I parked this machine ('07 TUV) last spring and have been putting off resolving the problem until now. This is my fifteen year old son's machine to use when we go out hunting. Last spring, during a weak moment, I allowed him to take it and haul some supplies into a duck blind with a friend and his dad. I'm guessing that he and his buddy hammered it pretty good while riding double. They sheared the bolt. The shock then trashed the beam shock mounts AND broke the shock. As if that wasn't bad enough they torqued the tunnel and bent it on the left side. I'm torn between dumping it or fixing it. Anybody have any words of wisdom? It's been a good machine and only has about 400 miles on it. Bend the shock mount straight, put a new shock on it and ride it like ya stole it? Or, replace the beam along with a new shock? What about the tunnel? Will it get worse if I don't beef it up? How much is a new tunnel (not sure I want to work that hard though)? What is it worth as-is? I'm inclined to sell it and buy a new XU. Here are some pics:

Straighten the tunnel and plate it. Gusset the H-Beam. New shock and make your son use it in the IRON DOG. He will never doo this again

I'll agree with Cain's Guest here Skich, right after you give Jr. a trimmin' (LOL), make him help you to pound that tunnel straight, then plate it up real good on both sides and rivet it through. As for the H-beam, haul it out and have a machine shop fab you up a real set of shock ears w/triangular brackets on the sides for additional strength. While you have it out, have this very weak part reinforced everywhere; outer ears refinforced, re-welded and angle braced. Do the same for all other ears on the assembly, plate them up to increase their thickness then use triangular brackets to reinforce them in bending.

Cain's Guest knows all about the bracing game for this part, maybe he can share a pic or two...

As requested I just hope Mark Nui is not lurking in the background! LOL

Thaaaaats how you do it! If you think that looks beefy in the pic, you should see it in action.