we talkin bout party crashin Easter Jeep Safari.......well I guess I will be the only one crashin it since Im the only guy without a Jeep. lol

 

lol, doesnt that suck. silly jeepers.

you will have a blast i am sure!

 

Well I actually just got back to workin on this thing everyday again this week. Feels good to be marking stuff off the "to do list".

I been working on finishing the bed so I built a removable bulkhead to protect the fan/rad and make the bed actually useful.



And I made a simple spare tire holder as well. Just need to add one more tube that will be welded to a plate I made that holds the center hub of the rim.



Tomorrow the toolbox will get mounted to the floor of the bed as well and then I can move on to the rear axle

 

Nice to see you didn't forget about this thing. Do you plan to drive it THIS winter at least?

 

I been so consumed with my turbo Ranger this summer I didnt get as much done on this as I wanted. Good news is the other Ranger is locked up in storage til spring so its all about the Truggy now! If all goes as planned Im thinking before Xmas it should be on the road.

 

Just skimmed through this thread. Subb'd for a later in-depth read. Awesome build man!

 

Well I have the rear axle out and tore down for its upgrades.



I started welding the rear brace on the housing and have the third member on the bench so I can start to swap the spool in.

I also put together my whole rear disc conversion and spent just under $200 on everything.

95 Dodge 1500 4wd front rotors
78 Chevy 1500 4wd calipers w/pads and hoses
large Chevy caliper brackets and brake hose brackets from All Star

Picking up all new bearings and seals in morning.

 

Well its back on the ground now.Everything took longer than I thought but turned out great.

Housing brace welded on.


Rebuilt the pig with all new bearings and seals,full spool,reused the factory 3.50 gears and got a perfect pattern.It had .022 backlash before I tore it down and I ended up with .010 after I was done.


Welded brackets on and put disc setup on.




I then installed it under truck,squared it up,bent up all new brake lines and hit it with some fresh paint.

Feels real good to have that huge part checked off my list! Starting on the doubler tonite and maybe pick at some wiring stuff also.

..oh and I picked these up as well.

 

Looking good. All around discs is where it's at. Can't wait to see some stuff on the doubler.

 

You going to have this ready for wheeling in the spring?

 

My doubler has a 1350 4 pinion planetary in it and I have two spare 1354 boxes here that Im going to steal the 6 pinion planetary out of to swap into the doubler and my other 1350 thats going in the truck.

Hope to be doing some winter wheelin here ASAP.

 

I've read about that. Would love to see some good pics of it being done when you get to it.

 

Small problem...both my 1354's are pre'93 so they are 4 pinion as well. Oh well.

 

brian progress looks good so far! where did you source those air bumps from? Good price?

 

I got em from a guy on GL4x4. They are not air though. They take those rubber pucks inside to cushion. Two different densities so you can adjust to your needs. I gave 135 for them. They are called Daystar Stinger Bumpstops

 

Interesting, I have never heard of them. I should really do something with mine.

Get it finished for tomorrow. Lets hit bundy or badlands in the snow!

 

Here is a link to them
Daystar™ - Driven by Design

 

Rough weekend but I got another major project almost wrapped up.

Started the doubler build.

I tore open the BW1354e I had to steal the 6 pinion planetary to upgrade the 4 pinion in the doubler but found out pre-93 they are all 4 pinion and my case was a 1990. Oh well.

I tore down the other BW1350 goin in the truck and found the oil pump was messed up. The retainer that holds the pump stationary so it dont spin with the mainshaft got broke some how and that allowed the pump to spin and rip the hose off the pickup.


I really dont see how this would have broke off other than somebody had the case open and didnt install the retainer correctly and it got broke that way. The broke off tab was laying inside the case so I just welded it back together.


So after the BW1350 was all back together I put the doubler together...what a PITA. For some reason the 5 bolts that hold the clocking ring to the main case were the wrong thread right from D&D so I just made it to hardware store to get the correct replacements before they cloesed. Also the 10 allen bolts that go inside to the clocking ring...they can die in a fire{not meant for fat guy hands}. But its all together and I had an extra c4 tail housing so I decided to build all my linkage and shifters on the bench rather than after its installed.



And I replaced the output yoke on the main box to the larger yoke off the BW1354


Should have everything ready to install this evening.

Some things I noticed today that I have never heard addressed before about the D&D doubler...
1. How the hell are you suppose to fill the doubler box? There is no room to even get a allen wrench on the fill plug to remove it.I plan to fill mine through the breather on the bench before I install it.But how much it take?

2.The main case shifter arm hits the doubler and had to be removed to put the two together. You cant reclock the arm to make it work so I just cut it apart and welded it together 90º from where it was.

 

Nice work Brian. How heavy is it? Are you planning to build a series of crossmembers to hold it?

I hope your shift linkage works well!

 

Yes Im going to build a crossmember to hold main case. Its not stupid heavy but I think there would be problems if it wasnt supported.

So far the main shifter works great. The doubler will be just a push down/pull up so very easy to make.

 

Sounds great! I didnt mean for that to sound like it wouldnt work, just they can be finicky! Yours look good though!

 

I know what you meant its all good!

I will post pix later but I got the other shifter mostly figured out now. On the bench everything is working great.

 

yess new work! love the 9"..makes me want one bad.

 

Hopefully the total weight of the truck wont be bad and the 9in will live a happy life

 

how much you think it will weigh?