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  #181  
Old January 18th, 2014, 01:38 PM
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I found a local shop that can do CNC laser cutting and bending of sheet metal and had them bend up my battery boxes. Because of the depth of the boxes I had to compromise and only have 2 sides bent up and the other two cut and just the lip bent so I could weld them in. I got the rear one from them last week and thanks to Ed's TIG welder I tigged up the sides and corners. They bent up the front one but since it's a little more complex than a rectangle it's sided and unfortunately they bent in backwards (my fault for not being specific). Luckily I have enough material left to have them re-do it.

Bobby Rains their manager has been great to work with and I highly recommend them if you need this kind of work in the area. http://www.metalcraft.biz

I forgot to take before pictures but will try remember for the front one.

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I think the welds came out pretty nice if I do say do myself. Thanks again to Ed for letting me use his TIG machine.

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I'm waiting until I have them both finished before finalizing the lid dimensions so they fit perfectly, but hope to get the boxes wrapped up over the next week to two, and move on to the rear skid plate and other sheet metal related fab stuff.
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  #182  
Old January 18th, 2014, 05:22 PM
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Charles - I will give you a thumbs up on the rig welds.
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  #183  
Old January 18th, 2014, 06:00 PM
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Nice welds mate! Almost as pretty as Huff..almost
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  #184  
Old January 23rd, 2014, 09:48 PM
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Front battery box.

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  #185  
Old February 10th, 2014, 08:59 PM
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Small update. battery box lids are done and front battery box mount is half done.

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  #186  
Old February 13th, 2014, 08:18 PM
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man....they say putting cellphones and their battery's next to your ear are bad.....looks like you will have monkey nuts pretty quick
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  #187  
Old February 13th, 2014, 08:19 PM
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Quote:
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man....they say putting cellphones and their battery's next to your ear are bad.....looks like you will have monkey nuts pretty quick
Tell that to the Tesla driving hipsters.
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  #188  
Old February 13th, 2014, 08:37 PM
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I'm done with kids so my nuts are surplus at this point. I'm more worried about having a 10k RPM motor next to my leg with just a 1/8" piece of aluminum between me and it should it decide to grenade. Not that I have ever heard of one grenade but...
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  #189  
Old February 13th, 2014, 09:59 PM
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Thanks! I find it funny that there is an actual product for this.
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  #190  
Old February 18th, 2014, 08:39 PM
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The weekend slipped away and I only managed to get a few hours in the garage on Monday since I had the day off.

I had reshaped the piece that joints the tunnel cover to the bulkhead but needed to add a new lip to it, so finally got that done.

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Then I had purchased a piece of VW steering rod to extend my steering shaft with, and since my truck is not going to have power steering I wanted to make sure it could handle the additional forces applied to it, so I turned down a 12" long piece of rod to sleeve the two halves with (they have slightly different inner diameters). I also cross drilled holes in the shafts so I could plug weld it as well.

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I probably should have picked something easier to try my first steel TIG welding on, but I figured I had the use of a TIG so what the heck. Not pretty but I am confident it is strong and this is all hidden in the steering column anyway. Didn't take a final picture but it's not hard to imagine what it looks like.

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  #191  
Old February 19th, 2014, 07:01 AM
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Looks great charles....steel is actually much easier than aluminum to weld. Just make sure you are using dc and make sure the tungsten is as sharp/pointy as possible.

Of course, i'm sure you know this already
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  #192  
Old February 19th, 2014, 08:16 AM
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Ooo, pretty!
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  #193  
Old February 19th, 2014, 02:15 PM
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Fascinating, so you don't need the transmission anymore, and batteries will now fill where the engine used to be at correct?
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  #194  
Old February 19th, 2014, 08:24 PM
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Quote:
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Looks great charles....steel is actually much easier than aluminum to weld.
Well, I'd say it was more the shape (small cylinder) in a tight space (about 3-4" between clamps). But doing a second run around the main joint seemed to find/produce a lot of impurities so I probably should have done a better job cleaning/prepping after the first weld.

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Fascinating, so you don't need the transmission anymore, and batteries will now fill where the engine used to be at correct?
Correct.
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  #195  
Old March 13th, 2014, 11:26 PM
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Looking good!
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  #196  
Old July 7th, 2014, 08:46 AM
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Dood... If this guy did it... You can.

