"Zuk" Another De-Ranged Project

[niblik]

lookin forward to seein these complete.. coolies fella..

[Big]

:D Just got the profiles for the axle pumkins......

they are just so cool I think I might just take the rest of the day off to play with them.....

Cheers Reece

They do look very cool.. how are you going to keep everything exactly straight in every way..? ie perfect so bearings etc run true..? do you have a jig..? loving the work though..

[Moriarty]

What size press are you using to push those babies into shape??
How much clearnace are you planning on having around the crown wheel?

Oh and looking uber cool as well Reece

That'd be some punch-press to whack them out, I wanta see it in action too.

Laser or plasma cut, Reece?

And.... did you have a nice play with the bits? House and sheds, or did you get out the matchbox cars this time?

(Are we going to seee a finished De-Ranged project???)

[De-Ranged]

Got a 50ton homemade bottle jack press so don't think I'll struggle, will take a while is all..... just got to make a knife thats short enough to fit into the housing first
At its closest the base will be 3mm off the crown wheel and thats going to be in 3 places, but thats in the 10mm and there will be alot of stucture from the folds so I don't see any problems
Bearings on the hilux axle can take alot of miss-alignment just the nature of the design toyota used this dosn't mean I intend to use that.... the housings will be face cut where the diff bolts on, from that face I'll fly cut the axle tube locators so they are perfict then the final welding will be done on a big jig I"ve had half finished for several yrs
Bob I think Rok was talking about the press brake and yes they are laser cut the tollerance is just so cool on them
Oh and I was going to put up a pic of me playing but she wasn't keen on it

Here's the afternoons work
Started by machining so ball ends down

Then set the caster and diff angle on the ball housing

Caster is going to be set at 4deg and the diff will be at 12deg
Then stuck things together piece by piece most of the pieces were a tap fit
This is what I ended up with



Won't be much happening for a few days as I've got to get the work I should have been doing done

Cheers Reece

[niblik]

i'm lovin this little bit of kit guy!! very trick.. offset axle tube.. mmmmmmmm

*fwap fwap fwap*...

[rokhound]

What he said. Yep, I was talking about the press brake. Lookin the tits fella

[Big]

What he said. Yep, I was talking about the press brake. Lookin the tits fella

Yeep what rok said.. lol

[De-Ranged]

A wee update
Been doing a bit of night shift and the body clocks screwed so decided if I'm gona be up I'll do some more

Right one of you commented about jig's to make certain things are true here's the one to set the king pin inclination

its setup for welding the ball to the tube, I'm doing some hefty tack welds in there then remove and doing the welding for each section in one pass as fast as possible, then when cold check for true... there was 0.005deg of change due to warpage
As you can see I've done the long side now too... so I've started into the diff pumpkin
Here's a shot showing why I like to prototype see the chalk lines that is where the laser cuts should have gone too will modify the cad files for next time

Before I got into bending things I had to make up a small knife

And the small knife in action

For the books the press is made from shop offcuts and scrap , if you look closely at the small knife you'll see to 2 holes in the spacer, this was part of a steering arm from a mates X over steering
Anyway heres the end result


Right I need to go home and try n sleep

Cheers Reece

[rokhound]

[callum007]

Very tidy.

[niblik]

i *heart* you reece..

what internals you gonna run guy? stock zuk? or in true deranged fashion, some hybrid mix...?

[De-Ranged]

Internals are gonna be pretty much hilux 4.5 heads, hilux longside and CV's, shortside shaft is 40 series, outback Im going to run hilux head again; with a modified 40 long-side shaft .
The short side shaft will be a cut down hilux axle that I 'll respline.
The plan is to run 35" tyres with the body being so light, shouldnt have any probs with this running gear even with my heavy foot

Cheers Reece

[Big]

Love ya work Reece.. you're a clever barsteward.. very cool.. wish I had the skills you have..
Keep it up..

[Nivapulledout]

Looking fantastic Reece!!!!!

good to see the lada is still lurking in the background!! shame you never got around to finishing that.

[De-Ranged]

Thanks for the comments Big
And yes the lada is getting some work good spotting I need the floor space

Right done a bit more on this (I'm having too much fun to stop )
Needed the inner brace's and diff face sorted so I can weld the bent sections of the cover down
Drilled them and pop'd em together

This is where I discovered not all diff nuggets are the same size see the bits sticking up through the front face yea well they are sposed to be be wide enough to fit the diff.... na, the lada 4.1 diff nugget housing is 4mm small dia than the 4.5's so a bit of welding and some machining and you have

Oh and just for skiteing rights picked these up 35" 833's yea baby

Cheers Reece

[mudslut]

Good work man looks mint

[kbjj]

I like

[De-Ranged]

