just throw it out and start over. I'd like to make something like the attached image (gytr rear). What is the general rule of thumb for the length you need to extend? A 136 vs 121 is what, 7-8 longer? For those of you who have made, or have purchased rear bumper/tunnel extensions, what gauge aluminum is used on the side plates?


Also, what should I do for hyfax?

 

[canoehead]

I stretched the rear bumper 8" by tapering a solid piece of Cold roll to fit in the bumpers ID. (OD was the same as bumper) then tigged it. Had a local shop cut and bend a piece of I believe .050 Aluminum so I didn't have to use the curved tunnel end, and put her together. I also tigged the folds at the end where the flap connects. Simple and a lot of people comment on it. As for Hyfax, just buy the 144 and cut it down. This is an older pic of it since install it's been polished and updated snowflap installed.

 

[Gone Blue]

I wouldnt copy the design of the GYTR rear bumper. They are junk. See my thread on the mods I had to do to it based on cracking the first one I had.

G.B.

http://www.ty4stroke.com/viewtopic.php?t=123124

 

[DigitalFusion]

yeah, I saw your thread in my searches. I kinda figured I would make some side plates out of beefier gauge and weld the thinner plate and tube onto that. Just wasnt sure what gauge to use and how big to make the extension. Also, the picture I posted is a reinforced GYTR

 

[OVR4D]

Hey DF,

I think I extended the tunnel by approx 9 inches (will check on that and get back to you).

As for the bumper, I cut the stock bumper and inserted tubing between the the two halves to extend the length, but also slid some additional tubing that is the same O.D. as the stock material over the smaller tubing being used to extend the bumper. To get the best fit up, you'll want to have the new track installed and the extra piece of aluminum sheet that you'll be using to stretch the tunnel at least clamped in place. Then mount up the bumper and set it to the length you want and tack it up. After you've got some tacks, you can pull the bumper off and weld it up. I wanted mine to look like it is one piece of tubing, so I ground the welds down smooth ... flush with the tubing. I had my bumper powder coated afterward, and you can't see the welds now.

Of course another option would be to just copy the design and build your own in one piece. This is assuming you like the look of the Stock bumper, which it sounds as though you're not too fond of. Really, the sky's the limit ... let your imagination run wild.

 

[canoehead]

Hey DF,

I think I extended the tunnel by approx 9 inches (will check on that and get back to you).

As for the bumper, I cut the stock bumper and inserted tubing between the the two halves to extend the length, but also slid some additional tubing that is the same O.D. as the stock material over the smaller tubing being used to extend the bumper. To get the best fit up, you'll want to have the new track installed and the extra piece of aluminum sheet that you'll be using to stretch the tunnel at least clamped in place. Then mount up the bumper and set it to the length you want and tack it up. After you've got some tacks, you can pull the bumper off and weld it up. I wanted mine to look like it is one piece of tubing, so I ground the welds down smooth ... flush with the tubing. I had my bumper powder coated afterward, and you can't see the welds now.

X2
That's what I did to wife's!! Looks stock and stronger than factory..

 

[DigitalFusion]

my stock bumper is pretty trashed though. I'd rather just toss it out and start over. I have a buddy with access to a waterjet, so I was thinking of cutting something similar to the GYTR side plates out of some aluminum, then welding a tube between them at the rear for a grab bar, and maybe some flat stock for a snow flap mount.

Gone Blues thread really shows the downfalls of the GYTR bumper. I wonder if just using thicker material for the side plates would be enough to make it strong enough, or if I would have to do reinforcing like gone blue and the pic I post have?

 

[OVR4D]

DF:

These guys have moved to North Branch now, and they're reasonably priced (see the "our products" page): B & M Fabrication They do custom stuff too.

 

[DigitalFusion]

hmm. interesting. Where in north branch are they?

 

[OVR4D]

Don't have an exact address ... Never actually purchased anything from them, but I did contact them (back in October) using the number listed on their site. That's when I learned that they had moved to North Branch.

My thought is that it may not be worth your time to build it yourself, as these guys could probably do it for less.

Here's their FB page: B & M Fabrications Facebook

 

[DigitalFusion]

Actually, my friend with the waterjet is swinging over tomorrow afternoon to get some measurements. I'll know better how much it would be to make a custom one, vs contacting B&M or going with a Skinz.

 

[DigitalFusion]

Any chance you could measure the total length from the mounting bolts in teh front to the bumper in the rear?

 

[OVR4D]

I take some measurements and get back you with a PM later tonight, once I get home from work (have to fight this ridiculous traffic we've been having lately ).

 

[DigitalFusion]

sounds good! Thanks!