Mikes lwb build and repairs !

[mike harris]

Morning boys

I know the forum is dead and not many people reply in this section any more but il keep posting help the cause !

Right so rear axle, need boggers shafts, limited by space and parameters I have. So I went and bought a j33p £206 ! Then took a diff out, so machine shop could copy the spline design and machine suzuki diff side gear and drive flange to the same spec, then have yet more custom shafts made, bore out the spindles fit it job done, also going to either dowl the drive flanges, or double bolt them.

Here's some pics.

[mike harris]

So sent them bits to machine shop to be shadow graphed

Basicly measured then transferred into wire erosion machine

Flange and diff side gear machined out and this is the result

[stimpy]

Looking good mike!..

Be interesting to see how they hold out - should bust something else first!!! lol

[mike harris]

That's kind of my thinking, I'm not trying to make it sonit doesn't break, I just don't want it to break shafts as they are expensive

Diffs I can deal with as there cheap and I can build and replace them, I can't machine shafts !

I'm hoping it will at least sort things for a short while, we shall see

[Anton]

Buy a bridgeport for £5k, a spin indexer, and make your own shafts. At the rate you go through them, it'd actually be cheaper than keep buying them!

[mike harris]

One shafts been done

Now waiting for three more then heat treating

I got lots to do now trucks got tired like me ! Haha

To do list

New batteries winch ones are fried

Now has no brake? Need to fix that

Hard to select gear (clutch is now over 10 years old) needs new one

Change diff ratio to 3.9 and build spare for events

100% rebuild of axles, I'm going to take them off for a change, clean the crap and metal out of the inside ect

Have the spindles for rear axle bored out for new shafts to fit through, also have the flanges dowled and the flange bolts increased to 1/2 inch

[mike harris]

So exploded an rcv ultimate front cv, blew the inner apart and has damaged the shaft. They sent me rebuild kit for the cvs so I built both of them up, these are my spare set so the new ones are in the car now.

Subaru Impreza master cylinder let go as well so fitted a new one.

Waiting for my 27 spline side gears to come back then I can build up the rear diff

Fitting two numax batteries for the 24 volt winches on Monday and going to replace the clutch, the paddle one in there been good for 10 years ! Think it's now worth swapping before it lets me down.

Trucks so beaten now I think I need to re think the rear bed now.

I've got one of them nitro lockers just turned up for the new rear diff, not used hen before so il give it a go, spindles I've tripped of a spare axle to have bored out for the big rear shafts to go through.

Spare diff is in the front axle at the moment, so il fit the rear to the front and then the 27 spline will go in the back once I have all the bits, problem now is I can have one diff as a spare to take to events, so I'm going to get creative with some spare 26 spline float shafts, as a last resort.

Only going to do two events this year, red winches stampede and the decider trophy, they'll be hard events on the car but be good fun I'm sure !

[mike harris]

Shafts ended up being a nightmare with rcv they where lost empty box delivered to me lol all sorted now have an extra extra pair of spare front shafts

Tears are now done and here you can see the size difference.

No just to bolt it all up, machine the spindle out a bit, fit the new paddle clutch

And hopefully go get muddy !

[ScottieJ]

Fingers crossed they hold up!

[mike harris]

I've got everything crossed !

Hub mocked up on the spindle I had to ream out a little bit for shaft to pass through.

Got them nordlock washers to use once all bolted up in the axle

12.9 grade bolts, still have to build the 27 spline gears into the diff, and ream the other spindle out. Il do some more on Monday