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Post new topic   Reply to topic    Difflock Forum Index -> 4x4s -> Custom Builds
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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Sun Apr 06, 2008 11:21 pm    Post subject: ZERO Reply with quote

The plan is to take this doner lwb sammy and chop it up put a few bits on and make a few bits (well allot of bits)

it came with the engine missing which suited me fine

the plan
shorten the wheel base to 86" and chop the xs from the rear
fit the axles from a yota lj70
ARB's front and rear
disks at rear
bfg 33x12.5 muds on fondmetaal aloys
1.6 16v vit efi engine with all the bits that go with it
vit gearbox,behind that the reduction part of a vit t/case
behind that a rocklobstered sj t/case with a disk prop brake fitted
the suspension will be a one link front with panard
rear is a setup designed by me to give max travel with zero rear steer
(hence the name zero)
the dislocation of the springs will be controlled by pneumatic cylinders

a few pics of the build so far




all the above are just a trial setup, when I'm happy with it all it will be stripped, fully welded and structured.

steering done had to be made to cope with the extreme axle travel.
using a yota steering box, and each end of the drag link has 4 deep grooved rubber sealed roller bearings.




shocks are now on so all the limiting factors are on,not quite the 90deg but not bad (might still have a play try and get a bit more)



[/list]

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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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Last edited by rockwatt on Mon Jun 30, 2008 5:45 pm; edited 2 times in total
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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Sun Apr 06, 2008 11:45 pm    Post subject: Reply with quote

started work on the transfer boxes you can see a full build of a dual case on one of my other posts(nat is going to put it in the stickies) but this is a triple so it will be a bit more work to get it short to fit.

vit trany case prepped ready for welding and output shaft shortened to go back in.



this is the shaft for the first case behind the gear box it is shortened and resplined to the same type as the gearbox output shaft in order for it to go into the second vit case input.

after the heat treatment and then giving the bearing races a polish.


it was nitraded then heated to 1100deg oil quenched then tempered at 250deg three times, maybe over kill cos the original is only en16 case hardened.so it should be strong. Pray

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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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xamtex
Difflock Royalty


Joined: 02 Dec 2003
Odometer: 11903
Location: nuneaton



PostPosted: Thu Apr 17, 2008 10:07 pm    Post subject: Reply with quote

excellent work...just 1 question????why cut a lwb down to 86"
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gods zoo is mighty....BUT..his fence is too low.?
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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Fri Apr 18, 2008 8:06 pm    Post subject: Reply with quote

xamtex wrote:
excellent work...just 1 question????why cut a lwb down to 86"

Cos a swb is to short for the triple trany and the lwb I'm using is reg-ed as a commercial so hopefully be a bit more strait forward for the sva. And i think 86 is a good compromise .

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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Tue Jul 29, 2008 6:57 pm    Post subject: Reply with quote







As you can see i have used the 80mm box for the sills. And also extended it to go up to the scuttle to form the bottom half of the cage. Ive done the same at the rear up to the level of the factory hoop then tube from there up. The plan is to have a fully integrated cage with just the screen hoop on the outside.

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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Wed Jul 30, 2008 6:09 pm    Post subject: Reply with quote

few more pic's



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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Wed Aug 20, 2008 11:29 pm    Post subject: Reply with quote

bit more done to top of cage





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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Tue Aug 26, 2008 5:58 pm    Post subject: Reply with quote

front end (nowt else to say realy)

.

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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Thu Aug 28, 2008 3:38 am    Post subject: Reply with quote


__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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big_patrol
Mud Obsessed


Joined: 10 Sep 2006
Odometer: 2620
Location: Rossendale


1998 Nissan patrol

PostPosted: Tue Nov 11, 2008 1:14 am    Post subject: Reply with quote

Im waiting patiently for an update
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Nobby
Mud Obsessed


Joined: 31 Dec 2004
Odometer: 3097
Location: Ty Gwyllt


1989 Suzuki Samurai

PostPosted: Sat Jan 10, 2009 11:34 am    Post subject: Reply with quote

Come on Rich where are these pics im getting bored at looking at the same ones
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customfighter
Articulating


Joined: 02 Apr 2007
Odometer: 781
Location: North East


1998 Suzuki Vitara

PostPosted: Sun Jan 11, 2009 11:05 pm    Post subject: Reply with quote

Over 4 months and no update? come on rich Wink
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98 vit engine for sale
http://forum.difflock.com/ads_item.php?id=3290
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Mon Feb 09, 2009 12:12 am    Post subject: Reply with quote

oh go on then

managed to get some done on my own truck this week so here goes

front clip finished just needs paint. enclosed head lamp bowls and the iner wings are fabbed from 3mm alloy sheet





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rockwatt
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Joined: 25 Jul 2007
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Location: North lincs



PostPosted: Mon Feb 09, 2009 12:25 am    Post subject: Reply with quote

started the tare down to weld up all the bits that were just tack welded.
front axle nearly done just a few gusets to add here and there. all the one link frame done and the diff guard in 6mm plate.



stripped out the diff and measured the backlash prior to rebuilding.
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rockwatt
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Joined: 25 Jul 2007
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Location: North lincs



PostPosted: Mon Feb 09, 2009 12:38 am    Post subject: Reply with quote

pics pics pics





diif all done ready to go back in and its got a bit of copper pipe on it wonder what that means Rolling Eyes
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customfighter
Articulating


Joined: 02 Apr 2007
Odometer: 781
Location: North East


1998 Suzuki Vitara

PostPosted: Mon Feb 09, 2009 1:41 pm    Post subject: Reply with quote

Nice ARB Wink Like the cardboard over the diff wish id done that Embarassed think mine might need a clean out before reasembly. Nice work as usual Rich
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Tue Mar 31, 2009 12:28 pm    Post subject: Reply with quote

another days work. Welding on front axle all done.
Swivel gussets cut out of 20mm plate and welded in.



