"Jafa's Jalopy"...3RZ-FE and on 40's:)

[Jafa]

Upon reflection, it may well have been, but I'm down the road now, so I'll carry on, once I get the chunk from China, itll still be cheaper than casting, its just the 'hassle' factor thats all

[Engineer]

any progress jafa?

Ryan.

[Jafa]

nope

[Engineer]

how bigga bit of aluminium did you need?

[Jafa]

2 bits, 1 @ 440 x 300 x 75, and 1 @ 440 x 300x 100

[Jafa]

Ok time for a bit of an update
Well I've changed direction yet again! Now instead of this being a road legal winch challenge truck, shes gonna be a trailer queen rock crawler only. Upon reflection, I think mine will be too heavy, too high and not built "specific" enough to be a good winch truck. I have other plans in that area!
To assist me in getting it finished, its booked on the ferry to go to Christchurch for Rockrash 09 at Xmas!! so I've got 6 months to get it done! Shouldnt be too much problem now that its not going to be road legal........
I've actually done some work on it this weekend too, so were away!
Built a coupler to join the Hilux geardrive transfer to Lexus auto

Step on the front is where the speed sensor trigger goes


Seal prevents ATF and gearbox oil from mixing together



O Yeah and a set of 39.5 x 13.5 Iroks will be on it also


And my block of 7075 aluminium has turned up



So plans now are no crazy PTO winch drive(on this truck....)but it will have tiptronic style gearbox management, dual reduction boxes with 2.28 in the front and 4.7's in the back, I'll remove my coilovers and replace them with Racerunner airshocks and probably go full hydro steering. No rear deck to speak of, just a toolbox,divetank and fuel cell, no dash really either, just the basics, bit of an exo to protect the cab, and thats about it, mite chuck the rad on the back too..

This is what we'll make out of the alloy as soon as the machining center is available






There's a few changes from this design, I've used a 23-23 spline coupler out of a chaindrive tf case and pressed it into a sleeve instead of making a 23-21spline coupler. I'll be using a 23 spline input shaft in the reduction case so it'll be 23 spline throughout

[Engineer]

Awesome!

[doddzee]

Nice choice of tyres ther Jafa! Id love a set of those.

[rokhound]

Come on jafa, are you serious?
Your'e just teasing eh?

[De-Ranged]

Damm Jafa I heard a rumor about how much you spent on that block of alloy my A class is cheaper than that block!!.... why didn't ya just fab up the basic shape in steel and then biff it at the cnc

As I've said before very cool

[Jafa]

:shock: Damm Jafa I heard a rumor about how much you spent on that block of alloy my A class is cheaper than that block!!.... why didn't ya just fab up the basic shape in steel and then biff it at the cnc

As I've said before very cool

Hey Reece, nah this bit as only $500 This is a prototype for casting some alloy ones for production, so we decided to make it from alloy, it will give us a better idea on machining time, and its much cooler!

[De-Ranged]

Might have been the block for the PTO... and oh yea it is way cooller

[Jafa]

Righto, we've all seen the pretty pictures from the cad system, now heres some pics of it turning into the real thing
A bit more CNC porn for ya

Here we go then, no turning back now.....its only a $650 chunk of alloy



Drilling a big hole through it



Ist operation is done, this is the end that bolts to the back of the trans



More to come this weekend

[turoa]

thats cool, nice work

[haynzy]

baaaa my dewalt battery drill would have done a better job,

[Jafa]

baaaa my dewalt battery drill would have done a better job,

fawkin builders!

[Jafa]

couple more of the transfer case side

[Engineer]

its always a bonus when components fit!!

[Jafa]

Got it finished last nite





and bolted up to the engine/trans...its looks long.... but its actually only 50mm longer than a 5speed and duals, so thats not so bad

[Steve_t647]

You decided to not clock the transfer cases?

But that does look cool, did you keep all the alloy shavings? you could almost pour them into a cast and get a second unit It does look very long tho are you thinking of having the lexus hard back in the engine bay for balance or are you thinking you will not use the standard body mounts and move everything back a little for better balance?

So with a Christmas time line and the new pace I guess it will be a little rough awesome work as usual keep it up.

[Jafa]

Nah no clocking, its already gonna be flat bellied, upon reflection it might have been beneficial, but its already sorted so it stays the way it is. Such things will be thought about harder in the next build
The engine actually fits the bay really well, with a little clearance at the fire wall, but shifting the cab back a bit might be worth looking at.Radiator will be on the rear so front of engine clearance wont be a problem.

[Jafa]

Got some work done tonite , only 5 months to go till RockRash 09! I gotta get my shit together!

Cut the output shaft on the auto




Tapped the coupler on


Installed the bearing and seal into the housing


bolted it up to the auto, heres 23splines waitin for some input


And here it is, 23spline input shaft


Also made a rear transfercase mount, kinda "Front Range Offroad" styles

[lilpigzuk]

go show them some north island reliability Jafa

[madaz068]

Looks bloody good

[timotheus]

So it will be Flat-Bellied then? What sort of clearance are you expecting under it?

Tim.

[rokhound]

That is looking seriously cool jafa.
Be nice to see something down here that is built properly. (also be a first )

[Jafa]

So it will be Flat-Bellied then? What sort of clearance are you expecting under it?

Tim.

Yer its flat bellied, I cant remember exactly how much, but I think its 700mm under the rails when its on 35's....wait till the 40's turn up

[Jafa]

Started tackin up the 'zorst tonite

[monaro427]

jeez jafa i was just checking this out on pirate the pics of the exhaust etc
great work wish i could do that sort of work

[MATT4U]

so thats the zorst finished then jaffa?????? should be sweet