[DMAC]

I have got some 6.5 gears to put in the Zuke.
Thought I would take the opportunity to strengthen the mounts while I had it out. Something similar to a mighty kong look.

LTM21 made templates out of cardboard and cut the plate to fit.

Started with the original mounts.


Welded some plate on to box it up.





The easy bit done.
Then I come across this.
Original case.



Case with gears in.


Original.


Gears case.


Sorry about image quality camera is playing up.

As you can see about 10mm has been ground off the original mounts. As a consequence of this the bottom threaded mount hole has been threaded possibly due to the bolt bottoming out and destroying the thread when tightened.

Ideas for a fix? I have a few ideas but am looking for options.

[v.w.dave]

make the hole bigger thread it and get different bolts. or even better get a rocktoy ring ther those bolts dont do much as the ring uses all the case bolts to hold on then welded to the holding arms

[Fatzook]

DMAC.

Sorry mate I never noticed this

You could helicoil it if you want to keep the same bolt size. Otherwise, there looks to be enough meat left on it to run a larger bolt also. But you will need an end tap ( or bottoming tap ) to make sure the thread reaches the bottom of the hole.

Also, be sure to measure the depth of the hole before you do anything, so that you can mark that depth on your drill bit and avoid drilling a hole through the case.

Peter

[DMAC]

Fatzook wrote:

DMAC.

Sorry mate I never noticed this

You could helicoil it if you want to keep the same bolt size. Otherwise, there looks to be enough meat left on it to run a larger bolt also. But you will need an end tap ( or bottoming tap ) to make sure the thread reaches the bottom of the hole.

Also, be sure to measure the depth of the hole before you do anything, so that you can mark that depth on your drill bit and avoid drilling a hole through the case.

Peter

No dramas Pete.
I see it as another learning experience for Lockie.
I'm going to try a product called Q Bond from Ripco to build up the Case mount to the original height.

Yep enough meat to tap out.
I'll keep you posted.

[Rusho]

I'm going to start bringing over the coily for LTM to do a bit of learning Your coming along pretty well aren't ya lokkie Good work guys, good luck with the mods boys

[brendan]

in my opinion you should get a roc toy ring. no point strenghthening the mounts. because the case is bolted in 2 different places the case will flex between them. roc toy ring solves this. standared sizes bolts have been fine for me so far. ive just used 8.8 bolts in all of them.

[want33s]

Dave I run a Spidertrax transfer mount that has one extra pickup for two bolts and you've seen the punishment it gets.

While the idea of a full circle brace (Roctoy) sounds great I don't think it is really necessary.

[royce]

I'm not a fan of the roctoy ring as anything but a way to build a stronger mount but I think in this case it could be the solution, that mount has been milled like that cause its been cracked I reckon, will only do it again with them gears

[brendan]

yeah i have cracked a case when i first put the roctoy in. about the mounting block thingo. i dont know if it was just a shit case as it had gears in it before the roctoy, could have been weakened. but when i replaced the case i added some extra gusets onto the roctoy and its been fine

[want33s]

You have two cases there.... Why not swap the bits of the case over?

[DMAC]

First I had to return the mount back to an original profile. Had seen this at Repco and thought I would give it a go before the weld build up and machining track.



Started on one corner to see how it went. Made a mould out of cardboard and playdoh. This took longer than anticipated as I hadn't played with playdoh for years.



Tipped some powder in.

Dripped the glue on and it turned out like this.



So I went all out as this stuff is good.







I'm happy that this stuff will be strong enough as it is really only acting as a spacer. I'll keep an eye on it and see how it goes though.

The case is to come.

[DMAC]

want33s wrote:

Dave I run a Spidertrax transfer mount that has one extra pickup for two bolts and you've seen the punishment it gets.

While the idea of a full circle brace (Roctoy) sounds great I don't think it is really necessary.

Have read all the comments and have decided to use a bit out of them all. As the normal mount strength has been compromised I will pick up the top mount same as the spiderax mount. I will also pick up the bottom three case bolts too similar to a roctoy but not a full ring. So it'll be a hybrid roctoy/spiderax/mighty kong mount.

Swapping cases will be the last option if it goes pear shaped.

[v.w.dave]

That q-bond will without a doubt in in my mind crack off and be useless after the first time you take it in the bushg and you will end up doing more damage. All it is, is super glue with compound. It WILL NOT last if it does last the first off road track it will come off the second time out because of the heat/cooling of the case and pressure put on that mount IT WILL BRAKE you need to do as what has been suggested to you and either get a roctoy ring or replace the case or you will have problems.

