: big 800 build / some progress


chris fresh
11-30-2008, 03:24 PM
started building the triple sticks for my 203/205 combo.built a bracket to fit the backside of the 203 case with a side piece to build off of.drilled that and welded in a 5/8 bolt for the pivot point.local hardware store had some 7/8 i.d steel spacers and some bronze bushings that fit,wich were 5/8 i.d that would go on the bolt smoothly.cut some 3/4 round stock to staggered lengths so the knobs would clear each other.,drilled and tapped for 3/8-16 threaded rod to attach the knobs. (jc whitney/j##p section,20 bucks each). welded the 3/4 stock to the spacers,hammered in the bushings and then slid them on the 5/8 bolt.then for the links,had some 1/2 round on hand,drilled/tapped 5 1/6-24 to accept the hiem joints from my local supplier( 5.20 each). i drilled 5/16 holes thru the shift levers and used 5/16 clevis pins with cotter pins.on the t-case side i made a bracket to go thru the slot in the shift rail out of some 1/4x1'' stock,used pins there also.welded the 1/2 round to the bracket.2 things i'm very happy with,one is nothing rattles,two is the operation from front to back is super smooth and a positive feeling in your hand.




also fabbed up my cross member for the back of the 205. used some 2x4 box,1/4 wall from side to side,made some pockets on the frame rails with factory style g/m bushings.used 1/2 plate machined out to clear the snapring on the rear shaft and the factory holes in the tail housing,now i'm going to replace those bolts with recessed flat heads so the rear retainer can go on,just have to clock the retainer a little so i can mark/drill/tap.even gaining the thickness of the 1/2 plate,theres still plenty of room for the retainer/seal with the yoke bottom'd out.couple new gaskets and some rtv and things should be fine

chris fresh
11-30-2008, 03:35 PM
cross member

plug ugly
11-30-2008, 07:19 PM
had to cut that much to fit the 205 huh?

chris fresh
11-30-2008, 07:43 PM
not really,the pic is lie'n to ya.thought so at first because i was tryin to keep a flat belly,so i cut it out.then just thru in a body lift and now it's undernieth.gonna patch in the floor after the shifters are completely done.also i always build aluminum dashes for my trucks,wich this one will get.and now i've decided to do aluminum center console also,kinda trophy truck style.so i will patch in the floor,close up anything else that's not functional and build the console.

ChiScouter
11-30-2008, 07:53 PM
Wow, maybe ive been missing something but I have never seen one mounted by the flange like that. It looks great for packaging, but it scares the hell out of me. I hope it works.

chris fresh
11-30-2008, 09:04 PM
i guess your refering to the case.i've never seen it done either,but i was kind of forced into it.with the 203/205 combo,the only mount i had was the factory one wich is the adapter between the 400 and the 203.problem is the front drive shaft,with the front 60 pushed out and the extra length of the 203 the front shaft is long.and it runs right thru where the cross member would be.so i had to figure out another way.as i see it,it can't be that bad on the tail housing,the housing is cast and beefy.as you see in the pics where it's bolted up i'm going to use different bolts that will be flush with the plate face and then just clock the retainer.i think it would be different if i ran bolts through the retainer and then into the housing because the retainer is cast aluminum.don't think it would last to long.but you gotta love the room undernieth.completly flat belly,the very bottom edge of the 205 is flush with the frame rails.i still think about it to,if it was gonna break,where would it be?all i can do is wheel it and see.i might also try and build off of that 2x4 heading foward to and tie in the 203 that way with maybe a smaller type set up.the hardest part was milling out the back of the plate for the ring that holds the bearing in.i don't have a mill,i used three diffent holesaws in my drill press and just set the depth accordingly,was alotta fun.but it came out perfect with no slop.