Okay guys I just wanted to let you know that I have finally finished our proto types and are ready to start making doublers for those who are interested. This is for a kick to Dana 300 t-case. Finally an easy way to get some low range and a front dig!

I tossed together some installation instructions on my club site that will give you a good idea what it is all about. http://kc4wda.12.forumer.com/viewtopic.php?p=1674#1674

Price right now is $600. Plus a $50 core.
For those of you swapping in tracker motor into the sami's here is a great way to use the trans and t-case as well.

I will get a thread going it the vendors sections soon but I wanted to let you guys know first. Give me all the feedback you can handle as well. :D

http://farm2.static.flickr.com/1344/1122296992_4335e9b2c5.jpg

time to build me a tracker! Good job jake, I wish I had the follow like you do.

Will it work behind a Grand Vitara t-case?

ooohhh boy!!! that's-a-nice!
I need some money now.

good job jake

and good luck

I would like to see some pics of a finished poduct as well as the cases on a bench. also, does it make it an official center output?

nice work though!

Thanks guys. I have put alot of time and effort into this project. We built the first one in a rush to get our comp rig together and finally getting around to ironing out some processes. Mine is just a welded shaft too. That was back in april.

I belive there are some pictures in our build thread of the original one. That will give you some ideas on what the whole package looks like.
http://www.pirate4x4.com/forum/showthread.php?t=528100

I do not know when they changed transfercases but I am certian someone here will be able to tell you what years it will work on.

and yes it would make it a center output on the rear. completly forgot about the sami being off center.

Ahhh alright back to the garage to get the bronco going.... oh yeah guess we should prep the tracker for the comp coming up too!

I was considering purchasing some t-case gears. Maybe a good idea to wait a bit, I think this might better investment to start with...

Very interested, keep us posted!

Hey i was wondering since you can hook it up to a dana 300, would an atlas II bolt right up?

I missed this thread...... Its good to hear there is another option out there!

good work guys!

I've been considering what direction to go with my LWB build-up and was thinking of using the Rock 4x sidekick doubler. How does this Dana 300 kit compare? The Dana 300 is a cast-iron case correct? So strength is a factor. A centered rear output is also a plus with a yota axle. What are gearing choices like for a D300? Is it as diverse as the Zuk case?

Just thinking out loud.....it's nice to see guys keep developing and introducing new products for the Zuk.

yes an atlas t-case should bolt right up to it.

Sorry I am not sure what the Roc set up entails.
You can still install the 4.24 sidekick from trail tough gears in the kick case. (Which is what I have) The dana 300 only has a 4:1 gear option. The stock gear is 2.62:1.
Mine is 11.1:1 in the transfercase alone. Both stock cases are 4.7:1 or 4:1 dana 300 with stock kick case would be 7.2:1. As far as
I know the dana 300 is the only way to get a front dig. You could also swap to a toyota tcase and I believe marlin offers an adapter to a dana 300.

Anyways hope that helps! Jake

I know the dana 300 is the only way to get a front dig.
What's a front dig?

The Rock 4x sidekick doubler is much like what you are offering, except it uses the front half of the Sidekick/Tracker transfercase and mates it to a stock Samurai transfercase. If you use this set-up in a Samurai, the second tcase bolts right back up in the stock location. Now.....if you swap in one of the many aftermarket gearsets available for the Samurai tcase you have the option of multiplying the gears for a low crawl ratio with the benefit of selectable gearing choices of running two tcases......just like the set-up you're selling.

What's a front dig?

The Rock 4x sidekick doubler is much like what you are offering, except it uses the front half of the Sidekick/Tracker transfercase and mates it to a stock Samurai transfercase. If you use this set-up in a Samurai, the second tcase bolts right back up in the stock location. Now.....if you swap in one of the many aftermarket gearsets available for the Samurai tcase you have the option of multiplying the gears for a low crawl ratio with the benefit of selectable gearing choices of running two tcases......just like the set-up you're selling.

not quite. the d300 has the unique feature as well as a couple other Tcases of being able to run the rear output in neutral, and the front output in high/low. this allows you to lock the rear axle and basically pivot around it (line lock will help) you can move the front end around to line yourself up better to a line, and on things like decents, you can drag the rear end to help from going over.


jake, ill be heading out in a couple weekends to get mine. thanks again :smokin:

No problem jesse! Use it hard and let everyone know what you think, good bad or otherwise! Has it showed up at the shipping place yet? I haven't checked the tracking number.

That sounds like a good way if you are runing a sami axle or have already bought gears for the sami case. The only down side I see to the sami case is that it needs to be mounted much better than stock to do any offroading. Which there are alot of companies out there offering good products to do it.

