[94ZR580]

I do have a ZL skid in my 94 ZR and the tunnel is probably similar to the 96 ZRT tunnel. I used the same front hole as my original skid and had to drill a new rear hole forward of the original, about 1.5", but it was a long time ago. The rear hole was well within the tunnel reinforcing plate, so no new reinforcing was required. The rear Fox shock form the ZRT skid should swap into the ZL skid, but the front shock will probably be too short.

 

[94ZR580]

<div class='quotetop'>QUOTE (SSGZRT @ Mar 8 2007, 08:08 AM) <{POST_SNAPBACK}></div>

I did go and check out a skid on a newer sled and the holes had a 21.5" span I think that I do need to drop the front down the 2". I just got some new 16 gauge plates to replace the front inside and one on the outside. I'm also going to add one on the outside in the rear to cover the multiple holes. What size rivets do you recommend for max grip? This is how it sits now. Also is there a big differance between the ZR and the ZL?

[attachment=65759:zrt11.jpg][/b]

I'm sorry man, but I don;t really understand what you said here. I'm not sure that you need to make all these new holes in the tunnel, but that does help remove weight from the sled. Have you tried using the stock front holes and seeing where the rear ends up? The ZL suspension has a softer geometry and gas bag, non-rebuildable shocks, more intended for trail crusing. You can install stiffer springs and Fox shocks and never really know the difference. Just don't make the project more difficult than it needs be.

 

[94ZR580]

Did you let out the limiter straps on the front arm? Did you try riding the sled to see how it works? Did you swap a shorter shock into the front arm position? The few extra holes should not be a problem for the strength of the tunnel.