landy_andy Posted March 31, 2023 Share Posted March 31, 2023 As requested, here is the start of my tube buggy rabbit hole ! Frame is based on a Jesse Haines chassis I modified to use a winch tray from Barnes 4WD with the rear switched out to shock hoops. This will allow me to build the frame out to a roller without having to finish all the cage work. DOM tubing is ridiculous expensive at present so, this will save some $ for the time being. 2 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted March 31, 2023 Author Share Posted March 31, 2023 Axles will be based on the same fabricated centre sections I used on the D100 but with 99-04 Super Duty C’s and knuckles on the front and Trail Gear unit bearing pockets on the rear. Here are a few pic’s of the last ones I built. 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted March 31, 2023 Author Share Posted March 31, 2023 Started to collect parts for the front axle… some cleaning required ! Already have the inner 4340 CrMo 35 spline axle shafts, ordered up a 35 spline outer to figure out the axle tube dimensions. Once that’s done we can get welding ! 3 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted April 4, 2023 Author Share Posted April 4, 2023 A few more chassis parts arrived from Barnes 4WD, nice H/D winch tray I’ll add some extra gussets to it for looks & stiffness. At $75 it’s not worth drawing one up & having it cut out ! Two sets of 10 degree square tube link mounts for the lower link subframe end. Some 3/8” threaded bushings to mount the belly skid and I’d already got some teardrop reinforcements from TMR Customs. I can now finish drawing up the reinforcements for the winch tray and just need to order the material to make the main frame rails, rest I have on the rack. 2 1 Quote Link to comment Share on other sites More sharing options...
Arjan Posted April 4, 2023 Share Posted April 4, 2023 Some serious skills here ! Thanks - please keep it coming - very interesting Quote Link to comment Share on other sites More sharing options...
landy_andy Posted April 14, 2023 Author Share Posted April 14, 2023 The 35 spline outer finally arrived, don’t think it fits the hubs 🤣 Found the special tool from Artec Industries to disassemble the Timken brand hubs and have the bores machined out. Getting an idea of 3rd member offset, highly accurate ! Now the waiting game again… at least the snows melting fast, finally have some green grass on the front lawn. 2 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted April 17, 2023 Author Share Posted April 17, 2023 Drew up a custom wrench (similar to Artec one) to disassemble the SKF unit bearings, already have the one so will get another for the front & get the Timkens for the rear as there a bit cheaper. Darn… Artec have stopped making the Timken tool… will have to wait until I get my cut parts to move forwards 😕 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted August 12, 2023 Author Share Posted August 12, 2023 After the first attempt at a custom wrench for the SD unit bearing I tweaked the dimensions & had it cut again, this time in 1/4” plate to reduce the slight errors in the cut angle. 5 layers stacked & TIG’d together… slips over the big nut a treat 😀 Next to pull one apart & get it machined out for the 35 spline stub axle. This projects going to be a long one… we’ve decided to do the early retirement gig, soon to be move it & building a new house in a different area about 5 hours away. Fun times ahead & looking forward to having a 1000+ sq. ft. shop 👍 2 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted August 17, 2023 Author Share Posted August 17, 2023 Well… looks like we won’t be needing the special wrench for the unit bearings after all. My machine shop managed to get the complete bearing in the lathe & skimmed out the bore 1 thou over the shaft diameter. Slips together a treat. I also had some free time so made a start welding up the parts I’ve acquired so far… just waiting on the rest of the diff housing plates to get bent up now. Hopefully we get some rain soon… the smoke from the local forest fire is really getting annoying ☹️ 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted August 20, 2023 Author Share Posted August 20, 2023 Now I have a partial 3rd assembly I can figure out the axle tube lengths. Just need a U-joint to mock it up accurately. Also, happen to have some 3.5” x 3/8” wall DOM left over from the last build… should save quite a few $. Quote Link to comment Share on other sites More sharing options...
landy_andy Posted September 10, 2023 Author Share Posted September 10, 2023 Got the short side tube mocked up, waiting on another stub to assemble the long side. Made sure the stub was all the way up to the circlip groove to allow for the shaft floating. Can now strip that knuckle assembly down, cut out the old tube stub & get the new piece pressed in. 2 Quote Link to comment Share on other sites More sharing options...
