Outer Limits 4x4 Board

Gwagensteve wrote:

MightyMouse wrote: Its not going to be as difficult as it initially seemed.

AT09.. here we come!

Steve.

Ohhh yeah!!!!!!

It will be AT IFS 09 Im there too!!

K&S Tuning in Germany do F+R Vacuum locker for Lada too


They do cost too

Im thinking one of them for the front and Spooled rear, with sierra transfer case.

Mock

do some measuring.... a vitara rear might not be a bad way to go.

Steve.

Gwagensteve wrote:do some measuring.... a vitara rear might not be a bad way to go.

Steve.

Maybe Navara, Lada are 4.1

Mock

Some progress updates....

After a longish period of forced inactivity ( illness ) things have started moving again.

The bearings required to match Sierra bits into the Feroza pumpkin are not available so a bearing that's close has to have its race ground very slightly. This is necessary so we can use the ARB Sierra actuator end which saves making quite a complex turning with the air passages and actuator seal surfaces etc.

The crownwheel end cover is a new part as the Feroza's crownwheel is slightly larger and has 12 bolts as opposed to the Sierra's 10. The ARB one is cast iron but I'm using steel as its cheaper, easier to source and stronger.

The centre section of the locker also has to be made from scratch as it the Sierra one also has the wrong crownwheel bolt pattern - but its a relatively simple turning. Has to be made of cast iron as the company that cuts the internal locking splines wont touch steel - which isn't an issue except cast iron is more expensive.... As its a windowless design its heaps stronger than the Feroza one

As stated earlier, side gears are complete and can use ARB cross pins, spider gears, locking clutch air feed etc etc.

So whilst its still a way off - things are proceeding well, the more work we do on it the more practical it looks.

Crownwheel end plate completed as are bearing adjusting rings.

Feroza crownwheel had to have its ID increased very slightly, and then pinion have a slight taper on end face as the locker body is now cylindrical rather than tapering like the old open centre.

Diff has been together for the first time, and the crownwheel and pinion do align correctly and can be set with correct "pattern".

Some minor machining still required to the crownwheel side end cap - its a bit too thick still - but as its steel that's not an issue.

The cylindrical mid section is next - cast iron on hand, just requires detail drawings before starting to cut metal.

Its at the point where it pretty safe to say its going to work.

thats great work MM.

Wish i had the knowledge, skill, tools and time for that sort of custom work!

Main question on my mind is what sorta cost are you looking at so far?

Its been surprisingly cheap so far as all I've had to do is buy materials.

That's been helped immensely by Matt at TT Drivelines having the zook internals on hand and cj! from the Suzuki club also lending me bits.....

Obviously I've got a spare front diff and that cost but, Geoff at DaiAuto was VERY reasonable and its not truly part of the construction costs.

I think the end cost for the locker ( unfitted ) will be no more expensive than any other - BUT as you can understand there's been heaps of my time and Matt's spent getting this far. Its certainly looking much stronger than stock , steel parts, 4 idlers and a solid core but without wheelspin to limit the torque to the front end its also necessary.

When its finished I will ask him what he'd charge to do a second one on a commercial basis. Will be interesting as all the development work has been done, but the machining will now be a cost. Still I think it would be still too dear for Feroza owners as we don't seem to be very adventurous by nature.

Minor update.... the cast iron carrier section is too big for my lathe and squareness and parallelism of the faces is very critical otherwise the crownwheel will runout and cause nasty problems.

Have had to wait on some spare CNC lathe time to have it machined so its paused till that gets done.

After that the hemisphere needs to be machine and the locking splines broached into the core.

Its been nearly a year now - but its had LOTS of no progress months.

Still its gone form can it be done to when.