I did alot fo looking when we built our comp rig. We needed front axle power only for tight turns and better manuverablity. We just had to have it to be competitive period. We had a 4:1 gearset from trail tough and it worked fine as I had many conversations with Brent I was dertemined to build a rear axle diconnect on the tracker transfer case. Brent talked me into the toyota trans and transmission but right when I went to order it I found out that toyotas don't have a rear disconnect either. Then I ran across Dan's doubler that he built out of some old dana 300 adpater and shaft so I set out to do the same. The only real difference is I worked to find a way to shift it that could be duplicated and also work with a manual or automatic. His only worked for the auto because of the shifter configuration. (wow am I still talking?) Anyways just another option to throw into the mix. I am not sure how it will fit in a stock tracker. Our tunnel cover was already cut out to get the seats to where we could meet min head clerance to the cage. So it's not the be all end all set-up but one worth offering in my opinion. Thanks guys for the interest and keep the questions coming! Jake

not quite. the d300 has the unique feature as well as a couple other Tcases of being able to run the rear output in neutral, and the front output in high/low. this allows you to lock the rear axle and basically pivot around it (line lock will help) you can move the front end around to line yourself up better to a line, and on things like decents, you can drag the rear end to help from going over.


jake, ill be heading out in a couple weekends to get mine. thanks again :smokin:

Now that I didn't know.:smokin: Cool option to have for a comp rig.

picked up my adapter yesterday and it looks good. everything looks to be in order and i am pleased. couple points which are small are a couple of the holes for the d300 bolts must have been off a little and were fixed with ???

the other is welds aint perfect in appearance, but with a case that has held oil most of its life, i don't expect them to be perfect thanks to all the impurities.

322359

322360

322362

322361

322363

322364

mounting points for the adapter to a crossmember :smokin:

322365

So what happened???? :zzz:

Is there any way that I can just get the modified main shaft since I've already welded up my case on my own?

I've got a complete doubler ready to go right now, well it needs bolts.... I got backburnered pretty bad by the machine shop. There is just not really any other option for getting them done as cheap as I am, just trying to make something so that we have another option for tracker stuff. Not really making any money off of it, just passing it on to you guys. I will call the shop and see what a shaft would cost by it'self.
Thanks! Jake
913-522-0135

Very nice! I appreciate your support to the Zuk community! This opens up some new options for me on my daily driver zuk thats getting a turbo diesel.

ttt

props for repping the suzuki stuff.

could the plate be used with a dana 20 t-case as the final case?

I am sure it could but it has a different bearing design that is different than the 300's or 205's. It would really be a complete reworking of the kit but possible. The pros to the Jeep D20 I see are they are lighter and cheaper.. But they only have a 2:1 redusction which is almost as bad as the tracker/sammi stuff.
Jake

this is still a smokin product - wish I had the money right now.

Another bonus to this setup that I haven't seen mentioned is the 1:1 in high/high. If you have a little power up front and don't need or want the high range reduction of the sami case, this could be for you.
Travis..

. Mine is just a welded shaft too. That was back in april.

I belive there are some pictures in our build thread of the original one. I do not know when they changed transfercases but I am certian someone here will be able to tell you what years it will work on.
and yes it would make it a center output on the rear. completly forgot about the sami being off center.

Ahhh alright back to the garage to get the bronco going.... oh yeah guess we should prep the tracker for the comp coming up too!

95 and newer Kick cases have a course spline output, Not the fine spline. It appears it would be a mute issue as it looks like you are cutting it all off and replacing it with the 300 input spline. Are they all welded or have you looked into a resplined shaft?

No they are all new shafts. 4340 I believe or 4130..... Chromoly at any rate.
Jake

No they are all new shafts. 4340 I believe or 4130..... Chromoly at any rate.
Jake

We may need to talk...

Yeah, if you can get the 4130 chromo shafts I would be interested since I've already welded up my case, but haven't decided what route I'm going yet. Oh, and if its not too much to ask, what about about the shift fork assembly too. That'd be sweet!

whats a realistic turn around time form payment to shipment? not really in any rush but some small company's can take forever to ship stuff. I almost sold the 300 i have laying around today. found this thread just in time

I have one that is ready except for buying the bolts and getting the case welded. Realistically, I can have it ready to ship January 30th due to leaving town tomorrow for almost a week.

ShaunO I checked on just the shaft and I didn't get a 100% firm price but it looks like about $350-$400. It takes him along time to make those and as you can see he isn't making any money on putting these doublers together for me.

Cool product. I want one, check your pm's

I want it for a vitara and got a few questions bout it. I would like to keep it tucked up in the frame rails for a flat skid, how many excedrin will I need to accomplish this? Is the new shifter rig up sealed? Because of my location I have to deal with occasional mud and a good deal of water. I could probably find a cable seal to rig on it if its not sealed.

Do you know what the length is from bellhousing to dana300 output?
Thanks

Got mine. Thanks inphobic for making these things.

Got mine. Thanks inphobic for making these things.

psychobilly: I know you are going to do a write up on your install into the Vitara, right?:smokin:

Eric

Would ya mind posting up an overall length from bellhousing to output when ya get it bolted up?
Thanks

I am pretty sure I gave a dimension from the front of the t-case to the output shaft of the 300. does anyone have the OL of a transmission? I can't see pictures here at work to see if I posted the one with the measurement.

