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  1. #1

    305coco FZR Tunnel reinforcement

    Talked with Jorge and he convinced me to install his fiberglass pump tunnel reinforcement shell on my FZR. Even though the factory glues on some thin sheets of fiberglass on the sides of the tunnel, this mod is far superior..
    Many times there are air pockets in the glue that hold the oem sheets on giving it weak spots.
    According to 305coco several FZR tunnels have already broke, so this is a mod you may consider..
    Taking a heat gun to remove the OEM glued on side sheets, trimming the inner hull liner to clear the reinforcement on the bottom, trimming and fitting of reinforcement to clear a couple transom mounting washers, using epoxy base with milled fiberglass as a filler for installation, and sealing some edges with 5200 after the resin cures.
    I opted to cut the reinforcement in half to ease installation. Installing 2 halves was much easier than fitting the entire shell at once on the tunnel. Wood shims and wedges were used to keep pressure on the halves as the resin cured.
    Final product is super heavy duty...
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  2. #2
    More pics. Shell fits perfect, nice job Jorge...
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  3. #3
    lets race.... mikeFZR's Avatar
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    Pretty cool stuff. Thanks for the how to and the pictures. I'll be keeping an eye on this thread for sure.

  4. #4
    Moderator beerdart's Avatar
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    Thanks for the write-up Ross. There is no such thing as a strong enough tunnel.

  5. #5
    hitman's Avatar
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    I know some good buddies who cracked their pump tunnels. It's not just a SHO issue. FZRs have it too, just not as bad as modded SHOs. A modded SHO WILL break. FZRs seem to be hit or miss.

  6. #6
    Site Admin Green Hulk's Avatar
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    Quote Originally Posted by beerdart View Post
    Thanks for the write-up Ross. There is no such thing as a strong enough tunnel.
    I agree. I'm installing Jorge's reinforcement on my FZR right now.
    Jorge and I will have these up in the forum's online store soon.

  7. #7
    SHOin OFF 02gpR's Avatar
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    i have had a Tunnel re-enforcement since VERY VERY EARLY 2009!!!!!! and no problems with my tunnel

  8. #8
    i will get all the rest i need when im dead corkycat's Avatar
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    same here, purchased from jorge, installed mine in 09, nice fit and not much sanding needed.
    this should be one of the first mods anybody does

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