Daan Posted September 10, 2023 Share Posted September 10, 2023 Very nice, what engine/tyre size are you going for? Daan Quote Link to comment Share on other sites More sharing options...
landy_andy Posted September 10, 2023 Author Share Posted September 10, 2023 2 hours ago, Daan said: Very nice, what engine/tyre size are you going for? Daan Am thinking 38’s & using a 1.9VW Jetta diesel with a Jeep AX transmission. T’case will either be an Atlas or a Behemoth 👍 Quote Link to comment Share on other sites More sharing options...
Daan Posted September 10, 2023 Share Posted September 10, 2023 Good choice of engine! Daan 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 6, 2023 Author Share Posted October 6, 2023 Got the long side axle tube measured up, will give me a WMS/WMS of 69.5”, not too wide for a compact buggy. Had the raised oil seal lands turned off & polished on the axle shafts for the Trailgear multi-lip axle tube seals to ride on. Worked out about half the price of custom made shafts. 4 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 9, 2023 Author Share Posted October 9, 2023 Made a start welding out the front centre section. 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 9, 2023 Author Share Posted October 9, 2023 About halfway through the first housing, top & bottom edges to complete. Then add the skid plate, remove the 3rd member and finish out the interior. This puppy isn’t going to fall to bits 🤣 3 Quote Link to comment Share on other sites More sharing options...
steve200TDi Posted October 9, 2023 Share Posted October 9, 2023 (edited) Yes! I was going to say the diff housing looks quite 'robust'! Steve Edited October 9, 2023 by steve200TDi 1 Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 10, 2023 Author Share Posted October 10, 2023 Front centre housing is complete, just need a good clean inside to remove any welding BB’s. Made a start on the rear one… time to let that fully cool to minimize any distortion on the front plate as they don’t get machined post welding. 1 Quote Link to comment Share on other sites More sharing options...
simonr Posted October 10, 2023 Share Posted October 10, 2023 That's a nice bit of sheet metal development. 1 Quote Link to comment Share on other sites More sharing options...
Daan Posted October 10, 2023 Share Posted October 10, 2023 1 hour ago, simonr said: That's a nice bit of sheet metal development. Indeed, how did you design the flat patterns? Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 11, 2023 Author Share Posted October 11, 2023 18 hours ago, Daan said: Indeed, how did you design the flat patterns? I didn’t… digital design… why reinvent the wheel… Diyoffroad.com link Quote Link to comment Share on other sites More sharing options...
simonr Posted October 11, 2023 Share Posted October 11, 2023 2 hours ago, landy_andy said: I didn’t… digital design… why reinvent the wheel… Diyoffroad.com link They look good - and better value than spending the time to design your own. Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 11, 2023 Author Share Posted October 11, 2023 5 hours ago, simonr said: They look good - and better value than spending the time to design your own. Exactly, this is the second set for an investment of $85… so, 20 bucks a housing. Have also come up with a way to save money on an alignment bar. Found an old forum post that discussed using 1.5” DOM instead of solid ground bar stock. If I use 2” x 1/4” wall it can turn into links once the axles are built rather than gathering dust in the shop. The guy also used 3D printed pucks but as I don’t have one machined ones will have to do. Quote Link to comment Share on other sites More sharing options...
landy_andy Posted October 11, 2023 Author Share Posted October 11, 2023 Ordered some full hydro, high steer brackets for the knuckles… will be fun glueing them on. Think I’ll be needing the Tiger torch from work for a bit of pre-heating. Quote Link to comment Share on other sites More sharing options...
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