I have really got too many projects on at the moment and here is the start on another one .

This is the gearbox and transfer that im going to be putting in my buggy together with the d60/d70.

This first pic is the modified output shaft of the LT95 gearbox/transfer (this gearbox/transfer is all in one piece) this transfer case (shaft size and gear size) is about twice the size of an LT230.

To adapt the shaft (essencially to make a spud shaft) i got the output shaft cut and board and then got a T18 yoke pressed into the board hole and then welded. I only hope it will be strong enough - it should be cause the diameter that the weld is on is fairly big.

Heres the pic of the new shaft next to an unmodified shaft. You can see where the thicker section is that we used to boar the hole and press in the yoke.

Sam

Other angle showing the internal spline.

new shaft sitting next to the output of the T18

heres the shaft mounted on the output splines. When the yoke was welded into the shaft the weld shrunk the splines a bit (we knew this would happen - but the question was how much). The shaft does fit on the spline and it is a good tight fit (meaning I will need to flog it on there with a FBH).

heres the last pic of the shaft sitting in the transfer case. This pic is looking from the top through where the selectors were mounted. What I am going to do is machine up a 20mm thick Aluminimum plate that mounts to the back of the T18 (holds the rear bearing in place etc) and then cut the lt95 housing at the right length (the cut will be at about the left hand edge of this photo) then mount the shaft on the end on the T18, silde the transfer case onto the shaft and weld on the plate and the jobs done.

This will give me a 6.4:1 first gear with a 3.3:1 transfer ratio. So that with the 4.56 gears in the diffs I will have a 96:1 crall ratio which is getting closer to what I need.

Hopefully the cost to do this conversion will be less than $400AUS.

Sam

OK heres the last pic showing the BW T18 gearbox sitting in front of the LT95 transfer. Where the black line with arrow is marked is about where I will cut the transfer housing and weld on the adapter plate. The assembly does look long but I think its comparable to a NP205 or similar as these use a fairly long extension housing before they get to the transfer case anyway.

The length of the overall drive train (motor/gearbox/transfer) will actually be the same length is the stock rover cause the 302W uses a much shorter bellhousing.

Sam

Yep thats right for the equivelent of twelve american dollars I have created a custom tranny transfer case that is stronger and more highly evolved than the $5000 hunks of crap that are in all your yank rigs. Oh yes, it only took a weekend and it fits perfectly thank you very much.

:)

We're not worthy . . . we're not worthy

"bolt on" Ron

bahhahah bolt on ron i love it.

after all, those portals do pretty much bolt in, dont they? :D

looks awesome sam, keep up the good work and be sure to post plenty more progress pics! :beer: for you!

Hopefully this conversion works out really well.

The way the main shaft of the LT95 gearbox/transfer is with the really thick section halfway along it really does lend itself to being modified in this way - that is being board and having a yoke pressed into it and then welded to get an internal spline. I think this transfer could be easily adapted to any sort of gearbox in exactly the same way. I think the strength of the welded in yoke should be fine cause the weld is on such a big diameter. The guys that welded it said it welded really well (the metal flowed together well) - they pre and post heated it and used special rods to do the job so it should be good.

Ill see if I can get some comparison photos of the size of the LT95 compared to an LT230. Ive heard guys saying that an LT230 is comparable in size to an Atlas and this LT95 is twice the size. You can actually see how big the LT95 shaft is in the above pic where the modified shaft is mounted on the BW T18. The T18 output shaft would be half the diameter of the LT95 output shaft.

Anyway, only time will tell.

Sam

great job sam :beer:

i'm diggin it


cheers

Sam,

An interesting excercize you've got goin' on down there.

Having both an LT-95 and several LT-230's this is of particular interest to me.

One thing that the LT-95's t-case section gives you (that the LT-230 does not), is the ability to change the high ratio gearset w/out affecting the low ratio. (wait, is that right?).

I have the highest ratio high-range gearset waiting to be installed into my LT-95 right now.

One thing your mod allows you to do is to start with taller gears, and potentially a broader selections of ratios through the gear range (is that correct?).

Otherwise, why bother right?

Man, re-reading that post you'd think I was a blithering idiot or sumptin'.

:flipoff2:

If I'm wrong on all counts fill me in man!

BTW, where are my slotted bushings? I need them on the crewcab now that I have those 25 inch rims mounted! :flipoff2:

Originally posted by Serious One
Sam,

An interesting excercize you've got goin' on down there.

Having both an LT-95 and several LT-230's this is of particular interest to me.

One thing that the LT-95's t-case section gives you (that the LT-230 does not), is the ability to change the high ratio gearset w/out affecting the low ratio. (wait, is that right?).

I have the highest ratio high-range gearset waiting to be installed into my LT-95 right now.

One thing your mod allows you to do is to start with taller gears, and potentially a broader selections of ratios through the gear range (is that correct?).

Otherwise, why bother right?

Man, re-reading that post you'd think I was a blithering idiot or sumptin'.

:flipoff2:

If I'm wrong on all counts fill me in man!

BTW, where are my slotted bushings? I need them on the crewcab now that I have those 25 inch rims mounted! :flipoff2:

The only reason Im doing this mod is so that I can run the T18 which has a 6.4:1 first gear where as the standard rover manual transmissions have around a 4:1 first gear. This means my overall crawl ratio goes from 60:1 to 96:1 which is a big difference.

The slotted bushes are happening but slowely. We got a set of the next generation bushes in my buisness partners rangie and they seem to work well (they drive well on the road and seem to have almost as much travel as the holey ones). Ill have a look at them today to see if they are cutting up cause hes done a bit of wheeling since he put them in and if they are OK then I should send you over a set to try.

Your radius arms would be the later version wide ones wouldnt they (as opposed to the early moder Range Rover ones when the radius arms were norrower).

Sam

the radius arms on the crewcab are the early narrow style, we also have another set of the early arms off of a grey market RR.

The rest of my trucks all have the later style wider arms.

Looking forward to more updates!