And some bits arrived from bits4vits

__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
email me for details

Find me on Facebook https://www.facebook.com/RockwattEng


Last edited by rockwatt on Thu Apr 30, 2009 2:34 pm; edited 2 times in total
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rockwatt
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Joined: 25 Jul 2007
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Location: North lincs



PostPosted: Tue Mar 31, 2009 4:52 pm    Post subject: Reply with quote

more pics





__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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daviie
Just got MTs


Joined: 01 Jan 2006
Odometer: 459
Location: Sunny Scunthorpe


1996 Suzuki Samurai

PostPosted: Tue Mar 31, 2009 10:33 pm    Post subject: Reply with quote

coming on well rich
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Chris™
Mud Obsessed


Joined: 28 Sep 2005
Odometer: 3052
Location: Warwickshire


1986 Suzuki SJ413

PostPosted: Wed Apr 01, 2009 9:15 am    Post subject: Reply with quote

Beautiful welding, looking awesome Very Happy
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rockwatt
Off-Road Guru


Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Thu Apr 02, 2009 7:42 pm    Post subject: Reply with quote

done some more today. Chassis welding.




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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Thu Apr 02, 2009 7:51 pm    Post subject: Reply with quote

pics pics




__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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Jimmy
Just got MTs


Joined: 01 Nov 2006
Odometer: 307
Location: Wirral, Cheshire


1992 Toyota Landcruiser

PostPosted: Fri Apr 03, 2009 7:07 pm    Post subject: Reply with quote

Monster in the making, looks good man
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mukkybugger
Gate Opener


Joined: 04 Mar 2009
Odometer: 32
Location: WARWICKSHIRE



PostPosted: Sat Apr 04, 2009 3:06 pm    Post subject: Reply with quote

wish i could weld like that...grrr Crying or Very sad
__________________________________
4.2 V8 4SPD AUTO..DE CAT ,NEW CANVAS ,BLACK MODULARS INSA TURBO, ROCK SLIDERS,
BODY SLIDERS,CHEQUER PLATE INTERIOR,SAFARI SNORKEL,
LIGHT BAR,WINCH BUMPER.....
YOU STILL LOOK UGLY...BUY ME ANOTHER DRINK..
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Sun Apr 05, 2009 11:13 am    Post subject: Reply with quote

Chris wrote:
Beautiful welding, looking awesome Very Happy

Embarassed aww shuks
Iv only posted pics of the good bits Laughing Laughing Rolling Eyes

__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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rockwatt
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Joined: 25 Jul 2007
Odometer: 1542
Location: North lincs



PostPosted: Sun Apr 05, 2009 11:23 am    Post subject: Reply with quote

put some recy points on the front xmember.

Cleaned it all up and have it a couple of coats of zinc primer.



__________________________________
Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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forkrentfitter
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PostPosted: Sun Apr 05, 2009 7:10 pm    Post subject: Reply with quote

richard,in the last pic it shows your pipe bender,is it a cheepy type?your cage bends look bloody good,any tips/i am just about to attempt my first cage,what type of pipe did you use?
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rockwatt
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Joined: 25 Jul 2007
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PostPosted: Sun Apr 05, 2009 9:45 pm    Post subject: Reply with quote

forkrentfitter wrote:
richard,in the last pic it shows your pipe bender,is it a cheepy type?your cage bends look bloody good,any tips/i am just about to attempt my first cage,what type of pipe did you use?

Yes it is a cheap sealy bender but the die's are tubela with an adapter the standard die's have to small a radius and can kink the pipe. The main hoops are in cds hydro pipe 4mm wall.
The front clip is just seamed 3mm wall water pipe and that bends ok if you put the seam at the side of the bend and not inside or outside

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Rocklobster gears / refurb cases /rockbuckets/SU manifolds/dual transfer boxes/ sj tcase to jimny cradles and speedo drives/bespoke machining / any thing made to a drawing.
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forkrentfitter
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PostPosted: Mon Apr 06, 2009 6:36 pm    Post subject: Reply with quote

thanks for that,are the tubela formers expensive?are the standard formers any good on blue band?my local pipeline center can do 42mm seamless for the same price as blueband,but i have had scaremongers tell me you need a mandrel bender to bend seamless.
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rockwatt
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Joined: 25 Jul 2007
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Location: North lincs



PostPosted: Mon Apr 06, 2009 11:12 pm    Post subject: Reply with quote

forkrentfitter wrote:
thanks for that,are the tubela formers expensive?are the standard formers any good on blue band?my local pipeline center can do 42mm seamless for the same price as blueband,but i have had scaremongers tell me you need a mandrel bender to bend seamless.

I got the dies from a pipe contractor that went bust so i dont know how much they would cost. Mine's all seamless and its bent nice. To stop the little dents from the little roller's pack them out with 6mm ply. You only need a mandral for thin wall high carbon like t45 or stainless

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