PDA

View Full Version : ROC box



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.

RalphDogg
02-25-2009, 09:20 PM
the gigantic welder that i purchased for this project.

http://img.photobucket.com/albums/v601/ralphdogg/welding%20stuff/100_0311.jpg

Barillms
02-26-2009, 09:12 PM
Killer

RalphDogg
03-11-2009, 08:11 PM
i had problems with my 60 amp breaker blowing so i didn't get to finish this yet, but big ralph put in a 100 amp breaker last week.

Deadman 94 xj
03-11-2009, 10:37 PM
i had problems with my 60 amp breaker blowing so i didn't get to finish this yet, but big ralph put in a 100 amp breaker last week.


I hope he ran a new line too. You're going to want 4 to 1/0 copper AWG.

CollinsPC
03-13-2009, 10:36 PM
Are you going to coat the housing before reassembly?

RalphDogg
12-02-2009, 08:09 PM
last weekend i dug out all the t case parts and started welding on it again. after a bit of re-wiring i got the welder working in tip top shape and i was so close to finishing this damn thing. most of the company's that modify the tcases and make this gear box dispose the rear tail of the case. i just shortened the rear so that i can keep the speedometer gear, i need the speedo for inspection reasons.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0392.jpg

http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0393.jpg

the tcase on the left is the new box, the one on the right is the stock suzuki.
http://img.photobucket.com/albums/v601/ralphdogg/ROC%20box/100_0394.jpg

RalphDogg
12-02-2009, 08:10 PM
Are you going to coat the housing before reassembly?


i was going to dump JB weld into the weld seams. my aluminum welds aren't water/oil tight.

Dozer45
12-02-2009, 10:25 PM
I have no idea what is going on here but it looks sweet lol. great job and stuff!!

ridgerunner97
12-02-2009, 11:15 PM
Lookin great Ralph, that thing will be a nice lil unique machine.

RalphDogg
12-03-2009, 03:31 PM
I have no idea what is going on here but it looks sweet lol. great job and stuff!!


basically i am making the stock transfer case a gear box, then bolting another transfer case behind that gear box. this will give me more low and high range gear options.

hackedup5
12-19-2009, 11:15 PM
nice job..new to the forum here and this is just what my back burner plans are for my tracker project, few questions..

1. do you know what year tracker cases switched splines to fit the samurai flange?
2. Are you just going to bolt the 2 flanges straight together from the 2 cases?

I remember hearing that 1/2 of the samurai shorty shaft would slide onto the tracker output..but never checked it out..

again good job, keep the info and updates coming..

Sloth_Fratelli
12-20-2009, 03:47 PM
im confused as hell, are you making this like a twin stick transmission? or it kinda sounded like mabye how old 18wheelers had a twin stick trans.

john00TJ
12-20-2009, 04:23 PM
he will end up with more gear range choices when engaged into 4x4 ...its like a 4speed Trans case but home brewed ..

RalphDogg
01-14-2010, 09:35 PM
nice job..new to the forum here and this is just what my back burner plans are for my tracker project, few questions..

1. do you know what year tracker cases switched splines to fit the samurai flange?
2. Are you just going to bolt the 2 flanges straight together from the 2 cases?

I remember hearing that 1/2 of the samurai shorty shaft would slide onto the tracker output..but never checked it out..

again good job, keep the info and updates coming..

i can't remember what year the t-cases were switched and the splines where different, i will have to look it up.

the samurai t-case will be bolted directly to the sidekick case. so the engine, tranny, gear box(sidekick tcase), and samurai tcase will all be one. the flanges will be bolted together no u jount or shaft. i want them to be as close as possible.

i am not sure about the shafts either, i move to so many projects it's hard to remember. i can check that if you need the info.

hackedup5
01-18-2010, 08:45 PM
thanks, but I shouldn't really need that..I have all the parts in my garage, but I'm not at that stage yet and some are still on truck..so when I get it all pulled, it will answer my questions for me..

I am glad to see you aren't keeping the sammy case divorced as most of these home brew situations go. I'll be watching for pics when you get there...

RalphDogg
01-20-2010, 10:21 PM
the sami t case is to weak to make it a divorced setup. i am not saying it won't work as a divorced case on 36's, it's just less stress and thought in the back of my mind. when i'm hammering on it i won't have to worry about the case splitting in half.