changed a tunnel out on a 08 xp last year cuz it got bent, its a big job probably about 15 hours total. not very long stipping it but getting everything back together a fitted just so took most of the time. I guess it depends how bad you like a powder coat????? oh and if you can hang it from the ceiling it works good for splitting the tunnel off.
We started on my friends 09 got everything off the top took about one day we worked till the motor was out then waiting for time to do jack shaft and skid/etc. Its scary for newbies(us) but going good so far. I'll take the camera next time and show some progress. Has to be back together for Nov 27! I spend more time trying to talk him into Pipe/Y pipe/Reeds/Big bore/etc then working. LOL I keep telling him "If you are ever going to do it....."
you have to strip the sled down to the frame and remove the front cooler and tape the bottom of the rear cooler to powder coat the tunnel/bulkhead ...there is little cooling transfer through powder coating ..if you can take thecoolers out and anodize them for better cooling properties ..