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Discussion starter · #521 · (Edited)
Thanks fellas! Chris, I don't know. My tcase is acting up and I might use it as an excuse to build the doubler hehe.

I must say, it's nice to have both these things hoggin my driveway again, away from their hiding places on the side and out back. They sound MEAN idling side by side! The ZJ is gunna be getting some noteworthy work here soon too

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Discussion starter · #522 · (Edited)
I tore the tcase apart, found the cause of the 4wd popping out
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I don't know if this has been a long time coming or if it happened all at once, but those teeth aren't happy. This is the 4wd shift collar
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So I made a drawing yeseterday hehe. I know I only need half of this for the doubler build, but it doesn't hurt to start by drawing the whole thing :D
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Discussion starter · #526 · (Edited)
I'm building the entire doubler myself with the exception of the intermediary shaft, which will be the original 242HD main shaft cut down and resplined by Dean and Performance Cryogenics. He does a full heat and cryo treat process after the remachining

I've been excited to attempt my own doubler build for a long time so it's time to put my money where my mouth is and see if I'm really capable.
 
Awesome, i have a 205 I saving for a my finace's buggy- what mounting ring are you useing and where are you getting ur intermedary shaft from??
I'm building the entire doubler myself with the exception of the intermediary shaft, which will be the original 242HD main shaft cut down and resplined by Dean and Performance Cryogenics. He does a full heat and cryo treat process after the remachining

I've been excited to attempt my own doubler build for a long time so it's time to put my money where my mouth is and see if I'm really capable.
Can you send me his info, i may end up doing something like this on the buggy, ill keep the 231/300 in my xj.
 
Discussion starter · #529 · (Edited)
He's a hell of a guy, he did all the machine work to help me convert my dana 60 hubs to 5x5.5 on the 609 and I held him to some TIGHT deadlines but he came through for me. Did I mention he's local to me? Makes it easier when you can go shake his hand and bullshit about things like this doubler :D

http://www.performancecryogenics.com/
 
Discussion starter · #535 ·
once I pick up the tube fawker haha. I've gotta talk to mr justin about hauling it home for me. It's only 900 feet lmao.

Some slight adjusting to the part file to help align bolt holes and I've got a tcase block off plate haha. Great makings of the doubler though, with school almost out I get to turn to some intense fab work in the coming months. I'm excited
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Discussion starter · #537 ·
Mmmm not really, I'm thinking 3/8" plate or two 1/4" plates doubled up with some cutouts for weight saving. Depending on the spacing I'm going to need between the cases I don't expect to add an extreme amount of weight to things overall though, maybe 20-30lbs of steel max? I'll be adding a mount to the 205 also, so sheer weight shouldn't hurt anything. It's nice that this NV3500 transmission is less than 100lbs fully loaded, my whole drivetrain weight should still say pretty low overall
 
Discussion starter · #540 ·
haha thankfully the plate is onl a peice of like 16 or 18 gauge right now, I was just testing the part file so I don't waste the time and steel cutting it out of thick plate.

David yeah they are just a BIT heavy, the 205 alone might weigh more than the transmission and doubler box combined :D. My cage plans are mostly internal, with a continuous external bar that punches out of the front fenders at the A pillar, up alongside the windshield and all the way to the back above the doors so there are no overhead bars inside. Plenty of triangulation of course :flipoff2:
 
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