I started out Saturday by putting together my
drive train. This picture shows the Ringr adapter which allows me to bolt
the 1.6 16v bellhousing and Toyota transmission together.
Here's a picture with the bellhousing attached.
The Sidekick throwout bearing and pilot bearing are modified to fit on the
Toyota input shaft. The stock 1.6 pressure plate is retained and then
there are two options for a clutch disc. One needs to be cut down, the
other is slightly smaller in diameter and requires no modifications. I
went with the larger, modified clutch disc to get the most contact area between
the clutch disk and flywheel.
I couldn't get the transmission and motor mated
together (it's a 3 man job) so I made a small stand to hold the transmission
into place so I could start on the second phase of the project.
Phase 2 involved constructing the sub frame where
the links and belly skid plate mount to. I also need to come up with a way
to anchor the transfer cases to the frame. The stock Toyota mount is about
an inch thick and mounts under the transfer cases. I was hoping to come up
with mounting system to eliminate that inch thick mount to keep the belly as
flat as possible. I am thinking about something like the t-case spine I
made for my Samurai case. Jack mentioned that Front Range Off-Road makes a
mounting system like that so that is the direction I will likely go.
The rest of Saturday was spent gusseting the sub
frame and making the cross members. I also mocked up my upper link mounts
in back so I could make sure they would fit.
I am doing all the bending with this bender that
Jay Kopycinski designed and fabricated. It is based off of a JD2 Model 3
bender (same one I have) so I am using my own dies for this project (1.62 x 4.5"
radius and 1.00 x 3.5" radius). I must say I am getting really spoiled
with this bender. It can do a nearly 110 degrees in one shot so it makes
the bending process very fast.
Sunday morning I cleaned up the garage before
heading over to a sawsall party at Mark Mason's house. We took his 4
Runner from what you see in the first picture to the second picture in about 2
he is planning on re-tubing his rig and
installing a four link suspension in back.
After the party, Pat and Jack stopped by and
helped me get the motor and transmission bolted together. Everything is lining
up like it should so far. I did make a small change to the transmission
hoop, I made it a bit taller so the firewall can mount to it near the top of the
From there I skipped ahead to phase 3 and started
to bend the front fenders. I am not very good with doing multi-plane bends
and I didn't quite get these right. I had to do some creative notching to
get them to sit like I wanted them to.
Update - 8-24-04
Some progress on the front clip from Monday, put
some of the cross braces in.
I traced the unused back half of the t-case used
for my crawler box to come up with this bracket. The basic shape was cut
with a plasma cutter, then I cleaned up some of the sharp inside corners on the
mill at work. The last step before bolting it on was a little finish
grinding to smooth out all the edges.
The mounting arms were made from some 1
5/8 x .120 tubing, slit up the middle. One of the mounts is below the
frame rails and the other is even with the frame rails to allow the bracket to
be removed (unbolt, rotate, then pull back). I still need to round out all
the edges when I pull it off to finalize the welds.
Note - As of Nov, Front Range Off-road
was selling a laser cut plate that you could bolt to the rear of the Toyota
transfer case for approx $50. Well worth the price, you just have to fab
up some mounting arms.
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