RalphDogg
02-25-2009, 09:05 PM
after much debate and weeks of thinking i have made the decision to make a doubler setup on my suzuki. i am going to make something similar to the OTT industries kicker. this setup will be a 1.6L engine,5 speed tranny, sidekick t case, and a samurai t case. this will give lots of gear selection and only add a few inches to my drive line.
the doubler uses a modified sidekick t case and a stock samuai t case. i used the older design sidekick transfer case which has the low number spline output shaft. the output shaft splines will fit a samurai transfer case flange.
here is the samurai tranfer case (left) and the sidekick tranfer case(right)
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0297.jpg
first thing is to take everything apart.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0316.jpg
i cut the chain off.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0317.jpg
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0321.jpg
cut a section off the rear where the rear drive shaft comes out. i am going to re-weld this part on after i shorten the case. i am reusing this part so i have a machined edge for my rear seal. then i cut off about 2 more inches off of the rear of the case. cutting more off of the rear will help with my rear drive shaft angle. 2 transfer cases can make you rear drive shaft angle very steep, especially on a 95" wheel base.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0315.jpg
here you can see where it will be welded onto the rear of the tcase. i went to my local auto parts store(66auto) and got a seal that will fit it and will also match the samurai drive flange.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0324.jpg
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0327.jpg
here is the first cut i made. i am taking off the bottom of the case. the bottom of the case is where the front drive shaftattached to.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0323.jpg
i trimmed it as far as possible for clearance. http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0325.jpg
fitting the plates to close up the case.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0326.jpg
the samurai case will be bolted directly to the sidekick case. this setup will look like a divorced case, but everything will be on one drive line.
the doubler uses a modified sidekick t case and a stock samuai t case. i used the older design sidekick transfer case which has the low number spline output shaft. the output shaft splines will fit a samurai transfer case flange.
here is the samurai tranfer case (left) and the sidekick tranfer case(right)
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0297.jpg
first thing is to take everything apart.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0316.jpg
i cut the chain off.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0317.jpg
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0321.jpg
cut a section off the rear where the rear drive shaft comes out. i am going to re-weld this part on after i shorten the case. i am reusing this part so i have a machined edge for my rear seal. then i cut off about 2 more inches off of the rear of the case. cutting more off of the rear will help with my rear drive shaft angle. 2 transfer cases can make you rear drive shaft angle very steep, especially on a 95" wheel base.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0315.jpg
here you can see where it will be welded onto the rear of the tcase. i went to my local auto parts store(66auto) and got a seal that will fit it and will also match the samurai drive flange.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0324.jpg
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0327.jpg
here is the first cut i made. i am taking off the bottom of the case. the bottom of the case is where the front drive shaftattached to.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0323.jpg
i trimmed it as far as possible for clearance. http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0325.jpg
fitting the plates to close up the case.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0326.jpg
the samurai case will be bolted directly to the sidekick case. this setup will look like a divorced case, but everything will be on one drive line.