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  #197  
Old October 4th, 2014, 05:53 PM
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Damn, I haven't gotten much done on my build this year have I? Well, I did get a few things done, and should have made some updates.

Let's see. I made a tunnel cover.

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I designed, bought material and cut out the pieces for a custom skid plate. I never got around to finishing it because the place I was using couldn't bend that thickness aluminum so I need to TIG it. But I want to flip the frame upside down before doing that, and that was about when the project stalled.

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A friend was helping me make the coupler between the motor and the transfer case. The one end is from an auto transmission, and the other a bought piece that fits the motor and a friend made the center piece for me. I had a shop weld it, although to be honest I don't think they did anything different than I would have done (just put it in a press and welded it). I was expecting some sort of centering/balancing... I think it's not perfectly aligned but not 100% sure yet.

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I made a little blanking plate for the top of the piece of R380 I am using as a spacer.

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And tried my hand at etching for fun

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That takes me up to about May/June.
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  #198  
Old October 4th, 2014, 07:13 PM
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Hey friend, if memory serves me correctly, you had a bit of a distraction sitting in your garage this summer!
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  #199  
Old October 5th, 2014, 11:53 AM
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Ok, what next. I am re-doing the front battery box. No pics yet but it's very similar to the other, just different in a few critical ways to hopefully solve some fitment issues I ran into.

At some point I designed and cut out the pieces for a new steering mount - the other looks too hackish. I got going on Kent's project before finishing it, but here are the bits

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I then got working on my motor adapter. I had actually started on it about a year ago - did the design and made a wood prototype, but at the time I didn't have the coupler nor could I spin the motor so I wasn't in a position to test it and didn't want to make it out of aluminum until I could.

As usual I started with laser cut prototypes, then made it out of wood.

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And test fitted.

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The idea was to validate the design and make sure everything worked the way I wanted. I spun the motor like this (my video doesn't seem to want to attach) and unfortunately I had a noticeable wobble/vibration which was disappointing. IT was a bit of a chicken before the egg situation. I wanted to verify each side was centered on each other properly but knew the coupler isn't perfect, and wasn't sure which was the cause. I decided it was just that the wood wasn't stiff enough and it was time to bite the bullet and make it out of aluminum.

Video - maybe you can download and play: IMG_2445.MOV

Now that I was ready to make it for real, I purchased 1.5" thick material (enough for 2 in case I F'd it up)

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Now the CNC Mill I have at my disposal doesn't have a big enough work envelope to do the piece in one shot so I had to get creative. I had access to a water jet cutter and after some test cuts I decided to keep two sides from the original piece so that I had uniform edges to work with when switching to the mill - so I could setup my model to the same reference point accurately.

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Now I could take this to the mill, re-establish x0,y0, align it parallel to the X axis and do the holes from the transfer case side. At the time I didn't plan on doing any holes from the other side so made the alignment pin holes go all the way through but it turns out I could have not cut those from this side and done them from the other. Otherwise everything went as planned other than running out of time to finish.
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I then tapped the holes that the transfer case (ok, the chunk of R380) attaches with.

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In the next session I needed to do the raised motor ring. First I faced the transfer case side, in order to get a perfectly flat surface before flipping it over. I had to use a different (manual) mill for this since the torch doesn't have a big enough work envelope. I got help leveling the vice and it came out beautifully.

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Back to the torch

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And the end result
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Test fit to the motor side. Fits like a glove!

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I got time yesterday to lug the motor back down to the basement and assemble it and give it a test spin. The good news is the vibration/wobble is gone! So I think the wood just wasn't stiff enough. The bad news is the adapter plate is 3/4" thicker than my prototype which means my coupler no longer has full thread engagement on the LT230 side.

So, I have a 5/8" steel piece that held bearings in the R380 that I can remove, but then I have to clearance a small section of the adapter plate and then it's still 1/8" too short at this little nub.

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I am going to take a chance and shave 1/8" off the nub which should result in the shorted adapter space possible, give me coupler full engagement, and not have to move my motor mounts (or if I do, in a favorable direction).

I hope to get this done later this week and will wait for the new setup to take pictures. The current one doesn't look significantly different than the wool mockup.
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  #200  
Old October 5th, 2014, 12:51 PM
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This is fantastic! Nice job! You'll have to teach me how to use the waterjet
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