JunKeBluB2 doubler build (lotta pics)

[JunKeBluB2]

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



The transplant



The operating room (my machine shop)



Remove planetary from doubler case



Split the case



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



Layout adapter plate & transfer holes



Cut plate



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



Machining splines on output



Boring sector shaft



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



Machining square on output shaft to press into sector shaft



shafts machined



Pressed & welded



Boring adapter plate



Machining doubler case for filler block



Locating bore for drilling mounting holes



Drilling holes for mounting to t-case planetary cover



Adapter plate done



Doubler case and parts ready for assembly



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



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



Put front cover on t-case



Bolt adapter plate to doubler case



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



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



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



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



Everything installed (I hope again)



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