Outer Limits 4x4 Board

started cutting up my hilux housing last night ready to flip it, here is some pics of what i have done so far,
just have to cut and rotate the knuckles. and weld the diff cap back on.

ok so ive done a few more bits and pieces and got the housing ready to go. heres a few more piccys,


diff cover re-alligned and tacked in place.


half welded.


full welded and cleaned up.






knuckles cut and rotated.




drain and breather holes plugged up.






finished product for now, or until i get it setup under the vehicle

Good work. Keep it up.

Would you do it that way again or just cut the tube either side of the diff head housing?

NJV6 wrote:Good work. Keep it up.

Would you do it that way again or just cut the tube either side of the diff head housing?

thanks, ahh yeah i'd do it this way again i would probably find it easier the way i done it than cutting the tubes and trying to re-align them and getting them running square and true to the center again.

Ryan,

Hey mate, Nice looking flip.
I am planning to flip a Nissan Patrol diff for my Jeep.

I did not understand why you cut off the diff cap? is there a reason for this?

Thanks,
Luke.

nice work mate! first time ever seen a job like these.

lukethedork wrote:Hey mate, Nice looking flip.
I am planning to flip a Nissan Patrol diff for my Jeep.

I did not understand why you cut off the diff cap? is there a reason for this?

Thanks,
Luke.

the hump for the crownwheel clearance is off centre, also the oil fill hole is above centre line, cutting and rewelding the cap keeps these correct

http://azrockcrawler.com/_images/tech/2 ... using.html

while not a cut and flip would be easy enough to do and recentre, ending up with a MUCH stronger diff housing as well.

love_mud wrote:http://azrockcrawler.com/_images/tech/2 ... using.html

while not a cut and flip would be easy enough to do and recentre, ending up with a MUCH stronger diff housing as well.

okay looks like a lot of work making jigs and all the other things they have to do to get it right, if you see in one of the above pictures i took of where i cut the welds on the knuckles to rotate them, you can actually see how thick my axle tube is and its about 5mm thick quite a lot thicker than the housing that broke in that link you posted. i assume on my housing the knuckles have been machined to fit the axle tube not the other way around so the thickness of the tube is the same all the way along. im not intending to jump the vehicle 3 feet high into a cement wall either lol. but thanks for posting the link was good reading Cheers Ryan

few more piccys:

snorkel





diff armor welded on












johnny joints










axel widening kit

thats really interesting what you have done mate.top job and keep up the good work and pics as you go

Love that snorkel - cleanest one i've seen for a while.

Need to find someone to make one up here (bris)
How much did that set you back? Do they want to make any more?

Great work on the other custom gear too!

jop wrote:Love that snorkel - cleanest one i've seen for a while.

Need to find someone to make one up here (bris)
How much did that set you back? Do they want to make any more?

Great work on the other custom gear too!

gday i made the snorkel myself was a bit of stuffing about getting it right but fairly easy, cost me next to nothing i got the 2 stainless bends for 30 bucks from work and the straight bit was laying around here at home, so i couldnt justify spending 100 bucks on a safari head when the whole snorkel cost me less

Very strong axle.I like it

Be carefull, johnny joints excelent for articulation but not so comfortable on road.Suspension will be harder than stock rubber bushings.

How bout some progress!!!

Nice ...
what are the coil buckets from ? they look range roverish

love_mud wrote:Nice ...
what are the coil buckets from ? they look range roverish

they're off a toyota bundera front housing.

A little birdie tells me you have the threaded bungs for the rod ends now, lets see the axle located and mocked up..

very cool. keep up the momentum!! cant wait to see this finished!

Nice work!

Your axle widening kit, I'm guessing thats for fitting IFS hubs to get the wider track....who made that kit? and how much?

I've got the ifs hubs ready to go for my 40, but need to start susing out which kit to get.

TWISTY wrote:Nice work!

Your axle widening kit, I'm guessing thats for fitting IFS hubs to get the wider track....who made that kit? and how much?

I've got the ifs hubs ready to go for my 40, but need to start susing out which kit to get.

these are the ones i got

http://www.marks4wd.com/products/Axle%2 ... dening.htm" onclick="window.open(this.href);return false;

Love the snorkel, can you let me in on how you connected it to the airbox though?? I cant woirk out how you connect a round pipe to the odd shape inlet on the factory airbox?
Cheers

corolla68 wrote:Love the snorkel, can you let me in on how you connected it to the airbox though?? I cant woirk out how you connect a round pipe to the odd shape inlet on the factory airbox?
Cheers

haha thats was the fiddely bit of the job, i cut a short section of the left over stainless up and made 4 cuts in the end of the pipe about 30 - 40mm long and bashed it into the same shape as the oval bit on the airbox and welded it back up and then riveted it to the plastic pipe and sealed it up with silicon and attatched the rest behind the guard with some flexy tube sealed it all up and she was away, seemed the easiest way at the time for ma anyway.

got any pics of that?? I wouldnt mind seeing exactly how you did it????

57oky wrote:got any pics of that?? I wouldnt mind seeing exactly how you did it????

nah sorry i dont just quickly made it up to get it all working pretty simple though,

housing ready to be blasted and painted ready for assembly
sorry bout the crappy phone pics

here is some more pictures, painted housing ready to be rebuild to fit up under the mighty paj!