Post by: Harrison on December 17, 2019, 12:51:49 PM
VW 1.8T/01M auto (180hp)
2 seater (obviously)
HP front/LP rear steering D60s
5.38s, shaved, chromos/superjoints, welded (until I decide on the right choice of locker)
Minimal trussing, single ended rams
1.75 X .120 wall DOM
ORIs
39s/KMCs from Cherokee
<3500lb
I would really like to have a roller that needs some details ironed out and money spent on ORIs and axle parts by roughly this time next year. Time will tell if that's a reasonable goal or not. No parts will be taken from the XJ aside from wheels/tires so I can keep wheeling in the meantime.
Since both transaxle outputs will be offset to the passenger side, I am building offset 60s with the HP in the front and LP in the rear. Every other option I considered was either more expensive by a huge factor or were questionable from a durability perspective. 2.125 x .188 sleeve is being used to switch the diff sides, literally cutting the tube off one side after careful measuring and welding onto the other side.
I started on the HP axle and ran into issue keeping the tube straight out at the end. I made many errors on this first attempt I won't bore you with. I had the machine shop at work turn me up some pucks and bought the 1.5" tie rod DOM on Black Friday sale. This gave me a measurable way to know where I was at. It takes more ability than I have to bend a D60 that's off by 1/4".
(https://i.ibb.co/Rz8qBYq/IMG-9883.jpg) (https://ibb.co/WgCLPGL)
(https://i.ibb.co/J57v69C/IMG-9889.jpg) (https://ibb.co/XSs70qV)
(https://i.ibb.co/xMSbft5/crooked-tube.jpg) (https://ibb.co/Zh6rYpT)
Long story short, I cut the sleeve out of the HP after lots of frustration and moved over to the LP. From the learning from the failed HP debacle, I did a much better job keeping this one straight. It is off by <.100". I am going to try to improve that when my rosebud torch tip arrives, but have already decided this is within an acceptable tolerance for a 30mph steering axle.
(https://i.ibb.co/QY5Gs67/IMG-9894.jpg) (https://ibb.co/L9Gf4CD)
(https://i.ibb.co/wBhDr3s/IMG-9927.jpg) (https://ibb.co/tQpyPkX)
(https://i.ibb.co/w4XP7wg/straightish-tube.jpg) (https://ibb.co/zZYBF7x)
While I waited for the new piece of tube to come for the sleeve on the HP, I started on the shave kit for the LP. I'd say about 3hrs total of work. Advertised 1" of clearance improvement, pretty close. Considering running some beads of hardfacing rod across the bottom.
(https://i.ibb.co/FVyW0pH/IMG-9932.jpg) (https://ibb.co/M6thGdB)
(https://i.ibb.co/5GnxjhY/IMG-9935.jpg) (https://ibb.co/S5d7mwQ)
(https://i.ibb.co/Drm8TXK/IMG-9933.jpg) (https://ibb.co/CP4MDd0)
(https://i.ibb.co/hyFFR0b/IMG-9942.jpg) (https://ibb.co/37mmyK2)
(https://i.ibb.co/S0RCp0P/IMG-9936.jpg) (https://ibb.co/3WBZHW7)
I chiseled off the skull immediately after this picture.
Here it is, my driver drop LP shaved steering housing.
(https://i.ibb.co/wCLjdRr/IMG-9943.jpg) (https://ibb.co/mtBgRGF)
Post by: Harrison on December 17, 2019, 12:57:18 PM
Low mileage but lots of chassis electrical gremlins and trashed interior from leaky sunroof. Has been sitting for about 4 years. Sticker on the radiator support said the timing belt was changed 200 and miles and four years ago!
(https://i.ibb.co/87w3WBD/IMG-9954.jpg) (https://ibb.co/1mNVDnf)
(https://i.ibb.co/tH8VLZ5/IMG-9962.jpg) (https://ibb.co/sgy8W5r)
(https://i.ibb.co/nwCVqXs/IMG-9963.jpg) (https://ibb.co/NFSkg06)
Post by: Harrison on December 17, 2019, 12:58:23 PM
Tube and seat purchase after the holidays. Need to figure out something for a chassis table.
Post by: mr.mindless on December 17, 2019, 03:55:28 PM
Very glad you made those pucks, the side gear splines thank you.
Didn't realize the VW was that fresh on miles and belt, that's super sweet. This one has a good trans, too? I will have a core trans for you out of the Beetle if you want one to build or spare diff parts. It SLAMS into all gears after a bit of lag once warm, (feels perfect when cold) both shifting from P/N, and when driving in D. all gears function. 2005 beetle 1.8t.
I know you were thinking of computer deletes and older fully hydraulic transmissions but thought I'd throw that out there.
Post by: M4wdFab on December 17, 2019, 04:32:46 PM
im not a spline materials junky but i bet there is a lot more clearance and play then you think allowed especially on the long side.
good efforts might keep things living longer. my front axle is a disaster with about 1/4 of a wheel turn stack up from drive slug to drive slug. yet to strip any splines out, but im sure its not helping dynamic loads on most of the components.
Post by: Harrison on December 18, 2019, 12:31:54 PM
If it's not fine, 70s VW transaxles seem to have common clutchy shifty bits across fwd and rear engine stuff and there is a lot of support out there with those for the dune buggy type crowd. That's my backup. I lose OD and go from a 4.53:1 "low range" to a 3.78 though. Probably still fine but worth trying to make what I have work first.
Regardless... if there is a cheap or free core to be had, I'll take it.
I suspect most axles with 10ft of weld holding Artec trusses on one side of the tube are not terribly straight either. I've never seen or heard of anyone who has stripped splines or anything like that in any scenario.
Post by: Harrison on December 23, 2019, 12:17:54 PM
Axles and drivetrain laid out on the floor. The proportions of my XJ seem to work well for what I wheel so I am shooting to roughly replicate them. 106" wheelbase and 20" belly.
Need to get serious about buying tube and seats now.
(https://i.ibb.co/6rLZs4v/IMG-0025.jpg) (https://ibb.co/rFNtyZb)
(https://i.ibb.co/G2cs1Q8/IMG-0029.jpg) (https://ibb.co/0MhBWy6)
(https://i.ibb.co/NKzRR5G/IMG-0027.jpg) (https://ibb.co/DQnddhj)
(https://i.ibb.co/J7hwY5j/IMG-0024.jpg) (https://ibb.co/vPt6NZ4)
Post by: mr.mindless on December 23, 2019, 01:50:52 PM
Post by: Harrison on December 30, 2019, 09:37:20 PM
(https://uploads.tapatalk-cdn.com/20191231/f662e8a888f2bca804df02b009095582.jpg)
Post by: mr.mindless on December 30, 2019, 09:47:52 PM
Post by: Harrison on December 31, 2019, 09:22:40 AM
Ecotec/Powerglide/D300 combo is probably in the same weight range as this setup and presents a lot fewer engineering challenges and reliability questions.
This has me second guessing my path a little bit. I was expecting 450-500lb for the VW drivetrain and also did not realize how light a conventional 4wd drivetrain could be.
Post by: mr.mindless on December 31, 2019, 11:31:26 AM
Post by: Harrison on December 31, 2019, 11:43:06 AM
Powerglide is ~140 with converter and fluid
Atlas is 110
Post by: Harrison on December 31, 2019, 11:48:25 AM
Powerglide is ~140 with converter and fluid
Atlas is 110
Post by: M4wdFab on December 31, 2019, 11:51:39 AM
Post by: Harrison on January 02, 2020, 12:12:20 PM
Lower first gear and two overdrives compared to 4spd. 3500rpm in 5th will be about 32mph, much better than the 22.5mph the 4spd would have given.
Working on axle trusses tonight. Gathering supplies for chassis table build. Ordering seats today, tube not far behind.
Post by: Harrison on January 06, 2020, 08:58:12 PM
Pics are at 22" belly and 20" axle tube centerline. Belly height is subject to change a little. Front driveshaft pictured length will be about 24", more or less planning to have to run one of the Tom Woods offset u joints at the output like I do on my Jeep.
Legroom is going to be at a premium. Doghouse will need to be well insulated.
Working on an output solution that mates an 8.8 flange to the VW flange via TIG weld after a little lathe time on the 8.8 flange. Planning to run single joint 1310s all around, have held up well on my Jeep and I don't expect more abuse on driveline parts than my pig of an XJ. I'd also rather snap off the shelf stuff like that over obscure transaxle parts.
Seats are on their way. Hopefully ordering tube this week, Dan is working on gathering people for a big order.
(https://i.ibb.co/RTrcXP1/5-DBEF715-EC4-A-4-F03-8-DB4-E5-F5-A700-C1-E5.jpg) (https://ibb.co/Xx0tnp9)
(https://i.ibb.co/HBsMtGS/F8-BB47-A7-A273-464-A-B21-C-F2-CCF8-BE8619.jpg) (https://ibb.co/FmMf58r)
(https://i.ibb.co/s1vWkrP/DF6-DB1-DA-C490-4-A47-A461-F4-C3012-D5-C13.jpg) (https://ibb.co/6tRXV5Z)
(https://i.ibb.co/DKSfhFk/18322-AC6-159-D-41-BF-89-A4-E14-CBB67-CCFF.jpg) (https://ibb.co/JkMjVT2)
Post by: mr.mindless on January 06, 2020, 09:10:09 PM
Maybe move seating a bit further back and further up than typical to help with legroom?