Thanks, Jake

psychobilly: I know you are going to do a write up on your install into the Vitara, right?:smokin:

Eric

I'll add it to the thread. Maybe some to this one.

Decided to put it together today. It went together pretty easy. All the holes lined up, all the parts were there and it took about 2 hours to assemble. Note too that this is going in a 5 sp grand vitara. The front portion of the GV case is a good bit longer than a track/kick/VT case and it has the coarse spline input. Everything worked out though, went together the same. This is really about the only option for gearing the GV. I'll have a crawl of about 120:1 and if I add 4:1's in the 300 I'll get around 180:1. Money well spent.

What I got

http://img.photobucket.com/albums/v146/psychobilly/vitara/grand047.jpg

Close up of some of the machine work on the parts

http://img.photobucket.com/albums/v146/psychobilly/vitara/grand050.jpg

together on the bench. I'll put it in the viagra next week.

http://img.photobucket.com/albums/v146/psychobilly/vitara/grand056.jpg

psycho where are you at in pa? I would love to come check it out if your anywhere near my neck of the woods. I will be getting one of these for my tracker build, just not sure when

psycho where are you at in pa? I would love to come check it out if your anywhere near my neck of the woods. I will be getting one of these for my tracker build, just not sure when

I'm about 60 miles east of pittsburgh so maybe 3-4 hours I'd guess from you.

Any of these still available?
I currently have a 231/300 divorced behind a sammy trans with a 2" long custom jack shaft. I think I would like to mount it solid to a kick box like you make here.

What would it take to get one of these? Any left over parts if you don't make them?

Jason

Yeah I believe you can still get them direct from the machine shop. Doug Mesa is his name and his number is 816-651-0537. If you need any help let me know. Thanks, Jake

do you plan on buying a yellow star?

No I let my yellow star lapse. Jake

in my library for future reference.

any way to get one behind a 2wd traker trans?

are these even still avabil

http://i1040.photobucket.com/albums/b410/kellers10/0b2455c8.jpg
.
.
.
.
.
.
.
.
:grinpimp:

They are still available. I just can't pimp them anymore here on pirate because I no longer have a yellow star.

To my knowledge the 2wd and 4wd th180 were the same in the tracker. I have not personally verified that though.

keller give me a call when you get a chance.

Jake

sweet stuff this is in a contender spot for my build

the 2wd and the 4wd have different tailhousings, and when you take them off, the output shaft is different (the 2wd is way longer)

keller, any more pics? I would love to see some underneath shots so i can get an idea on mounting this sucker!

this is the route i am taking. just need a Dana 300. hopefully i can find one with 4:1 gears installed already!

front digs!

no new pics as of yet you can follow my build hear http://www.pirate4x4.com/forum/showthread.php?t=918486


and I will also put a few pics up in hear as I go along

the 2wd and the 4wd have different tailhousings, and when you take them off, the output shaft is different (the 2wd is way longer)

Found that when I built my 97 2wd slidebrick however we were able to cut down the main shaft on the 2wd automatic trans and install the 4wd tail we then installed the first fully casted kicker(hard to get and hard to beat) to Toyota. I’m running 38s and it seems to be holding up fine

so i could cut some off the output shaft on my 2wd TH180 to run a 4wd tailhousing and the adapter to the 300?

What I know is it worked with my OTT Kicker to toy and has been running well I dont know much about the one but it looks like a copy so it should work

Will a d300 flip kit work on these?
If so that opens up more axles combos fo us.

Off the top of my head, I see no reason they wouldn't work with flip kit. There should be more room on the drivers side of the factory t-case than the passenger side. even after the front output is removed.

Off the top of my head, I see no reason they wouldn't work with flip kit. There should be more room on the drivers side of the factory t-case than the passenger side. even after the front output is removed.

So if that's the case we can now run ford d44s and ford d60 especialy a high pinion king pin 60
total sweetness.

have fun with the exhaust

exhaust

overrated


:homer:

have fun with the exhaust

Are you saying that Jeep and their inline 6 cylinders with a drivers side drop wont work? hmmmm, somebody shoul have let them know that. :D Really you may have to get a little creative but I don't see it being any more complicated that what non zuk people have been dealing with for years.
Jake

probably not. I just know on mine I had to notch the oil pan on the tranny for the driveshaft... and on the drivers side the exhaust is right where the driveshaft is on the other side.

bump for a sweet doubler

Just got mine!

Build thread here.


http://forum.ih8mud.com/ms-cottonland-cruisers/470761-samurai-stretch-auto-doubler-dana-300-stickies-5.html#post6539047

Nice job Lenny

Nice job Lenny

Thanks rockrat! It's getting there. You may recognize your rollcage that I got from you awhile back. Modifying the rear a little ; )