"Zuk" Another De-Ranged Project

[pruggerdore]

Its ok guys, its been decided by the support crew that if he dosnt finish it we'r going to beat him with it. somethings look great in photos but the flaws show up in the reality.
these look better in the flesh than the photos. a huge number of hours and bourbons have gone into them. Most would think its not worth the effort but if you could see the silly grin on the boys face when he's playing with them you would see its worth it to him

[De-Ranged]

why does everybody give me shite, don't I finish other peoples trucks and yes I do want to finish this one.....

Right here ya go
After the fly cutting the tubes this garrentee's they line up right

A shot for those that know this is why I'm not too concerned about weld warpage I've made this as tight as possible took alot of beating to fit in there


And the finished item (well nearly been given the call up for work, heading down south tomorrow morning so need to get home and keep the misses happy )

Still got to mount it in the welding jig to confirm true and weld the long end I'll do that this weekend when I'm home

Oh and puggadore was right I was grinning as this was coming together

Cheers Reece

[oldyella]

This means my gards are coming up, on the front that means the bonnet will sit down inbetween the gards I don't know how this is gona look.. F it I'll worry about that later

make sure you get some pictures of that Some bar work might be the best way to do the guards? Considering the inside of the tyre will almost be outside the guard anyway...

Housing looks like C4 explosives wouldn't scratch it. It is as heavy as is looks? Pretty cool machining work

[pruggerdore]

Is heavy but not sure how heavy compared to standard housing. will take the human scales in tomorrow and weigh it and a normal one and see how scary it is. what weight increase there is will be offsett by the weight saving by running smaller tyres and still getting the same diff clearance. My theory any way. reece will be along shortly to tell us Im wrong

[De-Ranged]

make sure you get some pictures of that Some bar work might be the best way to do the guards? Considering the inside of the tyre will almost be outside the guard anyway...

Thats what I was planing... 25nominal heavy wall, with sheetmetal back to the body then convayor belt out from there to keep me legal

Housing looks like C4 explosives wouldn't scratch it. It is as heavy as is looks? Pretty cool machining work

Yea it is a bit heavier, but I wanted something that I didn't need to brace, something I could abuse Rough estimates would put the axle tubes at around 50-70% improvement in strength, this is hard to assess as I've no idea the material they made hilux diffs from.... the diff head where they normally bend I'm way past that by virtue of the design, welding to the internal brace + the end of the diamond housing
my only concern is where I've attached the ball housings this is why I've got the bracing ribs
when its all up and racing I'll give it some good launches

As for pruggerdores theory your going to laugh at this Clive but I'd never thought of that, but did a bit of research based off interco's site (super swamper, Irok etc) a 2" increase in tyre size (will give 1" clearance, similar to the axle housing) averaged out to be about 14lb per tyre
28lb x .45(conversion factor) = 12.6kg
I'm pretty certain I'm inside that and I'm wider than standard

Cheers Reece

[De-Ranged]

Did a bit of work on the axle, started with a check on the longside for caster angle before welding.... it was out by 1 deg
so cut the spot welds.... apart from two inside teh housing had to remove the guard from the grinder to get the last two.... got the tube out and swopped the disk for a worn flap disk 15 sec's later I'm looking at the grinder hanging from my sleeve waiting for the red to start
now typing with one thumb up in the air and I'm up for another grinder

Oh and on a bastard note I stuffed up the cad a bit I made the short size housing 20mm longer than I should have for the 40 series inner axle... think I set the length off a 60 series... something I don't have... but I do have an old long side hilux inner that I can shorten looks like custom axles yay

Cheers Reece

[suzolla]

Hi Reece,
My uinderstanding was that the 40 and 60 short side were the same length. Long sides are different.
See below of my understanding of axle lengths. Dimensions are in inches

40 Series LH 29 1/8 RH 17 5/16 Total 46 7/16
60 Series LH 31 15/32 RH 17 5/16 Total 48 25/32
70 Series Pre 90 LH 29 3/32 RH 17 5/16 Total 46 13/32
70 Series Post 90 LH 30 3/16 RH 16 5/16 Total 46 1/2
Hilux LH 31 15/32 RH 15 5/16 Total 46 25/32

Cheers
Tim

[De-Ranged]

I must have stuffed up in cad then its not going to effect things much anyway.... the rear is going to be set to the width of the front, I'm using a 40 series long side, the short side will be from a cut down axle I'll respline so another 20mm wider isn't going to hurt
Up front I've got that damaged long side hilux that I can use.... just means a few extra hrs machining
Hey I'm a small guy so a bit extra is all good, so total of 75mm widder than standard

my g/f who is a nurse has just taken the duct tape off my thumb been told i need stitches it does look deep.....

