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dirtydiesel

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dirtydiesel last won the day on January 14 2022

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    Nottingham, England

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    Being boring and not spending nearly enough hours in the workshop.

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  1. From looking at your pics they look like the weaker style ring and pinions. Where the ring gear bolts to the diff carrier the mounting flange is quite thin, thinner even than the minor thickness of the gear. We've had three just blow a section of ring gear off about 4 teeth long. The (later?) Stronger type run a thicker mounting flange with more of a helical cut to the gears, from memory they have a larger pinion. They also have 2 "ears" cast into the carrier bearing caps that locate inside the diff pan. I wouldn't be too worried about your diffs strength. Every time I broke anything in a mog axle it deserved to break.
  2. Staggering engineering and ingenuity Stephen. 44 pages took some catching up on! I don't know if your research has turned this up but there are 2 different styles of ring and opinions used in 404's one style has a very odd ring gear design that breaks quite easily. I can't tell from the pics which style yours is. Earlier in the thread (page19) you asked if anyone had lightened or broken an axle case. I've never lightened one but I have broken 1. And repaired anothe that tibus offroad built, theres snapped in the middle where they'd done a shoddy job of joining the case. Mine cracked the outer under a suspension bracket then broke the inner tube off at the end where I'd welded it. The roller bearing you lost (and found) can be bought by the hundred from any bearing supplier. All the seals and bearings are pretty standard and easily available. I think the exception is the little rubber top hats that link the grease paths in the cv joints. I really like your diff lock setup, very clever and not too dissimilar to the sliding setup in a g wagon axle, although the cylinder is on the outside on those. One problem I've come across myself and with others when air actuating the diff lock, the dogs can sit on top of each other with the force of the cylinder holding them there until it slips in when a wheel breaks free. This then smashes the dog to pieces. A friend of mine converted his to cable with a spring setup like standard. As he claims to be able the "feel" them in. And hasn't broken the diff lock since. I'd be interested to see how your front 1 link looks complete. But from your description I think your overthinking the bushing needed, I've ran them directly welded to the axle cases for years with a ballistic joint at the chassis end https://www.ballisticfabrication.com/products/3-0-ultra-duty-ballistic-joint On my patrol, I run a ballistic joint at the chassis, and I've bolted the 1 link onto the radius arm brackets without any brushing, I've done about 40k road miles in it over 7 years and as regards NVH I can't tell the difference, there is no harshness at all. the loss of roll resistance in the suspension takes a lot of adjusting to though.
  3. Looking really good Daan. Will the VW diesel fit under the bonnet ok?
  4. I'm changing the fox air shocks for 2.0 coilovers as I can't get the ride height where i want it with the air shocks. Although they are both the same length and mountings the reservoir fitting on the coilovers wont fit in the mounts I already have.
  5. I'm all good here, hopefully you are too. I still have the MB is still not finished or even all in the same postcode!
  6. I've been reading your jeep thread, not fully caught up with all the content on here yet! The wrangler has had three weekends out, with quite a few teething problems so far. The discovery 2 radius arm bushes I used at the chassis end of my 1 links are too soft, lots of knocking and allowed the axle to wander around too much. I've changed the front one to a 3.0 ballistic joint, need to do the rear one yet. Developed a oil leak from the turbo drain, dumped most of the oil and killed the turbo bearings. And I (somewhat predictably) grenaded a cv being a dick in some rocks. I'm on stock cv's as rcv's are pricey for the g wagon axles. But it drives really well, the steering is epically light and direct, with very little fight back when the front locker is in. The Diff locks work beautifully in and out quicker than anything else I've had. I'm very happy with the amount of flex in the suspension, its really stable and cycles that freely it's sometimes hard to place where the wheels are by feel alone. However I can't seem to get the front ride height up enough even with 450psi in the air shocks. And after the last weekend out the drivers side one has collapsed to the bumpstop. The power is quite oddly seamless with the vgt, More tuning required I think. And the super swamper tsl's were absolutely rock hard, even with 10psi in them they didn't conform to rocks. Its currently on a set of ancient 37x13 tsl boggers, they are quite worn and probably still a bit too wide for the truck but they work well enough until I buy some mud trepadors.
  7. The G wagon is long gone Steve, I have still got the portal boxes and swivels off it and a few other bits. The workshop is nice and light but lacking in all my fabrication gear.
  8. Here's a few pics inside the front wheel arches, I'm in the process of changing the air shock on the front for coilovers as I can't get the ride height where I want it to be. I've rebuilt an old set of 14" fox 2.0 remote reservoir shocks forthe front.The black finish is nitriding.
  9. A few muddy pics of the rear cage mountings. ive linked the rear wheel arches into the cage.
  10. The main structure of the cage is 50x3.2 cds with 45x3.2 everywhere else
  11. Cheers guys. A lot of the build I haven't documented. These are lifted off my Instagram, I over skinned the rear tub in 2mm then built the arches in 45mm cds these were then tiger sealed and riveted on.
  12. Wide drum, bow2+ powered 8074 on the front. I've made the section above the winch removable to get the winch out for repairs.
  13. Nearly 10 years later, here's an update Rear bumper build.
  14. Hiya Daan

     

    Changes made - please pm me if anything that should work for you doesn't !

    Take care

     

    Nige @D

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