[DMAC]

Started on the skid plate for the mounts.

Template time.


Needed to find a bender. I have no vice so I had to put my thinking cap on.


Adjusted where required.


Aligned drilled and filed access holes.


Skid plate welded in.


Tomorrow I will pick up the bottom three case bolts and the one the spiderax picks up too. This should be plenty strong enough now.

[DMAC]

v.w.dave wrote:

That q-bond will without a doubt in in my mind crack off and be useless after the first time you take it in the bushg and you will end up doing more damage. All it is, is super glue with compound. It WILL NOT last if it does last the first off road track it will come off the second time out because of the heat/cooling of the case and pressure put on that mount IT WILL BRAKE you need to do as what has been suggested to you and either get a roctoy ring or replace the case or you will have problems.

I hear you Dave. Hopefully with the other pickup points it will be OK. I went this way as my mate who can weld ally has gone on holidays.

At least I will be a crash test dummy to see how good it is. If its no good I've only used about $5 worth of it.

[just_cruizin]

if it's a machined surface just get some 10mm plate and drill to suit. will do just as much as the Q Bond crap and will last.

[DMAC]

just_cruizin wrote:

if it's a machined surface just get some 10mm plate and drill to suit. will do just as much as the Q Bond crap and will last.

No it not machined. It had a nice curve to it and had different depths on every corner compared to the original.

2 negitives for Q-Bond. Is this based on previous experience?
What applications have you used it in before?

[ajsr]

ive used Q bond a few times
mostly on motorcycle cases and the like as a temp patch out in the bush.
its good stuff for a low strenth/load situation but I doubt it will last long on a high load situation like a transfer mount (worse if you are running gears).
gears can twist the standard mount like a pretsel I doubt Q bond will be up to it.
you might be better maching the mount square and making a steel spacer that gets welded to the mount and then bolting up like normal.
anyway good luck with it.

[lump_a_charcoal]

My 6.5 gears tore a brand new Tcase mount in half on the first outing. There is plenty of breaking power in 'em...

[Zachius]

"Brand New" has a few different meanings.

I (finally) broke a t/case mount a few months ago. I replaced it with a mount bought online, the mount broke the first time I went 4x4ing. I then replaced that with a genuine Suzuki mount which is once again lasting.

Now it could be that the mount bought online was just a one-off dud but I suspect their is varying quality in the mounts available.

This is after running 31" and 6.5 t/case gears for the past 5 years with the standard mounts.

Anyhow back on topic I think the Qbond is at best a spacer. If the bolts have enough hold in the original mount then I think it might be okay, if the bolts don't then I would be looking into other solutions. If the mount does let go now you risk damaging it even further and completely destroying the mount.

[Taff]

Why dont you just rip the gears out of the shitty case and put them into your good case?

Only takes an afternoon and your going to have to pull the other case out anyway.

[DMAC]

Taff wrote:

Why dont you just rip the gears out of the shitty case and put them into your good case?

Only takes an afternoon and your going to have to pull the other case out anyway.

Yep but that defeats the resason I bought the complete box and gears.
I would like to keep my standard case just that "standard" but I'm keeping it as an option.

Didn't get much done today. Very fiddley fitting stuff today. Lots of filing.

[Taff]

Makes sense i guess, but i can tell you now 100% that you will never ever want to put the standard gears back in once you take them out You will love them.

[DMAC]

Got the "Dmac Cradle" 90% finished today. I have picked up 4 extra mounting points on the case. Not the full roctoy but a few more than the Spiderax.



Just need to weld a little bit of crush tube on 2 of the lower mounts.
Fold up the leading edge a little.

A lick of paint and its all done.

I'll test it out on the weekend. Even bought a spare mount just in case.

[ZookiMonsta]

Nice work there DMAC.
I'd be keen to make something like this when I get my gears.

[want33s]

Dunno about that big plank of wood Dave..... You might get hung up on that!

[DMAC]

want33s wrote:

Dunno about that big plank of wood Dave..... You might get hung up on that!

No thats my fully sic workbench.

[Taff]

When will you be taking orders?

[alex]

ill grab 2

[just_cruizin]

DMAC wrote:

Taff wrote:

Why dont you just rip the gears out of the shitty case and put them into your good case?

Only takes an afternoon and your going to have to pull the other case out anyway.

Yep but that defeats the resason I bought the complete box and gears.
I would like to keep my standard case just that "standard" but I'm keeping it as an option.

Didn't get much done today. Very fiddley fitting stuff today. Lots of filing.

Buy another standard case, even if the bearings are shot who cares. You'd be up for $20 - $50. Then put the gear in that case.