my junk build

[ruf_zuki]

ok so theres gona be abit of work happening to my toy over the next... however long it takes me so i thought id start a thread about what im gona do and post some pics etc...
im pretty new to the whole 4x4 scene so ill try do as much as poss myself...
feel free to laugh/add comments etc

this is my toy...

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

so far it has had... newer motor/box(just a shitty 2L-t),4.55 LSDs front/rear, front axle shifted forward,10" shocks in front/rear, 35x12.5" BFG's,longer shock mounts, 50mm body lift, shitty rear lift shackles blah blah, probly more but not worth mentioning...

have just recently finished rebuilding front axle with new everything inc. diff seals/bearing etc...
not much of a job for some of you but it took me ages,


http://www.offroadexpress.co.nz/images/ ... .sized.jpg

my plans are as follows which will be getting tackled from middle then rear then front,
my dual t/case adaptor has arrived and im just waiting on my 2nd tcase to turn up so i can start pulling it to bits and install the bits for my crawler box...
once thats done ill start on my custom g/box crossmember to be rid of the horrible standard thing...
then i will mount a disk/calliper setup on rear of my t/case for my handbrake..
moving onto the rear ill be putting a wider rear surf axle in to get rid of my tyre rub issues,
on the axle there will be a disk conversion(still to decide on items to use)
i have a set of falcon rear springs to go in with sum long travel ranchos which will be mounted...
thinking of ditching my rear LSD and getting an auto-locker but ill see what happens...

in the front there will be my rear springs with ranchos with a hysteer conversion and possibly wider hubs...

so thats my plan...

so far the t/case is getting started...
it out for a start

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

http://www.offroadexpress.co.nz/images/ ... .sized.jpg

ill post up pics as the project progresses so stay tuned...


cheers
matt

[wjw]

To make the images appear in the post change [url]to [img]and[/url]%20to[/img]

or put

looks good tho

[niblik]

sweet.. will be good to watch the build...

[Steve_t647]

Cool makes me want to do more to mine. Damb budget I should have just skiped the holiday and spent it on the truck.

Would love to know all the details of the dual tc, something I plan on doing, but after I do a few other bits first yours will be well done by the time I get stuck into mine.

Good luck, and the diff service is a messy one been there took twice as long as it should! Don't want to go back!

[rokhound]

Would love to know all the details of the dual tc, something I plan on doing, but after I do a few other bits first yours will be well done by the time I get stuck into mine. lol:

Check out the http://www.marlincrawler.com. Have a look around, there is some good stuff there.

After having dual transfers, you just wouldn,t want to go with out them.
They rock for the rock crawling.

[ruf_zuki]

ok, today i got a bit done on the t/cases, my donor case arrived so i got all my bits arranged and started to pull the case apart,

this is the bare adaptor



and the other stuff



this is going to be my transfer case so i dont have to touch this part YET...



starting at the back ive taken off the big nut and the coupling off along with the speedo and oil pump gears and cover...




this shows the next housing with the 2wd/4wd gears etc...



same housing but the 2wd/4wd gears/bearings have been removed so i can get to the 4 nuts you can see...



with the nuts removed i can take out the bearing/retainer and remove the shitty little c clip that took me bout half and hour to get off...
this pic shows the front of the case and im removing the 2wd/4wd shifter fork but keeping the hi/lo one in...



here ive taken the bolts out holding the front housing to the middle and will scavenge the small bearing inside the output shaft and the large gear on the far right of the pic..this gear goes onto another shaft which came with the adaptor..




pic of the output shaft removed to get at the large gear on it...

[ruf_zuki]

gear is off the shaft



here i have installed the new needle bearing and shaft with hi/lo gear into the adaptor, a circlip holds the shaft on other side so it cant slide off...
circlip is yet to be put on as my circlip pliers dont open wide enough
ill have to grab some from work...



and heres the crawler box bolted up to the adaptor... ive shown where the hi/lo fork has been kept and 2wd/4wd removed



and another of it bolted up..



so thats all for tonite, more to be done tomorw so ill post up pics when done, sorry bout the blurry pics but i was trying to get the least amount of oil on my camera and its hard holding such a tiny camera with 2 fingers

more pics can be found in my album on page 14 of users pics....

cheers

[Steve_t647]

Nice, now I understand how it works too. I will have to keep this thread for when I get into mine.