Post by: Harrison on January 06, 2020, 09:40:47 PM
Will know better about legroom when I get the seats in.
Post by: M on January 07, 2020, 09:02:13 PM
Post by: Harrison on January 09, 2020, 12:54:43 PM
Seats are at Dans, grabbing Saturday. VW and 8.8 flanges are at the machinist.
Need tube!
Post by: Harrison on January 12, 2020, 06:57:16 PM
Hope to be picking up my tube from Dan this weekend. Tab assortment and some DOM/bushings from Ruffstuff are on their way.
(https://i.ibb.co/RTmZgCG/D04-CFD7-E-FD51-41-A6-8-CE4-A20-E3-D92-B7-F7.jpg) (https://ibb.co/N2PQFLg)
(https://i.ibb.co/6tmZp5k/B48-F9-BCE-F8-F0-49-EB-96-FA-09-DEA253-CF61.jpg) (https://ibb.co/Lg8Pqf3)
(https://i.ibb.co/mBnbKTy/D658-EB98-8974-486-E-972-A-40-ADAAE78-CE3.jpg) (https://ibb.co/BPhcJ36)
(https://i.ibb.co/NrwPB8X/679-E0-BF1-44-AF-4150-9043-21-E236-F730-D8.jpg) (https://ibb.co/sCLGY0h)
Post by: mr.mindless on January 12, 2020, 07:08:11 PM
Post by: M on January 12, 2020, 09:38:51 PM
Post by: Harrison on January 13, 2020, 04:12:59 PM
I would only consider rear if it can be done at shoulder height or lower, I do not want to sacrifice rear visibility. Not sure if that makes a front mount mandatory or not.
This is the chassis I am more or less modeling mine after.
(https://i.ibb.co/6bXX6d2/19817-CAC-A6-E8-4472-8539-0-D381-A5805-A6.jpg) (https://imgbb.com/)
Post by: mr.mindless on January 13, 2020, 05:16:56 PM
the plastic tanks and single core are big strikes against the vw, but those fans and controls are good stuff if not salted to death.
Post by: Harrison on January 13, 2020, 07:33:22 PM
(https://i.ibb.co/LhXyTy8/8-C7-BB0-DA-FF3-E-490-F-9210-D74-CDD07-B3-E4.jpg) (https://ibb.co/yBcCzCX)
Post by: M4wdFab on January 13, 2020, 07:40:46 PM
Post by: Harrison on January 14, 2020, 08:24:50 PM
(https://i.ibb.co/Tv0wkHR/21-CC346-D-CE06-4-CAF-BFFF-1-A5071-D066-F0.jpg) (https://ibb.co/ZLgfVhK)
Post by: M4wdFab on January 14, 2020, 09:40:40 PM
have you ever seen the plasma tube notcher cheat tools i made?
Post by: Harrison on January 14, 2020, 10:24:44 PM
Post by: M4wdFab on January 15, 2020, 07:20:14 AM
Post by: Harrison on January 17, 2020, 12:44:10 PM
(https://i.ibb.co/vXYJ8p0/7-E82-D78-C-ADB3-49-E5-8-A09-2-C6112-C132-F1.jpg) (https://ibb.co/phy3pcY)
(https://i.ibb.co/k3vK3hC/747-BFF76-4-F0-E-4944-9-AC0-1-D5-C3-A03-EC3-D.jpg) (https://ibb.co/bHD1Hr9)
(https://i.ibb.co/Yy6yqn3/F07-A2-A00-5-F07-4-CD3-BC1-F-4121655-D1064.jpg) (https://ibb.co/6121f9m)
Post by: mr.mindless on January 17, 2020, 01:40:35 PM
And how do the CV flanges come out, anyway? Split the trans and c-clip?
Post by: M4wdFab on January 17, 2020, 02:43:56 PM
Post by: Harrison on January 17, 2020, 03:32:14 PM
The VW flanges bolt into the transaxle, that was a significant factor in my choice to go VW. People have to come up with some pretty claptrappy ways of retaining standard "pop-in" CV stuff. They all work, but this is much better.
(https://i.ibb.co/ydfXrCK/D872194-A-B2-CC-41-F5-8-B1-B-0-FF1-D7-E5-D6-BE.jpg) (https://ibb.co/wB0Rfq8)
(https://i.ibb.co/k1PRgGH/82664-D15-022-F-4-B12-99-D5-18-A4-DAFCF902.jpg) (https://ibb.co/C2Sk5w1)
Post by: M4wdFab on January 17, 2020, 05:01:49 PM
how much they kill you for some what looks like fairly easy eye ball lathe work if you dont mind me asking?
Post by: Harrison on January 17, 2020, 05:31:06 PM
He had to shave some meat off the countersunk bolt heads to get them to not interfere with the 4.25 bolt circle.
Turn off pinion snub, add pilot bore
Drill and countersink 6 bolt VW pattern
Hardware provided, modify countsunk heads
2 times
Verbal quote was $100, ended up being $159.XX with tax and hardware. I don't have a lathe or any experience using one, didn't seem unreasonable to me.
Post by: M4wdFab on January 17, 2020, 10:46:28 PM
Post by: Harrison on January 20, 2020, 10:14:18 AM
Post by: mr.mindless on January 20, 2020, 11:15:30 AM
Post by: M4wdFab on January 20, 2020, 02:30:40 PM
On your guy's driveshaft pillow block bearings - what kind of fit do you guys shoot for? Press? Light, tap fit?able to slide in. usually have to turn out the 2" pillow bearings so 2" DOM will fit. I like the 4 bolt ones better than the 2 bolt saddle if you have room like we did in matts car.
Post by: Harrison on January 25, 2020, 06:42:49 PM
Had planned to use an off the shelf Toyota rear driveline disconnect but after some research I found that the Toyota stuff was 1.09" dia which is smaller than even the VW splines so I ditched that idea.
Grabbed a rotted out Dodge 2nd gen front 60 for $150 this week and am pillaging it for parts.
The yoke shaft will get a 1480 to 1410 conversion joint and and 1410 yoke flange that will bolt to my 8.8 pinion flange assembly.
The seal surface on the coarse spline end of that shaft is a hair over 1.875 and the splines are a hair under 1.875 - will have a buddy turn that down so a 1.875 pillow block slides right over.
The other shaft and the pinion will get cut up and somehow turned to match the ID of a standard piece of DOM, will defer to my machinist on the best method to accomplish that. Cut tube to length needed and weld together. 1.25 flange bearing should slip right over the outer bearing section of the pinion. Splines will hang out the back of the chassis, standard D60 yoke will bolt on sandwiching the flange bearing and keeping that shaft in place.
Reuse Dodge fork mechanism housing with a cable shifter setup.
Lots of claptrap. I started researching 1.8T to GM trans adapters as a backup :-[ It'll be fine! I think.
(https://i.ibb.co/WN9D3QN/D39-A4-A27-28-E7-42-E6-94-E2-C90-AA2-CFC110.jpg) (https://ibb.co/nq230Tq)
Post by: mr.mindless on January 25, 2020, 07:40:59 PM
Post by: dubt on January 25, 2020, 09:50:15 PM
Post by: Harrison on January 26, 2020, 08:40:38 PM
Looks like split the trans from the engine, pop the front cover off and lift the carrier out. Likely get the spiders welded up this week while I’ve got some time.
Helped DJ get some stuff sandblasted today so I brought my 60s along.
(https://uploads.tapatalk-cdn.com/20200127/cd58a2f4574a423102c697801731e450.jpg)
Post by: mr.mindless on January 26, 2020, 11:28:01 PM
I could do selectable hubs on the front axle but doubt I could get them to luck/unlock successfully since they’d tend to bind all the time.
Post by: Harrison on January 27, 2020, 08:00:28 AM
I plan to swap the Yukon selectable hubs off my Jeep and put them on the front. Considering welding the front and putting some kind of auto locker in the rear. I will never not be in FWD on the trail so I'm not sure I see the need for a locker there.
Post by: mr.mindless on January 27, 2020, 08:58:15 AM
Theres a great limited slip options but wavetrack (iirc) is $700.
Post by: Harrison on February 03, 2020, 10:29:42 AM
Decided to tackle diff weld in the meantime. Unbolt from engine, unbolt front cover/bellhousing, carrier lifts right out. Sealed back up, mating back to engine tonight WITHOUT stupid triple square fasteners.
(https://i.ibb.co/5n2LwMy/3-F886384-EF23-40-F2-81-E7-C9-E984938-E78.jpg) (https://ibb.co/61NFLnx)
(https://i.ibb.co/VqKhny3/64298062-0-A24-4007-8-F10-FEACBBC9-EDE6.jpg) (https://ibb.co/YLrKn9b)
(https://i.ibb.co/9wcpTq1/4-A66-D321-2-C09-458-C-9-FF6-07250-EB9-A5-D1.jpg) (https://ibb.co/M8ZgVRt)
Post by: M4wdFab on February 03, 2020, 06:13:22 PM
black magic!
