Some of you may remember a couple of months ago I had a topic going about my home made t-case for my mud truck, (49' ford 4x4),
Well the holidays slowed me down a bit but I've nearly completed my drop box,
one more bearing retainer and it should be good to go, I just thought I share some pics,

Here is the building of the bearing retainers/seal area,
https://www.ford-trucks.com/user_gal...=65901&width=0
https://www.ford-trucks.com/user_gal...=65903&width=0
https://www.ford-trucks.com/user_gal...=65904&width=0
Here is the out put shaft
https://www.ford-trucks.com/user_gal...=65905&width=0
And a couple of the box completed exept for the last bearing retainer,
https://www.ford-trucks.com/user_gal...=65906&width=0
https://www.ford-trucks.com/user_gal...=65907&width=0
https://www.ford-trucks.com/user_gal...=65908&width=0
https://www.ford-trucks.com/user_gal...=65909&width=0
I'll try and get a few pics of the inside when I finish & install the last bearing retainer,
sorry about the dark pics, I'm still trying to learn how to run the new camera,

 

Fool...you coulda just bought an Atlas and been done with it...
You're gonna put that in the MUD?! It's too dang beautiful to get dirty! What do you have for the gear ratio in there? And how are you getting oil to the top gears? What size chail are you using on the inside? And lastly, how much $$ do you have tied up in there? It's beautiful...

 

That thang is SWEEEEET! So is it going to be full time 4x4? Will you have a lot range or all high? That box looks just like what the monster trucks are using . . . I love it!

 

Is that steel or aluminum? It appears to be aluminum, as I would assume, from a weight standpoint, but...

 

damn man! that thing is SWEET looking. did you do all that work yourself at home? or do you use a machine shop at work or something?

-cutts-

 

Thanks for the compliments,
I am running a double 60 roller chain and the bottom sprocket can be changed so pretty much any ratio can be had up to 2.5:1, right now I have the lower sprockets & chains for 1:1, 1.5:1 & 2:1, as far as oiling goes I have the fill plug up high enough for the lower sprocket to run in the oil which should let the chain carry the oil to the upper bearings,
Yes the box will be full time 4wd but for a comp. only rig it should be fine, I will still be able to unlock the hubs,
the box and bearing retainers are aluminum and naturally the sprockets/chain & shafts are steel along with the tensioner, as you see it in the pics with the 1.5:1 gearing in weighs just under 70lbs,
All work was done between my shop and my dads shop, I have all the welding tools and he has the lathe & mill,
I figure I have approx $500-$750, I haven't figured it all up yet,

 

You know, I wonder if a 205 can be clocked to be totally vertical and just overfill it, same as you did...hmmm...sounds like a spring project to me...is there any reason that you didn't just do that? Aside from the cool factor, of course...

 

I'm impressed, good work man

 

Sweeeeeeeettt, i wish i had a lathe/mill to be able to do work like that.

 

Lookin good man....ya know what the sad parts gunna be...when ya open up your motor in a mud hole and ya hear. ..WACKLKELKKLEKKKKKKKKKKKKKKKKK.......second to last semester of my engineering degree i machined a bunch of stuff for a tranny for the race cars that we were building....well i take it out to test it and about two minutes into runnin....the tranny let loose and trashed itself.....there went three weeks of machining work...

 

I think that indexing the 205 would work fine, I had two resons for building my own box, #1 weight, I wanted a box as light and strong as possible, and #2 I wanted to get my output shaft both front & rear lower to help with the drive line angle, indexing the 205 would only help with the front ouput, of course the cool factor isn't a bad reason either,

 

Nice work, skipped!!!!! Have you actually tried the different ratios for chain fitment like we discussed earlier???? or does the mentioned tensioner make up the difference?

 

Yea, a buddy of mine has a dana 20 in his Jeep that he indexed, although not as vertical as I'm thinkin. The front is really the only one that I'm concerned about. With my current tranny/adapter/TC combo, I can't use a CV joint in my front driveshaft. My only real issue with indexing the TC to near vertical is 1) shifter engagement (I'm think just put it in 4LO and leave it there permanently), and 2) breakover angle. If I'm truckin along thru the woods and go over a stump, that might catch the TC and just break everything. We'll just have to see how things go...

 

I have tried two of the three combos, the 1:1 is perfect no tensioner needed, the 1.5:1 was a whole other story, It was real close to fitting but I can't seem to get that chain to strech an 1/8 of an inch (ha ha) and one more link was just to sloppy, so I used a half link and built the tensioner to work with that setup, as far as 2:1 I am waiting for my lower sprocket to get back, I had to send it out to get the splines cut in it to fit the out put shaft, but the case was designed around the 2:1 setup so the tensioner should not be needed,

 

Great fab work!