A snowmobile belly pan keeps snow from being pushed up into the engine compartment. The belly pan can be damaged by obstacles in the snow or any impact to the plastic or aluminum shield. Damage to a belly pan can often be fixed, but if it is too damaged to repair, it must be replaced. A belly pan doesn’t have to be perfect to be functional. As long as it keeps most of the snow out of the engine compartment, it is doing its job, no matter what it looks like.
Minor Crack in Plastic Belly Pan
1) Drill small holes (about 1/8 to 3/16 inch, depending on the size of the cable ties) about half an inch from the crack down each side of the crack. Make the holes as small as possible but still big enough for a zip tie to go through.
2) Put a cable tie that is long enough to reach from one side of the crack to the other and back through one hole from the top of the belly pan to the bottom.
3) Thread the cable tie back up through the matching hole on the other side of the crack. Put the tapered end of the cable tie through the eye of the cable tie and pull it snug. Some cable ties will latch either way, but make sure it won’t come undone.
4) Repeat this process until you have laced the holes the length of the crack, keeping the fastened ends of the cable ties on the top.
Large Crack or Aluminum Belly Pan
5) Use tin snips to cut a piece of aluminum large enough to cover the crack and overlap on all sides by about two inches.
6) Place the aluminum on top of the belly pan.
7) Drill holes slightly smaller than the screws you are using, or the size of the pop rivets you plan to use, through the belly pan and the aluminum, making sure they match up all the way around.
8) Put screws through the belly pan and patch from the top to the bottom. You can use pop rivets to fasten the patch as well.
*If you or someone you know has access to a plastic welder, you can try to fix it with that or with a flexible glue if the crack is small.
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