Post by: Harrison on February 03, 2020, 07:09:25 PM
is there a bearing cup in the table side up above diff?
black magic!
Correct! Pretty funky stuff.
Post by: M4wdFab on February 03, 2020, 07:15:31 PM
Post by: Harrison on February 28, 2020, 09:16:49 PM
Shooting to have drivetrain mounted tomorrow. Next up will be making the pass seat and rear driveline disconnect happily occupy the same space. Guess I should get some link parts coming.
(https://i.ibb.co/HhxywW9/CD8-C3-DDD-B703-462-A-842-D-B3-D0-F7-DC393-E.jpg) (https://ibb.co/6X1S93q)
Post by: M4wdFab on February 28, 2020, 09:54:49 PM
Post by: Harrison on February 29, 2020, 09:01:22 PM
Smike is right so far - this is much easier and more fun than building around a rusty Cherokee.
(https://i.ibb.co/0MQsBxS/46-B20-DFF-66-DB-4355-9917-FB83-FC5081-F7.jpg) (https://ibb.co/QNXD84R)
(https://i.ibb.co/SQRP9sk/1-CFE9-B58-6981-4-D6-E-807-A-E0-B1-E69-A0-F1-E.jpg) (https://ibb.co/Jx5KMBY)
(https://i.ibb.co/2kt001T/25610-B0-D-D348-41-E7-B647-BF116-FF8-C2-FA.jpg) (https://ibb.co/yQymmcr)
(https://i.ibb.co/wspKZvL/EEFCB4-E1-2138-4-D1-D-91-B6-622-E704-A11-D0.jpg) (https://ibb.co/cL2NKmv)
(https://i.ibb.co/mJbSqXD/12-EF95-A1-2136-4-A9-A-A43-B-C440-C8-A3052-C.jpg) (https://ibb.co/K6bmqL0)
Post by: Harrison on March 07, 2020, 11:29:47 PM
(https://i.ibb.co/Ky5Zq71/26701-C78-9-DCB-47-B7-B83-F-E5-B24409-CF1-B.jpg) (https://ibb.co/nkw2cfW)
(https://i.ibb.co/N9QM6hP/C50-B14-A0-2-E51-42-B2-A9-D1-47-CD10372-B3-F.jpg) (https://ibb.co/Lxb3zwW)
(https://i.ibb.co/Sn4SG7v/62-B60-E8-C-C9-C4-42-CC-9620-F3-A0241-D70-CF.jpg) (https://ibb.co/jMPtsZ4)
Post by: Harrison on March 09, 2020, 02:06:40 PM
What is this group's thoughts on the calculator? General rules of thumb? Short driveshafts mean keeping pinion pointed up. Need to do some reading.
Airs vs coilovers? I think either could work well given my application.
3rd drivetrain mount finished.
(https://i.ibb.co/DkY6w9w/7630106-D-FACC-4-EED-9558-182497-B4-E414.jpg) (https://ibb.co/pZQs4f4)
(https://i.ibb.co/Qv4JBcF/37-E10-B14-8849-4091-9-AEE-A49-E70631-E93.jpg) (https://ibb.co/PGdrpYZ)
Post by: M4wdFab on March 09, 2020, 02:54:51 PM
id run 2" air shocks on this rig without question. add 60-90 cc of oil right out of the box to them to keep the spring rate up and the lean / unloading down.
keep your lower links right around your tire diameter +/- 2"
keep separation of links at axle housing 1/4 diameter of tire or larger.
if you want more of a radius arm effect with the pinion always pointing to case yoke, lower separation at chassis side.
if you want the pinion to rise as the axle droops, make the upper link longer.
i have never found any of the calculators to be use full. usually you end up compromising somewhere and then throwing all the numbers you thought were great out the window. tack up what fits and works, flex and then adjust. if it ends up doing weird anti squat things, usually a simple adjustment can be a fix. flat lower or even negative links at ride height always help you.
Post by: mr.mindless on March 09, 2020, 03:38:00 PM
pinion angle change through travel is entirely related to antisquat. antisquat/antidive is the dynamic consequence of axle rotation through travel. You'll want relatively neutral AS. air shocks will stand right up or sink right down on application of power if you have far from neutral numbers.
The tendency for some rigs to really lean (I think Ryan's Atom Smasher did this? Something in our group did) or stand up when making tight turns while all 4 tires are locked together is a consequence of suspenios numbers too. If wheelbase changes a bunch due to a high angle roll center, when one side scribes a tighter circle, the push-pull on wheelbase on each side will try to steer the axles and force articulation. The shorter and steeper the links, the worse that'll be. When it gets into link angles with regard to inboard-outboard, that's when my mental model breaks and something that can graph it out helps.
The lighter the car is, the more suspension dynamics will push the chassis around so it might be worth thinking about those things.
otherwise, I echo every word smike said above. if you want light, 2.0 air shocks is the ticket, probably saves you near 200# in springs and such.
Post by: gif on March 09, 2020, 07:28:05 PM
if nothing else use it to get in the ball park before wasting a bunch of time and materials.
This was my target when building my buggy.
I think it worked pretty good.
- Flat, short (30-40â€) lowers
- 30-40% rear AS, adjustable +/- 15%
- (Taking into account the position buggy (up hill / down hill)
- Roll center within 3" of sprung CG
- front AD of 65%, adjustable +/- 10%
- slight over steer axis in front
- roll center height matching rear
i would be willing to post up my calculator numbers if you want.
Post by: mr.mindless on March 09, 2020, 08:16:22 PM
Post by: Harrison on March 09, 2020, 10:17:39 PM
Mike and Gif - if they’re easy to find, I wouldn’t mind taking a look at your numbers.
How are you guys estimating COG?
Post by: gif on March 09, 2020, 10:37:45 PM
Post by: mr.mindless on March 10, 2020, 12:03:51 AM
Post by: Harrison on March 23, 2020, 12:25:05 PM
Ordered a 5 gallon Jaz vertical fuel cell and 3 core alum TJ radiator with built in shroud and 16" electric fan.
Underestimated tube usage, need a couple more sticks.
Drivetrain disconnect parts are fully machined and mounted, ready for welding. Still need to mount fork housing and adapt it for cable actuation. Seats are being raised about 2" over what they were before.
(https://i.ibb.co/DVbpRBw/D185-F474-FC4-D-4-BBA-AB15-F38-BA9-BDEABE.jpg) (https://ibb.co/GxJT5ZC)
(https://i.ibb.co/71MB9yF/BA90-B841-3-A02-4-AAF-9-B95-76-BF551-DBAED.jpg) (https://ibb.co/d5CXhKy)
(https://i.ibb.co/JxVQDD9/422142-EA-7-CDE-41-FD-BB06-B4-F56-EFEAAA0.jpg) (https://ibb.co/VHRmffs)
(https://i.ibb.co/nQbw5zF/636-D2-F4-D-E6-BE-4806-A1-C0-A0943564-AFD6.jpg) (https://ibb.co/h2ygtDS)
Post by: gif on March 23, 2020, 06:39:27 PM
Post by: Harrison on March 28, 2020, 10:55:46 PM
Cutting brake master cyl comes Wednesday. Will go right next to disconnect lever. Fuel cell here, radiator comes Monday. Need more tube to get both mounted. Next up will be running coolant lines. Need to pull shifter and brake pedal assy from Jetta and work on mounting those too.
https://www.youtube.com/watch?v=tn-pY2wUVVk&feature=youtu.be
(https://i.ibb.co/D1ZffrM/647-BF85-D-249-D-48-B0-AC80-6-BC04-B9-F5-C0-B.jpg) (https://ibb.co/4FHRR1S)
(https://i.ibb.co/t8hxLxz/06-B2-FBC6-4511-4-A22-A760-30-BE3-E627-C57.jpg) (https://ibb.co/SRxdfdc)
(https://i.ibb.co/ZVxPJs5/327-B7675-A6-CB-447-F-9442-AD9-C7066527-A.jpg) (https://ibb.co/G0RLJwy)
Post by: dubt on March 29, 2020, 08:44:02 AM
Post by: M4wdFab on March 31, 2020, 02:43:47 PM
i think you mentioned the parts but i forget
Post by: Harrison on March 31, 2020, 02:58:47 PM
that collar seems like its half the size i would guess i would have made it. is that like front axle parts from dodge or something?
i think you mentioned the parts but i forget
Dodge Dana 60 CAD parts from a 2nd gen. It's all pretty beefy stuff, and is upstream of the axle gear reduction as opposed to downstream where it was designed to be. I think/hope 1310s will be my driveline fuse.
Post by: M4wdFab on March 31, 2020, 03:05:05 PM
Post by: TrailTamer on March 31, 2020, 05:24:58 PM
Drivetrain disconnect parts are fully machined and mounted, ready for welding. Still need to mount fork housing and adapt it for cable actuation. Seats are being raised about 2" over what they were before.
(https://i.ibb.co/71MB9yF/BA90-B841-3-A02-4-AAF-9-B95-76-BF551-DBAED.jpg) (https://ibb.co/d5CXhKy)
neat! I am looking forward on how well this set up will work for you.
Sorry if I missed it but.. It's going to be unsupported at the long side's shaft? Relying on carrier bearings and shaft's pilot bearing to keep the two piece shafts aligned? I wonder how well, or pita it'll be to engage and disengage on trails.