Cheers Reece

[GotFlex]

so cut the spot welds.... apart from two inside teh housing had to remove the guard from the grinder to get the last two.... got the tube out and swopped the disk for a worn flap disk 15 sec's later I'm looking at the grinder hanging from my sleeve waiting for the red to start
now typing with one thumb up in the air and I'm up for another grinder

pay back is a bitch ae reece

[De-Ranged]

I bet my face didn't look anything like yours tho

Got the housing all done last night, just got to make up some collets for the jig so I can run a smaller trueing bar (just true any weld warpage) and I'll be able to assemble
Oh and almost sorted the short side shaft

Cheers Reece

[Nivapulledout]

UPDATE!!!!?????

[pruggerdore]

UPDATE!!!!?????

there isnt one he's got that axle pretty much beat so he's moved on too making a leaf spring calculator to suport his leaf spring debate. not sure how this helps with getting a truck in the mud .

ps it's my job too give him grief to help motivate him into completing a truck. sadly its a battle Im not going to win.

[De-Ranged]

motivation you mean distraction
Had an issue with my camera it got nocked off the bench and it didn't like the bump so there hasn't been much in the way of pics
Got another camera off my motivation so here's a wee bit of an update
Was looking at the short side inner shaft and how much I needed to add and after a few motivational bourbons came up with this daft idea to extend it the side gear in the diff has 40mm of spline I needed to add 20mm that would mean that a join would be in the middle of the side gear helping to reinforce it ...... yep I decided to weld an extention onto the shaft

plug weld it to the end of the shaft, so I cut some spline off an old damaged shaft and machined it out, the side gear is from a blown slippery, I'm using it as a jig to line every thing up

All jiged up ready to burn, before I welded I heated the end of the axle cherry, this gets better penetration and stops the hard defined change in crystal structure between the weld and the parent metal

after I welded it I couldn't resist burning a lap round the outside then precision cut the spline through the outer weld with a freehand cutting disk
Time will tell if it works
Needed some X over steering arms with the correct ackerman angle (makes the inside and outside wheel track correctly when you turn a corner) this angle is based off your wheel base the zuk is a tad bit shorter than the hilux so that rules out trail gear arms that and I'm a cheap bastard, found an old grapple pin from my old log loader (4130) used some of that for the king pin key's, a couple of flame cut profiles $27 total, cap screws and nordlock washers $8 and a bit of time

And they are setup for 25mm center shaft king pin bearings (cheers Jafa for that tip)

[tomsoffroad]

Wicked.
You've alway been an inspiration.

Might have to get into that cad-whatcha-macallit myself Can I do it with a chalk stick and a scriber?

[De-Ranged]

Thank you for the comment
Don't worry I still use chalk and the floor
If you want to get into cad a cheap way is hit up any of the places that use CAD I found an old out of date copy of CAD that was given to me for a social fund donation keeps you legal that way and the saving in profile cutting is well worth learning to use it

Been playing on this axle last night and this morning.... I made the housing so tight I've had to cold chisel welds down inside the housing to fit the diff & spin it my jig is from an old 2 spider.... found they are a little bit smaller than the slippery (will have to add some packers to the jig for future use)
Diff is in and clear.... got one swivel housing sorted will finish the rest after lunch.... then back to work

[De-Ranged]

Was cleaning up the shed and found some of the clips that fit on the end of the cv's long story but the axle is together

and to my surprise an 80 series tierod just fits I'm inside the 1 1/2 dia of rod end in the tierod... not by much, will probably make another tierod thats a bit longer but that can weight

[tomsoffroad]

That awesome.
Hows it mounted to the truck?

[De-Ranged]

sorry for slow reply was down bluff for work

I'm doing a 3 link on the front, still got to build the mounts thats why its only primer on there

[Nivapulledout]

Looking farken purdy is all I can say.

