Snorkel Fitting Guide
The following information is offered as a guide to help with the fitting of the Bearmach Discovery 300tdi snorkel to the F73/78 Fourtrak. Although not a perfect fit, it is close enough to look like it could have been designed with the Fourtrak in mind. If you choose a different make of snorkel you may need to alter some of the measurements to suit.
Before starting, the plastic flared wheelarch, airbox/filter, voltage regulator and diagnostic plug (on post '96 models) need removing from the car.
Be prepared to put a day aside to fit the snorkel.
It is not a two minute job!
Mask up the wing panel as in pic as this makes for easier marking out and stops the swarf from the drilling marking the paint. Remove the plastic liner from the wheelarch. Mark the centre point of the hole for the snorkel 96mm down from the bonnet line of the wing top and 582mm from the rear of the wing at the same depth. Mark a second hole centre 60mm from the first back towards the door.
Once you are sure of your measurements, drill two 5mm pilot holes and then cut the holes with a 92mm hole saw. (If you dont have access to a hole saw mark out the opening and drill small holes all the way round the outside and then cutting to join them with a hacksaw blade or similar).
You will now need to remove the voltage regulator and, on post '96 model Fourtraks, the diagnostic plug aswell. (These need relocating later so remove and keep the bracket from the piece of steel you have cut out to mount the diagnostic socket). To make the hole in the inner wing, follow the line of the first hole marking over and down into the inner wing and drill another 92mm hole through there.
Take the snorkel and fit the front, top two and rearmost lower mounting studs, dab the ends of the studs with paint and then offer up the snorkel and when you are happy with its position press the studs against the wing to mark the drilling positions. Now drill out the four holes to 14mm using a step drill. (Remember to treat all cut metal with a rust inhibitor and paint).
Before trying to fit the snorkel, back off the studs so that they are only in 2 or 3 threads (a few mm).(This allows a little bit of extra length to help when fitting the nylock nuts inside the wing). Once the nuts are seated on the stud threads they will cause the stud to tighten into the snorkel before the nylock nut threads onto the stud. Do not overtighten the front stud.
If your Fourtrak has the plastic flared wheel arches fitted, you will need to trim the top edge of the arch so that the snorkel can sit onto the metal underneath it.
The voltage regulator can be repositioned in front of the snorkel tube using an existing captive threaded hole and by drilling another forward of it. If you have a diagnostic socket, drill the inner wing and bolt the mounting tab on to hold the socket where the wiring will allow.
The airbox will need a new intake cutting and welding/gluing in place. A piece of 3" tube is ideal for this, but care should be taken to make sure the joint is cut accurately and sealed air tight. When complete, the original intake needs sealing or removing.
The windscreen pillar bracket needs to be modified to suit the rake angle of the Fourtrak pillar. Cut a slot in the bracket from the bottom and bend the snorkel side 15mm forward at its lower edge, then weld in a fillet, clean and paint. Bolt the bracket to the snorkel finger tight and mark the rivet holes on the pillar. Drill with a 4mm bit and fasten in place with the five rivets supplied.
Check all the fittings are tight and re-fit the plastic wheelarch trim. The space between the snorkel and wing can be filled with Tiger Seal or similar to give a clean neat finish and you're done.
We allow 6 hours to fit onsite so dont expect to be able to fit this in a couple of hours but with a little patience it can look like a made to measure Snorkel.
Remember you can always ring us for advise if you run into problems.
Mask the wing
Measure and mark holes
Drill 1st 92mm hole
Drill 2nd 92mm hole 60mm back.
Drill inner wing inline wth 1st hole
Remove Voltage Reg & Diagnostic Plug
Removed inner wing plate
Bracket removed to save.
Spray all holes to prevent rust.
Slot A-pillar bracket
Fillet and weld A-pillar bracket
Paint A-pillar bracket
windscreen pillar bracket fitted (1)
windscreen pillar bracket fitted (2)
3" hole cut in airbox
3" tube fitted to airbox
New inlet made airtight and painted
Old inlet blanked & sealed airtight.
Airbox refitted to car and Snorkel
Fourtrak Snorkel fitted & Complete!