removing front drive from hilux transfer case

[dumbdunce]

has anyone modified a hilux transfer by cutting off the front drive outrigger? if so how did you close up the resulting hole? bolt on, weld on or other solutions?

the plan is to use the hilux transfer without front drive to drive a second divorced transfer case eg lada, MQ/K auto etc, using the front drive off the second transfer to drive the front wheels.

ideas?



cheers

Brian

[JohnJohn]

A couple of ideas for you to consider

Tack weld a plate to the seal and then silicone seal it all back into the hole, there is no pressure in side so it would be OK.

Or cut a round plate like a frost plug in an engine block and press and seal that into the hole.

[dumbdunce]

Hi JohnJohn

not sure I got what I wanted to do across - I don't want to just pull out the front drive gears and output flange, I want to chop off the whole front drive housing - ratty picture attached obviously not to scale but it gets the idea across. what I want a solution for is the hole that is left.

What would work well would be to weld in plates to the case halves, with provision for a couple of bolts along the resuling seam to add strength and sealability.




Alternative possibility: modify the front output part of the transfer case so it has flanges pointing forward and backward, and taking out the gears but leaving the housing and "output" shaft there as an idler shaft, driven from the second transfer case, and driving the front diff. maybe I need to make another sketch of this option.