Post by: M4wdFab on March 31, 2020, 05:38:56 PM
have you ever seen the compression saddle i made for the pillow block bearing i have in the rear of my car? depending on where you sourced that bearing you will notice like a huge price window from china cast 20$ bearings to legit (maybe) USA 300$ bearings.... well i broke one some how, and added a compression U to the 2 mounting bolts to "cage in" the cast. hopes were to make it stronger, and worst cast contain it to limp mode if complete failure again. my entire shaft kerploded and vacated when the bearing failed.
makes R and R no different and was good piece of mind.
in matts car we moved to the 4 bolt style flange and felt good about that one.
Post by: Harrison on March 31, 2020, 08:59:22 PM
I have seen less beefy parts in transfercases I have abused, but as with a lot of things on this build... time will be the true test.
Bearing saddle - no, I have not seen that but I like the idea and will probably do that. This is a $20 eBay unit so I’m sure it’s nothing that great. I am assuming it’s just a 3/16 or 1/4 strap that form fits the bearing and catches the bolt holes. I am definitely keeping in mind ways to contain parts flying with the pass seat right over all that stuff.
Now that I think about it... flange bearing like the rear would have worked fine there and would have simplified mounting the CAD shifter housing... bah! Oh well.
Thanks for the compliments guys, means a lot from this crowd!
Post by: M4wdFab on March 31, 2020, 09:39:33 PM
Post by: matt on April 01, 2020, 01:11:04 PM
My tractor 4wd is like that. Trying to disengage 4wd will moving forward and turning the steering wheel and pulling the level.
Post by: Harrison on April 01, 2020, 01:47:11 PM
Something to consider if you haven't already, Is the collar spring loaded to the shifter? Otherwise you will need to hold the handle until the splines line up and it engages.
My tractor 4wd is like that. Trying to disengage 4wd will moving forward and turning the steering wheel and pulling the level.
There are detents to hold it at each end of it's travel, but not planning to spring load anything. Not a whole lot different than shifting any other non-synchro machine, will take a little finesse.
Post by: Harrison on April 14, 2020, 12:16:45 PM
Comanche has a sweet rod knock so I retooled garage last night to deal with that, likely no updates here for a few weeks. Cool to see side profile from further away than 3ft, makes me realize how small it's going to be. Need to grab my spare 39 from the trailer when I have a chance to use for scale.
I am still working but Hannah's furloughed and uncertain times, so I am hoping to knock out some things on this with parts I have in stock or that aren't big dollar expenditures.
Finish coolant tubing
Mount pedal assembly - decided to use integrated booster, throttle, brake pedal assy from Jetta
Buy/mount steering wheel
Mount shifter
Finish chassis backhalf tubing
Buy/mount intake/intercooler piping
Likely take on link design myself - parts are all here
Buy heims and build tie rods
Wiring (dread)
AR plate for belly - pending material cost
Plenty of other odds and ends to be tackled I'm sure
Believe I have all axle components to make a roller. Bought 4 superjoints from Dan a few months ago but need all the other bling stuff plus air shocks - about rounds out the big expenditures left that I can see.
(https://i.ibb.co/TPLMG9B/67-EFAED9-09-A1-47-BE-8010-1-BF8665-AE439.jpg) (https://ibb.co/p4yjTYv)
(https://i.ibb.co/GvB7WM2/4-B7619-C4-1-F1-E-43-A5-8-F93-DBF0-C1-D42660.jpg) (https://ibb.co/jvBhywM)
(https://i.ibb.co/PjCBpKT/79-A9-F1-D2-A5-E8-4-ECE-B9-F0-C4-CF25-CDCE84.jpg) (https://ibb.co/9gYRX6w)
(https://i.ibb.co/0c5nmsZ/4327-B635-145-B-46-F6-96-A6-762725299-F38.jpg) (https://ibb.co/2yJFWZP)
(https://i.ibb.co/vJVmMys/5-EB0-B0-B1-7021-44-ED-BA72-79-D79-FDAAC88.jpg) (https://ibb.co/64rbq9v)
Post by: mr.mindless on April 14, 2020, 02:41:06 PM
curious to see how that radiator keeps up. You reusing the stock SMIC somewhere? Those are the packaging issues I keep thinking about.
Deciding between a short/wide FMIC behind the front bumper or the stock SMIC on the side behind the passenger front tire. Stock radiator doesn't have much in the way of air flow but size is OK, could probably run a quality shroud and be OK. It's behind the footwell in front of the engine. Bit of a scoop should help that not be a low pressure zone at road speed with the front axle causing undercar turbulence?
Post by: mr.mindless on April 14, 2020, 02:41:47 PM
Post by: Harrison on April 14, 2020, 03:38:04 PM
oh, I see that FMIC in the side shot.
Yup! FMIC with dedicated 12v fan. Radiator is a 3 core TJ replacement unit with 16†fan, I’m thinking that’ll do but we’ll see.
Post by: Harrison on June 19, 2020, 01:15:05 PM
But...
Comanche is running well.
Hannah goes back to work 9/8 and Covid benefits cover most of her pay.
...and we found out we have to leave our rental, so we are buying a house! Hopefully closing at the end of July. Has a big wide driveway and this behind it:
(https://i.ibb.co/RhPfk1X/garage.jpg) (https://ibb.co/0BZTRk0)
Gonna be a crazy couple months but once we are settled, I am excited to jump back on this project!!!
Post by: etk300ex on June 19, 2020, 01:44:54 PM
Post by: cracker on June 19, 2020, 03:05:59 PM
Post by: mr.mindless on June 19, 2020, 03:20:41 PM
Post by: Harrison on September 03, 2020, 08:47:04 PM
Spent the last few weeks getting myself setup in the new place. 100 amp subpanel, air lines all over, and many new tools purchased. Sinking my roots in so it's time to get my shop setup the best I can. I have spent the last umpteen years making brackets with a hand drill and angle grinder in a vise, and I am super excited to have some proper equipment.
(https://i.ibb.co/2gVnDkR/F562-F52-B-EDBD-4690-92-FF-4-B29-C045-EF69.jpg) (https://ibb.co/r487Cwq)
(https://i.ibb.co/PMR38zM/B3-E3-CCDA-BD40-4-C46-8-DA7-69-CE7-ED6-F0-CC.jpg) (https://ibb.co/qCzXwFC)
(https://i.ibb.co/9qHsSMF/DA3803-D5-241-C-4-E94-8-C41-78-F7275-ABD95.jpg) (https://ibb.co/K9xFS1M)
(https://i.ibb.co/4Zv27JP/ECDA1748-05-C0-47-C0-9873-3-B639-D281882.jpg) (https://ibb.co/zh9FrNG)
(https://i.ibb.co/vHyscRm/23-BC82-F4-09-DE-491-A-A526-58080558736-E.jpg) (https://ibb.co/HVwNK3Y)
Post by: M4wdFab on September 03, 2020, 11:46:11 PM
Post by: Harrison on October 06, 2020, 12:19:52 PM
Front suspension mocked in place. All appears to be happy, getting about 2.5" of driveshaft length change over 15" of up/down travel. Max angle 27°, hopefully clearanced 1310 yokes will tolerate that.
Rear suspension next, then need to find some smaller things to peck away at while I pile up some cash for steering parts. I had planned to run single ended ram with tie rod to stock knuckle locations but I have talked myself/been talk out of that. So I need Solid knuckles, arms, double ended rams, and misc hardware for TWO axles.
With the suspension setup, I can confidently move toward a lot of smaller projects. Driver controls, coolant plumbing, intercooler plumbing, dash, chassis finish. Hoping to get a ton accomplished this winter. Drop axles for gearing Aprilish and take on the last 10% that seems to take everyone else I know 6 months.
Looks a little weird from the side view but I think once shocks, intercooler, winch, etc are there, it will look like the Jesse Haines and similar examples I've been modeling it after.
(https://i.ibb.co/2k7rcwR/4-BEBA65-B-411-C-4-B89-A73-F-E280895-FA00-D.jpg) (https://ibb.co/0GjLYk1)
(https://i.ibb.co/dfRBHwp/375624-B7-78-F3-48-C9-8-F34-B3601-D96-D631.jpg) (https://ibb.co/Bf9LY56)
(https://i.ibb.co/M9XFcg0/1-A95-D5-B4-645-D-410-A-A3-B8-574-AA1-BFEF89.jpg) (https://ibb.co/cxm46yn)
(https://i.ibb.co/7R1GShF/0-AA48-D25-62-F8-4-A78-9-EA8-31327-FA7-BE44.jpg) (https://ibb.co/wwzKdt1)
(https://i.ibb.co/jZk0zYV/8-BD0800-E-16-E8-43-BF-95-BB-9-B802-C97-EC0-E.jpg) (https://ibb.co/3Ym6vbf)
(https://i.ibb.co/GRNXPS3/754-EF013-320-F-4-A4-D-87-E3-AF01-A817-C0-CB.jpg) (https://ibb.co/3cQwhZY)
(https://i.ibb.co/7ty63Jc/9-B71734-F-99-A7-4-FC8-A66-B-6-D511-CB76095.jpg) (https://ibb.co/k2cWLgn)
(https://i.ibb.co/1ZwKTPp/7-AAF2-F09-64-BD-45-B2-B9-DB-941-BE7-B5-AA0-B.jpg) (https://ibb.co/7v6VKZT)
Post by: mr.mindless on October 06, 2020, 01:20:24 PM
Post by: Harrison on October 21, 2020, 12:08:28 PM
Reworked front axle side uppers to kick pinion angle up a hair.
