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st1977

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Reply with quote  #1 
Thought I would start a thread, for anyone interested, of my homemade chain drive.
Ideas, thoughts and bashing welcomed lol.

I have about 2 ft between my 2.5 ton case and turbo 400, with about 5 inches of drop.

After all the measuring and pondering, this is what I came up with.

I got the top shaft and front output shaft out of a 2.5 ton case.

Bought some Martin double 60 sprockets with a 1" bore that could be bored to 2", 15 tooth and 23 tooth

I ground the gear off of the top shaft and turned it on lathe to 50mm, which is the bearing size for that shaft.
There were 4 or so roller bearings in that shaft and I picked 2 to use.
This will be my bottom shaft.
I machined some bearing holders out of 5/8 aluminum plate to drive the bearing in. These will bolt to the case and support the lower shaft. Also machined a plate to hold a 2.5 ton seal, as 2.5 ton flange yokes will be used.

For the upper shaft, which was the front output, I machined it down to 2" and bored sprocket to fit.
I turned the ends down to 1-3/4 and will use 2 bolt flange bearings, holes in case will be slotted for adjustment purposes.

The case is made of 5/8 aluminum plate, it will be enclosed with this plate and tapped and bolted all the way around about every 1 inch.

I could have bought shaft and yokes, but what fun would that be! Plus I don't have the extra money laying around to buy them.

This way lets me use 2.5 ton flanges and driveshaft pieces I have already, plus only 5.5 inches of drop.
Plan on machining a spacer, so I can bolt the two flanges of the transfer cases together, then making a short shaft between trans and tcase. Going to wrap it with tubing or something to mount it.

Still have some machining to do on top shaft and snap ring grooves to cut. And the longer shaft will be cut down on the non yoke end so the stock cover off the 2.5 ton case will cover it.

Will add more pics as I get further along.

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Rockford514

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Reply with quote  #2 
Looking GOOD [thumb]
Any chain adjustment ?

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shallowpockets

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Reply with quote  #3 
Looks good... Makin me want to build a reverse case
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st1977

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Reply with quote  #4 
Yes, chain adjustment will be done with the two bolt flange bearings, they should be here tomorrow.
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RedRio88

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Reply with quote  #5 
good job bud!


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iniviate

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Reply with quote  #6 
looks good.... keep posting pics as you go.

i'm thinking about doing something similar with 2.5 ton pinion shafts.

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ramrod

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Reply with quote  #7 
Looks good
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akerberg

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Reply with quote  #8 
VERY COOL. VERY KUSTOM!
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st1977

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Reply with quote  #9 
Mad a little progress in the past week or so. Got box made, doing a little more machining on shafts.

Flange bearings got here Friday.
Will post some more pics when I get it mocked up.
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st1977

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Reply with quote  #10 
Made a little more progress. Pretty much finished turning parts.
Now getting everything mocked up and holes drilled and tapped before final assembly. Also tapping fill plug.

Going to have bolts 1" apart all around the box.

The top flange bearings, thinking of just sealing shaft to bearing, and making a gasket to go between the flange and aluminum housing. The bearing has seals, not sure how they will hold oil.

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homewrecker

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Reply with quote  #11 
Love the fab work man... thought about doin this but I dont have a lathe... your chains will last alot longer with it filled with oil but you ever think about leaving it open in case u break a chain? If it can fall out it'll do alot less damage to your gears n shafts... I doubt you'll snap one but just thought about the carnage that could cause
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st1977

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Reply with quote  #12 
Yeah I have thought about leaving it open. If the scrap aluminum would have been bigger/longer I would have allowed room for the chain. I could build a box lower to give it room. But I hope it will be ok as is. I got 10 ft of chain and only used 2 ft, so I could change it regularly if needed.


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st1977

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Reply with quote  #13 
Opinions on mounting. I was wanting to just bolt the flanges of the transfer cases together.
Anyone see a problem with this? I made a spacer that fits the flanges so they wil center on each other.
If not I would have to buy 2 flanges and a u joint to mate them.

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homewrecker

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Reply with quote  #14 
Quote:
Originally Posted by syou'll be
Opinions on mounting. I was wanting to just bolt the flanges of the transfer cases together.
Anyone see a problem with this? I made a spacer that fits the flanges so they wil center on each other.
If not I would have to buy 2 flanges and a u joint to mate them.



Im sure youll be fine with the closed case... thats just as strong as a chain transfer case. .. and as for mounting it flange to flange it will work but if your motor and tranny aren't solid mounted it'll prolly break something. .. u got a slip yoke or a fixed yoke on your tranny?
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st1977

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Reply with quote  #15 
Slip yoke on trans.
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homewrecker

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Reply with quote  #16 
If you got room for a small shaft in between shouldn't be a problem... it'd be just like raising the input shaft on your tcase. ..
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Rockford514

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Reply with quote  #17 
How will it be mounted to the frame ?
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st1977

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Reply with quote  #18 
Going to wrap it with something......., square, angel whichever I can find laying around that will work.
Planned on bolting it to the case all the way around and weld some tabs off of that to mount to frame.


Drilling and tapping holes today!
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whitelightning

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Reply with quote  #19 
run the case closed with oil. if not the chain will heat up and stretch in no time. im running 80H in my case and 25 min of hard playing and the chain stretched and started to skip gears. filled with oil and new chain 4 mud holes and a lot of playing around my house and theres only a lil bit of play over about a 6 month time.
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LH mud

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Reply with quote  #20 
Looks good.
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Axle Splining, driveshafts, cnc & custom machine work. 386-215-9864
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