Tunnel crack

[DMCTurbo]

Has anyone had this happen?

 

[1nc 2000]

Seen it just in the outer layer of tunnel. Stop drill holes and add plate to inside that all three bolts go thru.

 

[DMCTurbo]

Ya its just in the outer layer. My son's buddy is a welder, he said he can fixer up.

 

[RAMSOMAIR]

You are just putting waaaay too much stress on that old girl lol.

 

[1nc 2000]

The way the tunnel is designed in that area two pieces come together with a crease for the brake caliper mount. With the flex in that area the crease will crack over time. The sharp edge should be lower in the tunnel before it gets to the caliper mount.

 

[stgdz]

Ya its just in the outer layer. My son's buddy is a welder, he said he can fixer up.

Not sure on aluminum, most of the welders that I talk with say welding aluminum will weaken it.

Is this crack near the brake caliper?

 

[DMCTurbo]

Not sure on aluminum, most of the welders that I talk with say welding aluminum will weaken it.

Is this crack near the brake caliper?

Ya it is.

 

[earthling]

Brazing a plate over the existing area is an option. Brazing is very strong and does not cause the aluminum to loose as much of its temper as you are not heating it up as much as you would for a weld. The plate will also help you distribute the load. On the other hand, a decent weld is better than a crack/split even if you are ultimately losing some strength right in the weld area.

 

[Upstater57]

Instead of welding maybe drilling some holes in steel plate securing it with cherry rivets with steel washers behind them would work best. We used that method on the old chassis ( pre procross ) and it worked pretty well.

 

[1nc 2000]

Brazing a plate over the existing area is an option. Brazing is very strong and does not cause the aluminum to loose as much of its temper as you are not heating it up as much as you would for a weld. The plate will also help you distribute the load. On the other hand, a decent weld is better than a crack/split even if you are ultimately losing some strength right in the weld area.

The brake caliper sits right there so building it up higher is not an option.
$400 plus fasteners for a new center section of tunnel.
The center section of tunnel rips apart where it is riveted to the top of the heat exchanger also where the crossshaft mounts they crack there also.
So we know of 3 different areas to look for issues.

 

[1nc 2000]

Other areas of concern also....

 

[earthling]

The brake caliper sits right there so building it up higher is not an option.
$400 plus fasteners for a new center section of tunnel.
The center section of tunnel rips apart where it is riveted to the top of the heat exchanger also where the crossshaft mounts they crack there also.
So we know of 3 different areas to look for issues.

Forgot where that sits relative to the caliper, you are right.

I thought for that center section over the heat exchanger you put in that plate from craigwsrx? I have one sitting here but the sled is still parked from last year waiting for all the other projects to finish.

 

[1nc 2000]

Yes I installed the plate from craigwsrx and also installed tunnel saver plates from BOP for the front crossshaft mount.

 

[stone88]

Has anyone had this happen?

View attachment 168797

Looks like damage from flying debris

 

[GR8BBQ]

Did you have a BOP driveshaft saver? Travis has a video on YouTube saying that you must not over tighten it because it can cause the rotor to not have free play which can cause tunnel flex.... Just a thought.