PDA

View Full Version : my version of d300 flip



justin'sbig7
01-10-2011, 07:52 PM
i originally did the $20 flip as written here:
http://www.pirate4x4.com/forum/showthread.php?t=161815&highlight=dana+flip

but i found that it is a big deal keeping everything perfectly lined up with the shift rails to keep the interlocks and detents working right. i also missed my cable shifters, so i started a new one.

i could have just double sealed the rails and used flip shifters from D&D machine, but i didnt like having the rails below the front output yoke... and i like making simple things difficult HA!

design 2.0:

started with 1.25" 1/8th wall square tube, welded it into a box that fits nicely over the pan opening. after it was all lined up right, i drilled all the perimeter holes to bolt the pan and adapter to the tcase

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/DSCF2063.jpg
then located and drilled the holes for the shift rails (oversized to .75" using a crappy chinese bit that makes crappy wobble holes)
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/DSCF2062.jpg

mock up of the new .625" shift rod through the shift fork
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/DSCF2064.jpg

then i took a piece of 1.25x1.50" solid bar stock, marked my EXACT centers and bored the holes through to 41/64ths with a good usa made bit. this creates a nice guide for the rods to slide on as opposed to the square tubes thin walls. i then used a 1 7/64ths bit and bored a .25" deep hole in the outside of each rail block. this allows a press fit for factory 1 1/8" shift rail seals to seal the rails on both sides.

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/004-17.jpg

justin'sbig7
01-10-2011, 08:08 PM
the blocks are then welded to the spacer. i took extra care in aligning everything so that there was no binding on the shift rails. shift rails are .625" OD .120 wall dom.

i then made a bracket for the cables to mount to. the tube over the bolts are spacers (in the process of adjusting it all here)

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/008-11.jpg

the cable rods slide up into the tubing wich solves two issues, it helps keep the cable rods from deflection under load and keeps the length of the overall length compact.

i then center drilled and tapped 2 pieces of 3/8" round stock. this slides into the dom with almost no slop. this allows the cables to thread into the rails as the attachment method. there are no interlocks or detents, this will be managed at the shifter end.

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/009-2-1.jpg
this pic gives you the idea of what it will be when done, the slug will just be further up in the rail and welded at the other end.
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/010-3-1.jpg

drilled and tapped the old shift rail holes for 1/2" pipe plugs to keep it securely sealed (hard to see)
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/008-5-1.jpg

joe_and_jeep
01-11-2011, 10:03 AM
I never double sealed my shifters, I just flipped it and made shifters. Only leaks are the covers for the rails. I gotta sillycone them.

highlandercj-7
01-11-2011, 10:32 AM
Chalk that up as that's what ya get for putting the drive shaft on the wrong side ;)

Nice solution though.

justin'sbig7
01-11-2011, 08:22 PM
Chalk that up as that's what ya get for putting the drive shaft on the wrong side ;)

Nice solution though.

yeah, who wants to run a HP 60 anyway :083:

OverkillZJ
01-11-2011, 08:30 PM
Nice flip!

ridgerunner97
01-11-2011, 08:59 PM
Nice solution Justin looks good.

dan58
01-11-2011, 09:15 PM
yeah, who wants to run a HP 60 anyway :083:

<waves hand> Oh, it CAN be done. :lol:

justin'sbig7
01-11-2011, 09:29 PM
<waves hand> Oh, it CAN be done. :lol:

i know:045: i am just fixing the few things jeep screwed up from the factory :040:

highlandercj-7
01-11-2011, 10:55 PM
Nothing wrong with HP just put it on the "right" side ;)

justin'sbig7
01-13-2011, 09:22 PM
seals installed
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/001-18.jpg

justin'sbig7
01-15-2011, 07:37 PM
getting assembled for the last time.
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/015-3.jpg


http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/016-2.jpg

finished product
http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/017-3.jpg

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/019-4.jpg

fathersnsons
01-15-2011, 10:01 PM
you continue to amaze me more & more
awe sum job

justin'sbig7
02-27-2011, 12:58 PM
heres some shots of the shifters. after much debate as to how i was gonna do it, i picked up a set of Kluhsman Racing Products circle track locking shifters.

http://cgi.ebay.com/ebaymotors/NEW-K...Q5fCarQ5fParts (http://cgi.ebay.com/ebaymotors/NEW-KRC-7300-DUAL-LEVER-3-SPEED-SHIFTER-RODS-NR-_W0QQcmdZViewItemQQhashZitem1c0745ffc2QQitemZ12038 1112258QQptZRaceQ5fCarQ5fParts)

i am going to make a limiting bracket to go between the shifters to keep them from shifting into high and low at the same time, as well as a "keeper" to make the stops a little more effective. these were a nice base to build off of at least.

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/005-17.jpg

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/004-21.jpg

http://i48.photobucket.com/albums/f214/justinsbig7/fabrication/002-20.jpg