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)

[blazinchuck]

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]

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

[66bronco]

very cool.
bryan

[krazybronco]

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

[69bronco]

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

[JunKeBluB2]

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]

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]

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

[66bronco]

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