Rear suspension mocked up. Same length uppers as front, lowers different only because chassis side mounts needed to be outboarded to miss the output. Both axles are 36" from the chassis belly that's 40" long, so 112" wheelbase.
Ordering knuckles, high steer arms, rams, tie rod hardware, misc KP stuff next week. That should keep me busy for a while. Hoping to be ready for some 14in 2.0 airs around the new year and have a roller not long after as long as tires, chassis, and driveshafts all seem like they get along with each other OK.
(https://i.ibb.co/NsNZnSD/7-A38-BAEB-2934-41-D8-A182-865-A2-FB6-FC51.jpg) (https://ibb.co/VtC2pmn)
(https://i.ibb.co/bPgvWw3/2-F2-CB8-CB-31-F0-4-CD8-8-DA8-7985-CA3-A0174.jpg) (https://ibb.co/t4M2mjh)
(https://i.ibb.co/wsgBdBw/0-A0-F225-B-64-FD-454-A-B4-C9-250-D7-B2-E910-A.jpg) (https://ibb.co/C28mwmM)
(https://i.ibb.co/gv3BZz5/1-EC3-A24-F-0-C07-4-F6-F-A9-C5-7-A4-E6-DAA0-F9-C.jpg) (https://ibb.co/5Y6fhBN)
Post by: Harrison on November 02, 2020, 01:17:32 PM
Planning to measure from knuckle turning axis to center of stock tie rod location. Then replicate that measurement to the high steer arm and drill accordingly.
Am I missing anything? No plans to do the double shear stuff.
(https://uploads.tapatalk-cdn.com/20201102/e2075056f7c5b5f1d20020a0afa3c956.jpg)
Post by: M4wdFab on November 02, 2020, 02:56:58 PM
Post by: mr.mindless on November 02, 2020, 04:00:29 PM
It will probably be fine. no matter what.
Post by: TrailTamer on November 02, 2020, 07:09:30 PM
Post by: M4wdFab on November 02, 2020, 07:23:54 PM
even more with a rear steer buggy.
Post by: mr.mindless on November 02, 2020, 08:04:57 PM
Post by: Harrison on November 02, 2020, 08:21:18 PM
I think my plan is welded front with indexed shaft yokes, auto locker rear. Up in the air on full case or Torq, probably just do Torq. Not that worried with 180hp and LP rear.
Front will get Hardcore selectables from my Jeep. On the trail, it will always be under load so I don’t see much point in a locker there. Rear can be left to ratchet around when in FWD.
Selectable lockers are too much claptrap for me. If I change my mind down the road, throwing away stock carriers and selling a lunchbox is fine to get into that world. I think stuff that does 50° steering would be a lot more beneficial anyway.
Post by: mr.mindless on November 02, 2020, 08:29:28 PM
Why hubs for front and not slugs other than you have them
Post by: Harrison on November 03, 2020, 07:08:24 AM
Yup yup n yup
Why hubs for front and not slugs other than you have them
Because I have them is the main reason. When my Jeep was spooled front with flanges I found it really annoying maneuvering around the driveway to get into garage or trailer.
Post by: Harrison on November 03, 2020, 08:07:59 AM
As short your wheelbase is
112 inches! Not short.
Post by: TrailTamer on November 03, 2020, 10:41:31 AM
As short your wheelbase is
112 inches! Not short.
oops. longer than a XJ, even!
find out correct distance from king pin to match your steering system and run it! :)
Post by: M4wdFab on November 03, 2020, 10:55:30 AM
you probably dont care about steering power or steering speed in this application, so do what fits.
and ill add "your steering system" is full hydro and a bunch of best guesses- so again do what fits after some thought. if your really worried about lock to lock turn estimation with what ever ram and what ever cylinder you get- wait until its all set up, use C clamps on the steering arms to hold the heims instead of drilling the bolts. adjust arm radius then drill.
Post by: Harrison on November 04, 2020, 11:21:04 AM
you probably dont care about steering power or steering speed in this application, so do what fits.
and ill add "your steering system" is full hydro and a bunch of best guesses- so again do what fits after some thought. if your really worried about lock to lock turn estimation with what ever ram and what ever cylinder you get- wait until its all set up, use C clamps on the steering arms to hold the heims instead of drilling the bolts. adjust arm radius then drill.
Yeah, I'm probably overthinking it. I had the same thought with the clamps, too.
Buddy says he bought his arms pre-drilled at 7.5" from center of the knuckle. I would like to get the most angle I can with minimal clearancing to the axle yokes.
Post by: Harrison on November 22, 2020, 08:14:32 PM
Front axle is pretty much all laid out aside from shock mounts. Lots of gusseting for both ram and winch mount left to do.
Can't find second set of lower kingpins. Once I get a set it'll be onto the rear ram mount.
Axle stuff coming together faster than expected. Going to need shocks soon.
(https://i.ibb.co/7R6G0Wv/9-B0-DC7-FD-2104-4-C3-B-AE05-35659652-B0-BC.jpg) (https://ibb.co/3ML0PN1)
(https://i.ibb.co/QFVMqKc/C5-DF9-C2-D-0-BD3-4146-B131-A065-F621-EBF8.jpg) (https://ibb.co/gM8JXR7)
(https://i.ibb.co/WV2Mw5Z/60629-A53-873-E-4801-B222-DB29-F4759434.jpg) (https://ibb.co/TWg7S26)
(https://i.ibb.co/H49tDM3/D178-EBB1-DCF6-43-D7-8-A6-C-D8808-CF56-D18.jpg) (https://ibb.co/sRXKvDz)
(https://i.ibb.co/y4ttp2J/1-A2-CD554-243-D-4-B31-95-EB-8-EC4649-E4-D42.jpg) (https://ibb.co/8YqqbkV)
Post by: Harrison on December 06, 2020, 09:49:48 PM
Coolant lines all run tentatively, assuming suspension doesn't drive any major changes.
Fox 14in 2.0s here Tuesday.
I think once the shock mounts are done and suspension cycling confirmed OK at full stuff full lock in all directions, I am close to build point where putting together a punchlist is in order. Fuel system plumbing, engine tuning/wiring to make engine make noise. Then the last 10%of details that will take at least 6 months!
(https://i.ibb.co/sb2Vmnh/F8-CB5349-4725-4749-A937-23-D61-C6384-A9.jpg) (https://ibb.co/bQPKWTx)
(https://i.ibb.co/3WxwpBf/C0-DE9-AEE-D353-4-C56-9-D8-F-4-BF4-C807-AB4-D.jpg) (https://ibb.co/GkZXWcs)
(https://i.ibb.co/qnKnqyW/7-EEAFDAE-F792-4809-9076-FD384-DF7-FBF7.jpg) (https://ibb.co/GJyJYxt)
(https://i.ibb.co/h882p9z/6442-C7-FF-252-E-4233-B84-F-96-F8718-DCE86.jpg) (https://ibb.co/s33sLRY)
(https://i.ibb.co/ZLVMbWF/B07-DDA9-A-5716-4705-BE8-C-33041-E755-A01.jpg) (https://ibb.co/DVtRj5v)
(https://i.ibb.co/1zx4R4Z/74-ABF28-B-40-D6-4346-85-BA-908-E25-CC28-CE.jpg) (https://ibb.co/qJw2m2B)
(https://i.ibb.co/mJ8q2VQ/BE6-E2642-68-C4-4537-8-ECF-20827-C3-D1-E4-E.jpg) (https://ibb.co/XX8sKrm)
(https://i.ibb.co/vY4KjKS/D7-C952-F6-13-E4-4-BB7-863-B-E0-BCFADF343-D.jpg) (https://ibb.co/hfFtmtS)
Post by: Harrison on February 16, 2021, 12:51:15 PM
Shock mounts are set front and rear after a couple iterations of each. Major tire/shock/steering arm clearance issues on the first couple tries.
Rear chassis section finished.
Caught up on chassis welding without flipping it over.
Next steps:
Roll it outside on 39s and see how it looks. Need to finish up the H1 project so I have something to put on my Jeep.
Unbolt axles and pull drivetrain and do a whole bunch of welding.
Source some 3/16" AR plate for belly and get that welded on.
Reassemble
Hydraulic system, plan to go with Radial Dynamics stuff
Electrical system... big one. Have a vendor that can load the swap file into my ECU to delete immobilizer and evap stuff. Plan to send my harness out to them as well.
Shop insulation is amazing... R13 above R6.5 board. Little convection heater keeps it at 60 without issue on even the coldest days without the obnoxious noise of my old forced air unit.