Bastard.... was working late hope'd to get one of the diff heads together
Was burning the top half of the cover "V'd" weld with a high amp noticed the weld starting to peak up... then a little bit later she starts to bubble Bastard out of gas

Guess its time to go home

Cheers Reece

[Big]

Bastard.... was working late hope'd to get one of the diff heads together
Was burning the top half of the cover "V'd" weld with a high amp noticed the weld starting to peak up... then a little bit later she starts to bubble Bastard out of gas

Guess its time to go home

Cheers Reece

lol.. been there done that.. farks ya right off when ya on a roll too..lol

[De-Ranged]

Got 4 Nights of night shift coming up so decided to stay a bit late and help the body clock adjust

Got stuck in on that head... ground out last nights welds interestingly the only porosity was right in the root of the weld.
Anyway burned all the 6mm cover and started into the 10mm strips on the base, just for overkill and since I like to burn wire I'm welding both sides here's a shot looking inside the top cover while I'm fitting the first of the 10mm strips

This shows how tight I've keep the bottom this is all about getting the max ground clearance and still keeping it strong enough I can come down canty and grind

Heres the outside welding finished


I've still got to finish welding the last two strips on the inside of the head but I'll wait for things to cool down before I take the jig off
The next step is to mount the diff face in the Mill and fly cut the holes for the tubes.... going to be a slow job cutting through this


Right time to go home and have tea

Cheers Reece

[GotFlex]

why didnt you just buy a diamond axle housing from the states

[De-Ranged]

why didnt you just buy a diamond axle housing from the states

Becouse this is cheaper I don't earn manager wages.... and I'll have more ground clearance

[oldyella]

Got 4 Nights of night shift coming up so decided to stay a bit late and help the body clock adjust

Heres the outside welding finished

This is a real interesting build. The virtual lift is mint, those 35's have heaps of room.

Will you will be widening the wheel track a bit as well to try keep it on its wheels and what internals are going into this new diff housing?

Cheers,

Pete

[Fakey]

why didnt you just buy a diamond axle housing from the states

Becouse this is cheaper I don't earn manager wages.... and I'll have more ground clearance

That an wheres the fun in buying shit an bolting it on when ya can make things yourself? Learning an building is half the fun of a new truck
Very impressive work, Im watching this build with great interest as Im sure most people on here are

[De-Ranged]

This is a real interesting build. The virtual lift is mint, those 35's have heaps of room.

Will you will be widening the wheel track a bit as well to try keep it on its wheels and what internals are going into this new diff housing?

Cheers,

Pete

that virtual lift is nothing its all CAD'd I'm trying to keep this as low as possible CAD is such a cool tool
Some figures for you
53cm clearance to the base of the chassi
1.26m to the top of bonnet
1.80m to the top of A pillar
And the cool part measured from the outside of the wheel 70cm of travel at each axle
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
As for the axles 50mm wider than a standard hilux I'm planing on running IFS rims for less scrub steer will help with road handling (oh if you read back a few posts your'll find the axle details)

You got it Fakey this is my fun!! yea 4WD'n is fun, I do have a ball out there with my mates but building them is more fun... its taking what I can imagine, what I can dream up and building it seeing it come together in front of you

Cheers Reece

[De-Ranged]

Just a wee update before I head to New Plymouth got a wee bit of time up my sleave so pulled the diff jig and welded up the few remaining inside welds


Right thats me better scoot

Cheers Reece

[GotFlex]

Becouse this is cheaper I don't earn manager wages.... and I'll have more ground clearance

i was only taking the mick son

Love the work you do, makes me wana do more to the mu when i see your stuff, hmmm coil over conversion up front ??

[De-Ranged]

Right a wee update

Got the other (rear) diff head welded up...
Made up a jig to hold the heads in the mill so I can cut the axle tube mounting holes these will align the tubes
Here's the reason I have a crap mill its saving grace... the head can be pulled round on the tower so I can do odd ball things on the side of the bed

heres a shot showing the guide bar setup

I've got the fly cutter in just removing a bit that got in the way when I was trying to center it
Before I start cutting (tomorrow morning) all I've got to do is sort out an extension to the flood cooling
Hopefully tomorrow night I might have a front axle
Then onto the back, got the FJ40 rear longside inner axle this arvo.... just got to talk to a couple of very wise people about what I plan to do and that will be all go

Cheers Reece

[SMOKEY]

work there Reece , I like what you are doing and like all manufacturing, take the LOVE out of it and you wouldn't be able to afford it,

PLEASE FINISH IT,

FITZY.

[Big]

8) work there Reece , I like what you are doing and like all manufacturing, take the LOVE out of it and you wouldn't be able to afford it,

PLEASE FINISH IT,

FITZY.

I Concur..