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Carolina Broncos
JunKeBluB2 doubler build (lotta pics) - Printable Version

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JunKeBluB2 doubler build (lotta pics) - JunKeBluB2 - 09-21-2007

This build started as a BW1350 twin stick & it can be done the doubler case goes behind the t-case but i'd have to build bearing blocks, shafts, move rear axle back and more modifying than I wanted to do so i opted for what all RBV wheelers do, a doubler. A lot more to it than posted here. But here's the skinny of it.


The patient

[Image: 1SIDEVIEW.jpg]

The transplant

[Image: 2thetransplant.jpg]

The operating room (my machine shop)

[Image: 3theoperatingroom.jpg]

Remove planetary from doubler case

[Image: 5planetaryremoved.jpg]

Split the case

[Image: 6splitcase.jpg]

Back half & parts junk (unless u need them krazybronco)

[Image: 7backjunk.jpg]

Layout adapter plate & transfer holes

[Image: 8layoutplate.jpg]

Cut plate

[Image: 9cutplate.jpg]

Machining output shaft (others have used shafts from trannys and pressed and welded but I wanted more strength pics show what I mean)

Turning output shaft

[Image: 10turnoutputshaft.jpg]

Machining splines on output

[Image: 11splineoutputshaft.jpg]

Boring sector shaft

[Image: 12boresectorshaft.jpg]

Cutting square bore in sector shaft (this is for torque strength)

[Image: 14machsqrsectorshaft.jpg]

Machining square on output shaft to press into sector shaft

[Image: 15machsqroutputshaft.jpg]

shafts machined

[Image: 16readyforassy.jpg]

Pressed & welded

[Image: 17weldedandfaced.jpg]

Boring adapter plate

[Image: 18boringplate.jpg]

Machining doubler case for filler block

[Image: 19machforfillerblock.jpg]

Locating bore for drilling mounting holes

[Image: 20locatebore.jpg]

Drilling holes for mounting to t-case planetary cover

[Image: 21drillingmountholes.jpg]

Adapter plate done

[Image: 22adapterdone.jpg]

Doubler case and parts ready for assembly

[Image: 23doublercase.jpg]

Transfer & drill & tap holes in t-case planetary cover

[Image: 24tapplanetarycover.jpg]

Now I'm ready for assembly (I hope!)

[Image: 25caseassy1.jpg]

Put front cover on t-case

[Image: 26coverontcase.jpg]

Bolt adapter plate to doubler case

[Image: 27plateondoubler.jpg]

From inside doubler case bolt to t-case w/ 20 1/4 SHCS

[Image: 28doublertotcase.jpg]

Next installed shift rail (length cut) shift fork and sector shaft outer-spline

[Image: 29forkrailgearinstall.jpg]

Install planetary set in doubler case then bolt t-case to doubler case

[Image: 30tcasetodoubler.jpg]

Shifter linkage. This was the hardest part I opted to use manual shift cases cause I don't like electric shift. I had about 2 days of design in it trying to clear everything & make the shifter & arm on the t-case travel the same distance on a different radius

[Image: 31shifterlinkage.jpg]

Everything installed (I hope again)

[Image: 32installed.jpg]

Two manual shifters one shift knob (shift knob donations please)

[Image: 33dualshifters.jpg]

JunKeBluB2 doubler build (lotta pics) - blazinchuck - 09-21-2007

wow is not enough, but WOW, what a beautiful job Ronnie. You have some serious skills bro!! Did you have to modify the cross member or add to it?

on a side note, I saw your son on the gutches site...is he online with us yet? Whats his rig look like?

maybe you should offer this as a BII upgrade 8) Very cool,very well laid out! Chuck

JunKeBluB2 doubler build (lotta pics) - JunKeBluB2 - 09-21-2007

Thanks Chuck for the kind words but I have been doing machine work and some design for a long time (30+ years) don't do much now though kinda semi-retired as for my son junkyarddog he's only 15 and drives a '99 dodge 1500 4x4 w/4" lift & 31 all terrains (wish I was that lucky when I was his age) as for as the post on the build I could fill a book with all that was involved oh yea didn't mod the cross member yet with the 20 mounting holes I clocked the t-case up & w/ my D44 high pinion front I hope the front shaft will clear
Ronnie

JunKeBluB2 doubler build (lotta pics) - 66bronco - 09-21-2007

very cool.
bryan

JunKeBluB2 doubler build (lotta pics) - krazybronco - 09-21-2007

Build me one i need one with the 3.45 gears i think you have a something around 6.something :1

SICK i want one heck chuck you still got that d44 eb

JunKeBluB2 doubler build (lotta pics) - 69bronco - 09-21-2007

What the Confusedhock: , who the Confusedhock: , Holy crap that is cool 8) , what a great shop to have esp for a 4 wheeler.

JunKeBluB2 doubler build (lotta pics) - JunKeBluB2 - 09-22-2007

Krazybronco,
with 3.96:1 in tranny w/ 2.48:1x2 in t-cases & 3.50:1 in axles its at 85:1 final
and you can use my shop any time you won't to build your own :lol: :lol:

JunKeBluB2 doubler build (lotta pics) - JunKeBluB2 - 09-22-2007

69bronco
thanks,it is cool having the equipment & experience to do this stuff, but I don't do as much as I use too.

JunKeBluB2 doubler build (lotta pics) - JunKeBluB2 - 09-22-2007

oh yea thanks Bryan but you need to get your's off the stands and on the trails the JUNK might need a tow!

JunKeBluB2 doubler build (lotta pics) - 66bronco - 09-22-2007

I have been looking for a small manual mill and lathe to put in my shop. Just have not been lucky yet.
bryan