(https://i.ibb.co/6FrZQtC/A584-AB1-F-20-D9-4-D2-D-87-E1-7-E87-A074-B002.jpg) (https://ibb.co/3c4sKFZ)
(https://i.ibb.co/tcGpnBy/F4187-D26-84-FB-47-B7-B544-84-D940758-F78.jpg) (https://ibb.co/5v0hCTq)
(https://i.ibb.co/9mDwfY0/1-DF2-DD14-CA38-4-B8-D-A6-A8-975494600600.jpg) (https://ibb.co/hx6Xn8N)
(https://i.ibb.co/9mDwfY0/1-DF2-DD14-CA38-4-B8-D-A6-A8-975494600600.jpg) (https://ibb.co/hx6Xn8N)
(https://i.ibb.co/2P8Gzk6/75-B9-CAD4-3553-4190-BE1-F-52978-CF84159.jpg) (https://ibb.co/L6QVTZP)
(https://i.ibb.co/vH5xTrx/CC331-E86-5747-46-E2-B01-F-8-CC4-A0-E42-B53.jpg) (https://ibb.co/9NX91f9)
(https://i.ibb.co/LhtHhr3/6241-B722-DF79-4-EAA-A522-9-ACAA658-EDF3.jpg) (https://ibb.co/qFsVFCv)
Post by: mr.mindless on February 16, 2021, 04:16:17 PM
Post by: M on February 16, 2021, 05:10:05 PM
Post by: M4wdFab on February 16, 2021, 05:27:20 PM
Post by: Wingman on February 16, 2021, 10:24:20 PM
Post by: Harrison on February 17, 2021, 08:06:50 AM
When it’s all threads, then it’s time to retire it
Yup! My buddy Eugene would consider that a perfectly useable tire as is. I have seen his rig do some silly things with red label slicks.
(https://i.ibb.co/SfvGQsP/45902-C0-F-9-CEE-4-F15-8-C01-ACCBE72-C0-B8-D.jpg) (https://ibb.co/g4ghvj3)
Post by: etk300ex on February 17, 2021, 08:41:42 AM
Post by: Harrison on February 28, 2021, 07:51:33 PM
(https://i.ibb.co/QXrRJsj/111-E6574-D539-4-D05-9-F34-49-F558-AD83-FC.jpg) (https://ibb.co/4JPGFBg)
(https://i.ibb.co/g9qK42v/F52-FEA0-E-AE62-461-F-B651-582-DC412-E5-B8.jpg) (https://ibb.co/C8CGPcJ)
Post by: M4wdFab on February 28, 2021, 08:05:10 PM
looks good
hows sight lines up front?
Post by: Harrison on March 01, 2021, 09:09:40 AM
why welded joints on cooling water runs?
looks good
hows sight lines up front?
Didn't want to run 1.75" so I got some 1" mandrel tubing. Going to TIG it up, should work well I think.
Lots of visibility up front. I don't plan to put a full hood on it, just enough to cover the engine.
Post by: Harrison on April 19, 2021, 12:32:38 PM
Radial Dynamics steering stuff. Have pump mount mocked up, belt will be here tomorrow then final weld and paint bracket.
(https://i.ibb.co/VVV9NKZ/C0-D39-C8-F-6-E00-4932-BCE7-69-D586-F6493-E.jpg) (https://ibb.co/y00PR31)
(https://i.ibb.co/drszSmF/306-EB6-B6-168-D-44-EE-BCCE-49-A97-A4-B9286.jpg) (https://ibb.co/Msy3bBr)
(https://i.ibb.co/7C7YMJG/1-A60-E297-30-FC-45-BB-BE88-65-BEF773606-B.jpg) (https://ibb.co/6w6n9R4)
(https://i.ibb.co/mz7CPsf/1-A906914-2-ACE-46-D1-A7-BD-E0-EB43-CBCC76.jpg) (https://ibb.co/PC8ZVpq)
(https://i.ibb.co/ncfQpfh/16874542-CB98-480-D-8610-473-AF0-B4-E4-F5.jpg) (https://ibb.co/R0PQ8PL)
1.8T Evap parts fall off
(https://i.ibb.co/zQ9wrpY/8-C257221-5-B3-A-487-E-8964-4532-FDA97-AA6.jpg) (https://ibb.co/BcWRtbx)
(https://i.ibb.co/W5SpgYd/275-D7400-A974-40-F8-9-FB9-E7-ED83-CE5-DFE.jpg) (https://ibb.co/JtXF5Mb)
AR400 belly skids fully welded in place.
(https://i.ibb.co/3kB6CBs/91-F78-F45-AD85-489-B-8953-910-F2-D222-E95.jpg) (https://ibb.co/nRzdLz0)
(https://i.ibb.co/XtXPP8k/CE750946-3033-46-BE-9-E71-07-DC8-BE711-D7.jpg) (https://ibb.co/jDhYYRZ)
Lots of painting.
(https://i.ibb.co/0m3n76Z/7469221-B-CAB5-4438-A20-C-B4-ACDCBFF927.jpg) (https://ibb.co/bQn60CL)
(https://i.ibb.co/GsLf1TG/285-AE49-F-D4-E6-4-F9-D-8-A60-1-C7-C9-C8-ADEEE.jpg) (https://ibb.co/Jx4WbQ8)
(https://i.ibb.co/4JsVmK9/39510-C7-F-49-D8-441-F-B84-C-4-F29-EC78-DEC7.jpg) (https://ibb.co/8Xz7KNT)
Color scheme as envisioned by Hannah.
(https://i.ibb.co/2WN0RHb/8-D80-A79-E-F38-C-4-B86-9-F2-B-1545-D446602-F.jpg) (https://ibb.co/NtSgfb4)
Next:
Finish weld and leak check coolant tubes
Reinstall drivetrain into chassis
Get axles back underneath
Plumb steering components
Sooo much left to do (and buy), but feel like I can start to see the finish line...
Post by: TrailTamer on April 19, 2021, 01:28:03 PM
looking great!
Post by: Harrison on April 21, 2021, 05:04:59 PM
(https://i.ibb.co/YRb1cF0/4-EA3-B6-A2-242-F-478-B-A64-B-2-FCE267-E3852.jpg) (https://ibb.co/r7vzxRd)
Post by: mr.mindless on April 21, 2021, 05:59:38 PM
any evaluation of the VW pump done or just fuck it an go with known quantity?
Post by: Harrison on April 21, 2021, 07:34:14 PM
Post by: Harrison on May 27, 2021, 03:01:24 PM
(https://i.ibb.co/TmSfsGT/1-EDF91-D6-2944-4-E95-AAD9-D0-C6605-D8-E8-D.jpg) (https://ibb.co/D5yJZFb)
(https://i.ibb.co/TTmfShK/6-E54-CCA3-DDB2-4-ECA-BD07-4-E07-A0951627.jpg) (https://ibb.co/PYwLnCT)
(https://i.ibb.co/GQbgsz0/148-B786-F-B86-F-40-E9-AC72-DA9-AB5-FE8-B8-A.jpg) (https://ibb.co/qYPb0Td)
(https://i.ibb.co/qMmJkdh/BB67-C8-D7-7-A9-D-4-C00-83-C8-BE25-AB655-CDA.jpg) (https://ibb.co/Y7f0p3J)
(https://i.ibb.co/PMfZdxc/F7-F4336-B-7562-43-BB-8926-A499315-C5732.jpg) (https://ibb.co/gdBMxyS)
Front axles are back from Dan with 5.38s and Torq lockers in both. Ordered one custom inner to test between both axles and confirm fit - all good. Wasn't too concerned but a load off my mind as far as proper measurements but mostly that my re-tube was in tolerance. Shaft has plenty of wiggle in both housings and tested to rotate with no issue with knuckles turned in both directions.
Ordered two more custom inner shafts (spare)
5 stubs are here
Short side inners (stock 80s/90s Ford) are out of stock according to everyone that dropships, I think I managed to grab a couple loose ones on eBay.
All other axle parts are in stock and just need assembly
Lugnut4x4 GM 3/4 caliper kits at all four corners
(https://i.ibb.co/tH3w3w2/D0-A2911-C-BAA4-46-BA-8-C92-F28931133-D8-D.jpg) (https://ibb.co/9pGmGm4)
(https://i.ibb.co/64TpzT8/2-F6229-D9-FD6-A-4-E8-A-835-C-B922-AD3-DC216.jpg) (https://ibb.co/FByf2yX)
(https://i.ibb.co/QM4KDMF/AF74-C629-0-A37-4-A0-C-A96-D-ADD04-D777-AB1.jpg) (https://ibb.co/4pHV1pZ)
(https://i.ibb.co/jM2QkXS/407-A66-F0-FE0-D-4-A6-A-9707-36475347-A2-D2.jpg) (https://ibb.co/7W5Ztmq)
(https://i.ibb.co/8DGj783/C21954-C0-E8-C9-49-C1-8-B95-002-A9651-ECD0.jpg) (https://ibb.co/rGqZwyP)
Front axle back in and double checked power steering pulley clearance and driveshaft angles/clearance with shocks in place. All good.
(https://i.ibb.co/Cw06WrL/550-C3-B20-4495-4-F48-819-B-1-C9-E191-E3437.jpg) (https://ibb.co/8m8bXhk)
(https://i.ibb.co/Q6j7R3n/9-F321-CEC-7583-4038-BA3-A-85-BDD62-F1972.jpg) (https://ibb.co/wKrZXFC)
(https://i.ibb.co/R6T4pTS/5-DCBC0-AD-B5-A1-4-EDD-961-A-19119562-E18-F.jpg) (https://ibb.co/7ptNJtz)
Working on my aluminum skills - coolant flange needed a hose rerouted, plus I added 1/8 NPT port for gauge sending unit.