Looking at the quality of the work you are doing I think you could use the Ruf

Keep up the good work and at this pace you could set a record build time at least compared to me

[niblik]

i'd love the dual transfers one day...

whats the price of those like? approx.....?

great write up... pics a great help, very thorough...

nicely done. keep it comin tho!

[ruf_zuki]

got bored at work today so i decided to draw a tree diag. to show how many different combinations of gears i can use...





first is gearbox
second is crawl box
thrid is t/case but on my t/case seeing as i didnt get a top shift one i have to make my own gear stick/s , i could just use 1 stick like a normal case but mike(suprasurf) mentioned to me i could use 2 sticks, 1 for hi/lo(just like the crawl box) and one for 2wd/4wd but have them next to each other...
i havent started on this yet as i wanted to get my crossmember underway,

i finished off the crawler box by putting the circlip on shaft and welding a gearstick locator key onto the hi.lo fork, this had to be done because there used to be 2 forks there and when one is removed the gearstick will not stay in place,(ill post up pics next week coz i forgot to take 1)



i went out at lunch and got some bolts/wahers/nylock nuts and then brought some bushes for the mounts of crossmember to chassis...
then i got some 4mm wall tube to suit the bushes



after work i wnet and had a good look under my truck and did a whole heap of measurements, other than getting myself really confused i figured that my zorst was gonna be in the way... so...
out comes mr cutting disk and out comes a section of the exhaust...
(this gave me ideas of having it exit just behind the drivers door




then after abit more measuring and confusion i thought it was time to start mocking up the Xmember out of cardboard, ill make it out of card and triple check everything then take to get profile cut, i could use the plasma cutter but id rather have it perfect...

first i did a ruff cutout of how i want the Xmember to bolt to the t/case...



and i kept working at that shape till i had it how i wanted it then accuratley(with a spraycan) marked the points where i want the holes drilled



once the mount was finished i moved onto the brakets that will be welded to the inside of the chassis rails... they will hold each side of crossmember on the bushed support...(not yet started)

i pissed about with different shapes and thought that some placements of the holes might put stress on one point rather than spread it out... will only be minimal though, this is the basic shape i decided on after seeing it used on another truck(ive copied this idea if you havent realised im not the designer) anywayyyyyy....





thats all i could be bothered doin... i cant really do much more because i need to mount the cases back in on the old crossmember to check for new crossmember floor clearance and also to see how far under the chassis rails i want it to stick out...

will be starting on shifters on sunday so ill post up pics then...

cheers [/quote]

[rokhound]

I'll be reallt interested how you attack the twin stick option. I have have done it on my wreck, but getting/making a boot to fit to stop water ingresss is a real arse
Awesome thread dude, and it's looking really good. Won't be long before we have you out for a play

[niblik]

that coro cardboard is tough stuff...

great thread on how to ya self stuff... personally its way beyond me... :'-(

[rokhound]

PS to the twin stick thing, have alook on Pirate 4x4 main page, under products teseted (or similar).

[muddy_munke]

Hey Matt, didn't know you had started on this, SWEET. I'll pop over to workshop tomorrow. Looking sweet though.

[ruf_zuki]

niblik
Posted: Sat Jun 24, 2006 11:15 am

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that coro cardboard is tough stuff...

great thread on how to ya self stuff... personally its way beyond me...

dude im 19 i dont know shit about shit, it aint way beyond ya... ya just gotta think about it, if i can do this then anybody can..

cheers for that rokhound... i had a look under 4runner tech to see how others have done it but the way im tackling it i havent found so ill have a look again...

quote]muddy_munke
Posted: Sat Jun 24, 2006 6:05 pm

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Hey Matt, didn't know you had started on this, SWEET. I'll pop over to workshop tomorrow. Looking sweet though
[/quote]

yeh daniel pop round and have a gawk at my very accurate spraycan measurements

[Insky]

hey bro truck lookn gud great 2c u doin it all ur self i saw u up at mt hutt yest ur mate cudnt get his hilux up the acces road aye its crap nt bein able to go out 2 the waimak any mre i want my motor aye steves puting the supra in in 2 or 3 weeks aye shud b mint

o and is that daniel pinkbits?