[De-Ranged]

Just a wee update
Front brakes are almost on well they would be apart from one small issue, bought some new pads yrs ago for a client turned out to be wrong model but being LN160 ones figured I'd throw em in the parts shelf.... well I'm using LN160 calipers on this toy so I go grab em and discover that a "mate" of mine has borrowed two of the pads
Anyway calipers have been re-kitted and soon will have new pads

Had the Certifier through had a good talk about plans and requirements... he complained about the amount of paperwork my ideas are going to cause but surprisingly I'm allowed to do all the things I want to

Still stuggling with a few details --- does anybody know the gear ratio's in the Nissan RWD S15-13 auto
Still working on the gearing options, would like to find a way to use the cruiser transfer behind a RWD Auto

Anyway got one more job to do before I can get back into this... got to build up a digger for log loading at the local port.... whole different level of engineering inche and thicker plate and some real serious armor
If anyone is interested I'll post up some pics

Cheers Reece

[rokhound]

I'd like to see the pics on that Reece.

[meatc]

Still stuggling with a few details --- does anybody know the gear ratio's in the Nissan RWD S15-13 auto
Still working on the gearing options, would like to find a way to use the cruiser transfer behind a RWD Auto
Cheers Reece

s13 (CA18 motor) 1st=3.027, 2nd=1.619, 3rd=1, 4th=.694
s14 (Sr20 motor) 1st=2.785, 2nd=1.545, 3rd=1, 4th .694
WD21 Terrano/pathfinder 89-95 (TD27and T) as per s13
Later Terrano (QD32, later td27 and V6) as per S14

All have the same centre section RE4r01A, different bell housings and possibly pumps.

Non turbo 300zx also share the box. Turbo 300zx and Patrol use similar but have more clutch packs, same outer housing centre section though. Believe the ratios are the same as the later model stuff listed.

[De-Ranged]

Thanks for that, from the reseach I did rear diff on the auto is 4.064;1 on a s13
Based on that if I fit them to the Zuk 35" tyres and 4.85 diff at 100km/h without the torque converter lock around the 2600 rpm and if it locks 2000 rpm..... third gear will be 3600 rpm.... my guess is it will be tripping between 3rd and 4th especially if the lockout kicks in hmmm might keep looking don't really want to be buying higher ratio diffs from the states
Oh and just for you rok I'll do a digger build thread

[meatc]

Yeah a non turbo SR will struggle to spin the 35s on standard box. I run a Ca18de and auto through Hilux transfer to 4.88 hilux diffs running 32 simexs and it was OK in low range but really didnt like hi. Super charged it and goes whole lot better now. (thats all in a zuk.) Not sure how you are going for diif to sump clearance but I had to rear sump mine which a heap easier with the CA as the oil pump is the old around the crank jobby, from what I understand the SR ones stick down a lot further.

[De-Ranged]

Not too worried about the sump if its a problem it will be modified
The gearing is an issue I do have a suzuki case there and the high ratio has a 1.4:1 reduction... problem is it then means I have to build a PTO pickup, cruiser box has one already

[meatc]

Zuk case wont stand the heat. How bout the cruiser case and 5.2 ratios out of a auto hiace van. i know they are a bit wealer than the 4.8s but cant see a 2L and a light weight Zuk busting them

[De-Ranged]

yea I know the ones arghh rocking horse shite comes to mind
And yes I have thought of getting a set of Yukon ones and building them up
but price keeps poping up and the way I drive I will brake em will see what I options I can find

[GotFlex]

And yes I have thought of getting a set of Yukon ones and building them up
but price keeps poping up and the way I drive I will brake em

just buy the 5.29s and i can bet you my truck they will never break as it will never leave the shed anyway

[badnuz]

And yes I have thought of getting a set of Yukon ones and building them up
but price keeps poping up and the way I drive I will brake em

just buy the 5.29s and i can bet you my truck they will never break as it will never leave the shed anyway

OWNED PFT

it will get pushed outside occasionally surely!

[De-Ranged]

considering its just an axle at this stage I'd have to build a fair bit more to roll it.....

I don't want your truck anyway... since your all big words, I'll do you a deal.... If the zuk is running you come on a run with me that means you don't just talk about it, you don't get too tired and go to sleep or any other excuse, you've used in the past...... just keep telling yourself there is no shame in being beaten by a zuk

Was up to half 2 this morning looking up auto trans ratio's looks like I'm not going to be able to find a RWD auto with the right gearing.... means I'm up for a set of 5.3's
Right next Q, meatc when you got your trans where was the trans computer found in the doner car ??