(https://i.ibb.co/bjh18fN/84114510-CD44-44-D9-AA04-5-BA326320-ADC.jpg) (https://ibb.co/j9Kh1p3)
(https://i.ibb.co/GxLsF4N/24-F67260-02-A3-4300-BB12-43-A7-C2-B7-E446.jpg) (https://ibb.co/PmnTtv0)
Had a long conversation with my ECM/harness guy. He's nervous about the auto but was reassured I was aware of others using this trans in this application without major headaches. Sending out all that stuff tomorrow with a ~2 week turnaround time.
Coolant lines are leak tested and painted, ready to go in once chassis is finished and painted and ready for the rest of the cooling system to be installed.
Hydraulic plumbing next.
Have some fuel system parts in my Amazon list.
Chassis needs the last 10% of tubing and gussets added.
August is coming up fast...
Post by: mr.mindless on May 27, 2021, 04:09:30 PM
Post by: etk300ex on May 27, 2021, 04:32:32 PM
Post by: etk300ex on May 27, 2021, 04:32:51 PM
Post by: Harrison on May 27, 2021, 07:30:29 PM
Fall Crawl is early September and depending how it all goes, Humble Pie is end of September.
Would like to have a good idea how well this whole experiment is going to go with a little time to react to those things.
Post by: M4wdFab on May 27, 2021, 07:59:09 PM
Post by: Harrison on May 27, 2021, 08:17:35 PM
looks fun
It is
I have never permitted myself to spend money like this. But with a deadline, clear deliverable, and supporting wife - just going for it. Feels awesome.
Post by: M4wdFab on May 27, 2021, 08:21:39 PM
Post by: Harrison on June 15, 2021, 01:04:27 PM
(https://i.ibb.co/wdQV8fW/D769-F288-1738-4-CE0-ADCD-2-B0343-E899-E7.jpg) (https://ibb.co/Bf6bv9Z)
Axle weight. Pretty satisfied. Don't really see where I could have lost much more other than fancy brakes.
(https://i.ibb.co/rFHXgKb/FC7-D4755-B3-DA-4-E6-A-B7-C7-C92-A30-C0-AE94.jpg) (https://ibb.co/xX6ryKm)
Steering components mounted. All fittings in-stock. DJ and are going to bring it to his buddy's shop to make up hoses once the chassis is a roller again.
(https://i.ibb.co/688kKfZ/432773-B4-3461-4-CB4-8-E11-306-EF91-A7907.jpg) (https://ibb.co/Lrr3T2P)
(https://i.ibb.co/t4jGbqX/CABD9145-6976-4147-9297-0-E46-D2-C83-FA0.jpg) (https://ibb.co/nbdGD7C)
(https://i.ibb.co/XjTyGr4/722-BEB9-F-CA84-4-AB2-9145-6-C870-E371-BB5.jpg) (https://ibb.co/Ntz1Gd3)
(https://i.ibb.co/mH6QGxh/A95-F4-B21-38-CC-4-B5-B-9-DA4-5-F67730-CD666.jpg) (https://ibb.co/198HLSR)
Winch at full bump. Going to take gearbox cover off and clock the engagement lever forward by one hole pattern.
(https://i.ibb.co/Y2Y69JF/8-FBB5056-C372-45-EB-8-E92-0057-FC37279-F.jpg) (https://ibb.co/2qmw2R1)
Steering wheel and shifter mounted.
(https://i.ibb.co/Y3r9jk1/AF9-CD8-A8-CF8-B-44-EA-B9-DD-953-B6591-D4-B4.jpg) (https://ibb.co/L8Gwptc)
(https://i.ibb.co/5LnRtf3/D9818-E15-3-A8-F-4830-9-BE0-111572-D69-BF9.jpg) (https://ibb.co/yqYQGbC)
Started on dash/doghouse. SO tedious. Pecking away at getting 1-2 panels done a night. Happy with how it's coming out, though. All the pieces around the engine/trans will get noise/heat insulation on the inside.
(https://i.ibb.co/QkhxwQk/47-ACED77-D7-DB-413-E-81-DB-73347-B2-A2-AFF.jpg) (https://ibb.co/G9GrSp9)
(https://i.ibb.co/X2JBmy8/7112-F26-B-872-D-4-BD1-8890-AFEDBBD3-C6-E3.jpg) (https://ibb.co/vwz52sY)
(https://i.ibb.co/475JdyM/0568094-F-FD3-C-48-C7-8603-BC5-B746-B6829.jpg) (https://ibb.co/DtSLpXk)
(https://i.ibb.co/kxSYZTz/D924-F58-C-B698-45-F5-8-E2-E-64-C99-E705188.jpg) (https://ibb.co/dr5nZvX)
(https://i.ibb.co/pXrBwjD/602-C487-F-0377-4212-A61-A-0-B0-F3-CC98978.jpg) (https://ibb.co/12JtQGV)
Harnesses and ECU shipped to dude for reflash and cutdown.
Transaxle outputs sent to club member for cryo treatment.
Chassis still needs another half a dozen tubes added.
Need to decide on and order harnesses and make mounts on the harness bar.
DJ came over the other night and we had a couple beers and put together a HUGE Amazon order.
All in stock:
Gauges
Switches
Wire
All exhaust components
All brake components
Odyssey battery and mount
Fuel pump and filters
Lights
Steering cooler
Rear suckdown winch
It's all about putting in the time at this point. Doing as much as I can every day.
Post by: mr.mindless on June 15, 2021, 01:45:50 PM
For my use, I would put a boot around that shifter. I expect there are electronical bits in there that are only the least bit waterproof for drink holder splashes and not for powerwashing or mudfest downpours.
Loving the doghouse panels.
Post by: Harrison on June 30, 2021, 12:38:18 PM
(https://i.ibb.co/FYTChQn/E70279-FF-3-B2-E-4-F91-979-C-7930184-DF66-E.jpg) (https://ibb.co/09bvn0Q)
(https://i.ibb.co/cJ0dkv5/51-CD7-A64-2-A6-D-4-EA4-9-B98-A2539-CA9-BAF7.jpg) (https://ibb.co/v1p8VB5)
Exhaust tacked together, happy with how it came out. Will get wrapped and then paneled over where floor panels don't offer coverage, then all panels will be high heat insulated on the inside.
(https://i.ibb.co/YT1jQ8j/606-F1-EAD-066-F-4-F77-BD56-85-FF7-F7-F26-A9.jpg) (https://ibb.co/wrP6gC6)
(https://i.ibb.co/XSQcFTk/9459-F996-2859-42-EE-93-FA-295-DFA7-F1-B99.jpg) (https://ibb.co/3B3gSHY)
(https://i.ibb.co/52cyw02/E295-D333-6-DE8-4-C62-8758-4140324-BBFBE.jpg) (https://ibb.co/SJv8GjJ)
(https://i.ibb.co/N9MmMYW/4-EDFD94-C-5-D56-4-E57-8943-1-D90-F39-EBEC8.jpg) (https://ibb.co/sKZ6Z3s)
Next is intercooler mounting and intake tubing.
Wiring harness and flashed ECU are in the mail back to me. Ordered fancy Ross-tech software and dongle thingy that I'm told is a must-have for VW tinkering.
Dad is not doing well, this coming weekend will be #4 in a row spent in Sodus. Progress is slow right now. August shakedown goal looks unlikely, hopefully can be out for a late fall run somewhere local at least.
Post by: mr.mindless on June 30, 2021, 04:41:45 PM
Post by: Harrison on August 19, 2021, 02:36:37 PM
Intercooler/steering cooler mounted, intake tubing complete with MAP sensor port.
(https://i.ibb.co/Njkdpmc/79-EE23-B5-DF91-4-AD3-A37-F-CBA3-F1460-ADD.jpg) (https://ibb.co/LtqX6JV)
(https://i.ibb.co/NrpfCL3/29-BC1136-112-F-444-D-89-CE-9-A31-F588-E44-F.jpg) (https://ibb.co/bFLYmr3)
(https://i.ibb.co/dMgjHzc/30-EA65-A9-41-CB-4-F9-E-B635-B83-C7-FB5-BBEA.jpg) (https://ibb.co/wgsB2xL)
(https://i.ibb.co/YNvKPmB/7-F5-A9-EA4-64-A2-4753-8668-A1-CBCBC0-E595.jpg) (https://ibb.co/8mFRNqg)
(https://i.ibb.co/N7SsH4K/933-DDCE0-B2-F2-454-E-9-AF6-2842-F23-E69-B9.jpg) (https://ibb.co/25Nyfbd)
Remaining doghouse panels completed. Heat shield covering exhaust done.
(https://i.ibb.co/d766XZv/F75-C24-A7-C9-DA-481-E-94-A8-DD0-C0-BB8-ED82.jpg) (https://ibb.co/QXnnh0V)
Fuel cell mount completed.
(https://i.ibb.co/MpBL2rh/6922-F49-F-6-BE6-4320-B8-CB-FF052-B8-F7-EA6.jpg) (https://ibb.co/rMdJ7Yt)
Chassis tubing done.