[mercutio]

i hate to be rude

but i really don't like to read text speak

[ruf_zuki]

dont read it then,


brett yeh, mates surfs front hubs wernt engaging(shitty auto's) so we had to hitch up...

nah its another mate daniel...

[SupraLux]

This is looking good... nice to see people who aren't afraid to cut stuff up and weld stuff back together

Keep up the good work, and the photos ... looove the photos

Steve

[ruf_zuki]

ok its been a few days since i last posted and to be honest i havent much more done...

ive started clearing all the un-nessesary brackets and things in the way of where my new x-member and rear shock mounts will be going, while i was grinding away i decided to relocate a certain item...




i didnt like where it was so its probly gona go behind the rear axle...
theres so much more room now...




seeing as the exhaust will exit just infront of the right rear wheel im getting rid off all the brackets and heat sheilds that held it up...
have only done these at the moment,



^^^^this is the bar that will have my shocks mounted to...

i have mounted the crawl box and adaptor back into the truck using the stock crossmember so i can measure the point where the new one will sit when the rest of the case is back in...



forward shift crawl box...



this is a pic of the ugly looking retainer for the crawl selector...ugly but strong
by the way i tiged it with 312 stainless then brazed over top with flux coated steelbraze incase you were wondering





i have pulled apart the rear transfercase and removed the hi-lo and 2wd-4wd forks to be modified for the twin stick setup...
i made a mock up of how the twin sticks will work, its pretty crappy looking and basic but im a simple guy so i didnt want to get too technical on it...

heres a pic of how it will sorta look like (SORT OF)



i took the model to craig at goodman engineering and explained what i wanted, amazingly he understood me and he's currently making it all...
once its all finished ill put some more pics up, it will be easier to explain that way...

cheers

matt

[ruf_zuki]

Well its been fawking ages since i last posted, obviously coz im lazy, so heres whats been done

craig finished the t/case fork and bearing holder thingy and i picked em up...




test fitted the modified items and found that i needed to grind a bit of the fork back to allow clearance



fitted everything back togethor and cut the excess fork back...too me a few times to get it right but its ok now...




done !!!

did some measuring and chopped a big hole in the tunnel to fit the new shifters and also because i have lifted the trans up 2 inches i had to cut more out to allow room for my crossmember to be bolted up

i acutually cut i bit more out after the photo...



dummying up the crossmember and getting measurements,



got the final design drawn up and all measurements done and ready to take to the laser cutter, it will be cut on 10mm steel



(just realised i didnt put a hole in for filler bung...
ill do it tomorrow)

took my rear axle and shocks out, now ive gotta find a wider axle...



cut some channel out of 50x50x4mm box section...



put holes in it...



and presto... i have part of my rear shock mounts,



the open ends will be capped and notched to suit my rear axle out of 6mm plate, havnt got any photos of those...

took my Xmember brackets to the laser cutter and this is the result...

perfect


ready to be welded to some 6mm plate for strength insted of straight to chassis...



and the brakets are welded..they distorted because of the heat from welding but nothing that a little LPG heating and bending couldnt fix...





thats all for now, more photos up soon, cant be skrewed right now...

[krawlr]

are they a nolothane bush?they look it....

have you done this before using nolathane?on crossmembers for gearboxs etc?

[ruf_zuki]

there maxi-trak bushes, i just went to repco and grabbed a pack then got pipe to suit...

i figured if there sweet for leafs etc then the'l be sweet for this...

[De-Ranged]

Hey K just a tip if your looking at doing this go to the truck parts places and cheak out the rubber barrel style mounts, they've got some nice meaty ones
I'll post some pic's soon of the ones I've used on the lemon

Oh ruf you might want to reconsider your design a bit and possibly swop to a rubber, having your mounts right out next to the chassi means your going to get all the vibs from the motor since your now wider than the motor mounts.... making for a rougher ride and if what I've read about nolethene on pirate is anything to go by this is going to add to it

Another thing to consider is reinforcing the chassi where you mount to, this sort of design adds a lever to the forced created by the motor and torque from the box

Bugger just re-read what I said clear as mud look if your worried about whats above give me a call
027 541 8794

Cheers Reece

[krawlr]

bingo reece (thats what i was getn @)

yep its gona vibrate and shake all day man and even worse on the open road.....just thought id mention it b4 you go any further