(https://i.ibb.co/RNRdwLB/2-B067-C3-E-18-AE-4-BC2-B43-F-B19-DD3-C0-B3-DC.jpg) (https://ibb.co/dt8xYnL)
(https://i.ibb.co/mb7WDH9/DA8831-A5-97-F0-485-E-B996-4-C1-ED59-A2-E0-B.jpg) (https://ibb.co/7jFmYGn)
(https://i.ibb.co/gPGCzrD/4-D75-A8-CD-9302-4-F17-ADEE-92-CAFD1-B8-C7-F.jpg) (https://ibb.co/0Fk3hnf)
(https://i.ibb.co/NNfbP6F/87-E44695-27-C5-441-F-9-CBE-41509-E4-F60-B3.jpg) (https://ibb.co/GMGNLvd)
Modified harness. Came out nice, very happy.
(https://i.ibb.co/jwpyDBL/E1-D5-AFC0-663-B-4579-B891-13-BD7-F4423-D9.jpg) (https://ibb.co/SmLtBWK)
Added a tube to support the engine skid last night. Harness mounts tonight. Couple other odds and ends to weld on and it's getting painted tomorrow night.
Once painted, there is a ton to reassemble.
Next goal is making noise. All wiring and fuel system components on hand.
The list is slowly getting shorter but there is still a ways to go...
Post by: Harrison on August 23, 2021, 12:04:09 PM
Chassis paint complete
Fuel system complete
Brake plumbing complete minus one special fitting
Doghouse panel insulation complete
Cooling system installed
Several other miscellaneous tasks also got crossed off the list.
DJ and I have moved onto wiring. Computers and relay boxes are mounted. Fingers crossed it can make noise this week or weekend.
I feel confident it can be done and moving in 2-3 weeks, but there will not be much time to react to any unexpected things that pop up.
Post by: Harrison on August 25, 2021, 01:58:35 PM
Next:
Wrap up engine and fan wiring
Install gauges/switches into dash
Build driveshafts
Hydraulic plumbing - DJ knows a shop that will let us pull it in and make all the hoses ourselves.
Then it should be ready for a test drive around the yard.
Aside from any major issues that could arise... left will be:
F/R winch install and wiring
Shock charge/oil fill
Install and wire headlights and winch lights
Post by: etk300ex on August 25, 2021, 03:21:28 PM
Post by: mr.mindless on August 25, 2021, 04:29:44 PM
Post by: Harrison on August 30, 2021, 09:28:45 PM
It’s tiny
(https://uploads.tapatalk-cdn.com/20210831/ccdc2c9ce03f776d7ba6b935e5069a31.jpg)
Post by: etk300ex on August 31, 2021, 08:56:43 AM
Post by: Harrison on August 31, 2021, 11:00:55 PM
Drives
Shifts
Steers
Cools
Huge win on all those fronts. Unknowns I’m not longer concerned about.
Brakes need bled
Shocks need more pressure
Steering stops need trimming
Punch list of small, easily achievable items left. Off all next week and Fall Crawl the weekend after. Aiming there for a shakedown.
Post by: M on September 01, 2021, 09:51:06 AM
Those the tires you're running on it?
Post by: Harrison on November 14, 2021, 03:45:48 PM
(https://uploads.tapatalk-cdn.com/20211114/c62f8829e0aafc6dea6daf9daceadb30.jpg)
(https://uploads.tapatalk-cdn.com/20211114/8ce38e0c4eee663d5375c6ad3c65d878.jpg)
(https://uploads.tapatalk-cdn.com/20211114/17f035cbd8cf7452ca6faba820689e6f.jpg)
Post by: mr.mindless on November 15, 2021, 07:49:49 AM
Glad to see the splines are whole though and the clamp on collar makes sense.
Post by: Harrison on November 15, 2021, 08:19:41 AM
There is a plastic bushing where the male nub on one shaft engages the female pilot on the other and it was completely MIA. That leaves the collar as the only piece keeping the two shafts in alignment which it's really not suited to do, and I'm sure left no chance of a couple hose clamps keeping it where it needed to be for my trail fix. That was also replaced and I plan to have a brass replacement to go in the next time it comes apart.
Post by: mr.mindless on November 15, 2021, 11:26:57 AM
Post by: Harrison on March 21, 2022, 12:23:29 PM
Pulled apart everything, fresh nylon bushing is destroyed, male splines on disconnect shaft are wasted.
Noticed drivetrain moving more than I'd expect shifting from R to D. Checked 3rd drivetrain mount and found this:
(https://i.ibb.co/M29GJq1/0-D870-EAA-F384-4671-8-AF7-1-FAB15-BD68-C8.jpg) (https://ibb.co/1vbd4HX)
Chased threads with M10 tap but when reinstalling new bolts, the threads did not survive umph with with 3/8 ratchet. I was able to run a 7/16-14 tap up through the holes and installed new bolts that did pass the umph test.
(https://i.ibb.co/cvfGWv3/4-C3-EB357-FC42-474-F-915-E-97-FDB691-F6-FC.jpg) (https://ibb.co/thj70hK)
After a little thought, I ordered a 7/16-14 bottoming tap and some grade 8 threaded rod. Plan to bury studs in there with red loctite. Hopefully better clamping force can be achieved and if they do loosen up, my hope is that the studs hold tight while nuts come loose preserving the threads in the bosses.
I am thinking excessive drivetrain movement was a major contributing factor in how quickly the last two lockout/repair iterations lasted. I am currently in the process of designing a solid replacement shaft. I have every intention of revisiting the disconnect but haven't come up with anything I feel more confident in yet - considering taking apart a transfercase to see if I can borrow some components to make something more robust. Solid shaft will get me back in the woods and will serve as a good backup to throw in the trailer once the new disconnect is designed.
Other things to do:
Exhaust flex connection is blown out
Ram guards - bent a rod at F&F in October
Hood and door skins
I see I really need to get this thread caught up to it's current status... I really let it go once I got it running. Here is mostly up to date pic from the starting line at Humble Pie.
(https://i.ibb.co/wQHYTjf/79-CCEDF8-89-EF-46-B0-8-DF7-C11-C7-DAFC7-D3.jpg) (https://ibb.co/X5BV9Mq)
Post by: M4wdFab on March 21, 2022, 06:51:36 PM
would be a cool project for my G&E shaper to make one. then get it heat treated or something fancy.
random thought, find a drive shaft slip yoke thats same spline and cut the yoke off to make a 4 or 5" collar?
In all honesty id be bored of this failure at this point and replace it with a solid shaft and delete this function.
Post by: mr.mindless on March 21, 2022, 07:31:48 PM
agreed on value for effort until and unless this becomes a points-chasing cone dodger where backups matter
Post by: M4wdFab on March 21, 2022, 07:36:49 PM
no like find a slip you to cut the yoke part off and make a better collar
(https://www.dennysdriveshaft.com/img/products/1444867826_DANASPICER1-3-18KXSlipYoke1100Series_1-3-18KX_Front.jpg)
Post by: M4wdFab on March 21, 2022, 07:38:34 PM
Post by: mr.mindless on March 21, 2022, 07:43:57 PM
Post by: M4wdFab on March 21, 2022, 08:08:14 PM
For 5" engagement, need 15" total to disengage.
false. take a 5" spline slug thing and move it 2.5" its disengaged.
Post by: mr.mindless on March 21, 2022, 10:22:14 PM
Brain fried.
Post by: Harrison on March 22, 2022, 09:45:00 AM
(https://i.ibb.co/LxByJs3/Screenshot-2022-03-22-093522.jpg) (https://ibb.co/VgbGQks)
These have been out for a long time and people seem to like them. 27 spline Toyota is just a hair smaller than the output in the transaxle which originally steered me away from this as an option but but on second thought, that may actually be ideal. I know a lot of people with Toyota t-cases with similar power and weight who don't have any issues breaking rear outputs and I'd rather break that than a transaxle output.
Solid shaft is still the priority in the short term - want that as a spare regardless. The ability to have fwd is really nice for cruising between trails. I went through the cost and effort to build the cutting break into the rig, would really like to maintain that feature if possible.
Post by: Harrison on December 03, 2022, 09:30:30 PM
Would still like to add the rear disconnect back in
Hood and door panels
Bigger rams for a little more steering is on the "at some point" list
Tried on some 42s today. Went well and placed the order. Raceline is having a sale all month long, 20in Avengers are $100ea off, so I guess I'm pulling the trigger on those too.
Hopefully 300Ms aren't in my future (knock on wood)
(https://i.ibb.co/mzdwvL5/FD78180-C-BF58-4-A10-8303-22-BA09-BD4-F37.jpg) (https://ibb.co/ZTvPHnz)
(https://i.ibb.co/ph5p5z5/0-A9-C38-AA-5-ACB-4-DEC-8-EDC-8670-B92-A2381.jpg) (https://ibb.co/SfGpGnG)
(https://i.ibb.co/1vnqLMm/A269-B83-F-3952-48-F2-A107-738-BC5-B33296.jpg) (https://ibb.co/p0PzxQL)
Post by: etk300ex on December 04, 2022, 12:22:21 PM