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Post by hootie on Jan 8, 2010 13:16:04 GMT -8
I have opened a new can of worms on my project blazer.
I have a ORD doubler kit.. and a few choices for 205's.
anyone with much experience here? or.. anyone with a machine shop than can open up the input opening to fit a larger bearing?
Contact me.. if you have done one of these set ups.. This is a project that is beyond my experience. thanks ,, Dave.
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tonka
Ok to Drive
My Heep
Posts: 256
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Post by tonka on Jan 9, 2010 8:15:18 GMT -8
I have built a couple. You need to use the t cases from a th 400 or 4spd. as the input shaft is larger than the th350 ones. If you need help let me know
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emjay
Active Member
Posts: 85
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Post by emjay on Jan 9, 2010 10:24:53 GMT -8
Winton said he would be happy to help with any machining needed - just give him a shout. We should be around most of the day.
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Post by hootie on Jan 26, 2010 20:55:32 GMT -8
OK... Doubler is mostly built. here is the progress so far. A 203/205 doubler is a combined unit consisting of the front half of a 203 transfer case attached with an adapter to the entire 205 transfer case unit. It makes for one of the hardiest low range systems available. All Cast Iron and All Gears. First thing was to disassemble a 203 to be used for the range box. The range box is the front half of a 203 transfer case. The back half ( which is the chain drive portion,, is discarded. This box will allow you to shift a second box to low range and get two low ranges. in my case both are 2 to 1 low range so by using both the 203 and the 205 in low ranges it will be 4 to 1 low. multiply that 4 times the lowest range of your tranny for your lowest gear selection available. The disassembled 203 is modified with a new output shaft that will connect to the input of the 205 unit ( through the bright aluminum adapter. This unit by ORD ( Off Road Design ). this picture is of the 203 and the adapter... waiting for the 205 to be completed and connected.
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Post by hootie on Jan 26, 2010 21:03:12 GMT -8
Next was to disassemble the 205 unit. Patrick ( Tonka ) graciously offered to help with my project. He and his wife came to my shop and He and I tore down my 205. After seeing some broken bearings falling out... and discovering several signs of excessive wear and tear on my unit.. It was decided that we should also tear apart a unit I was going to sell. This unit was a Ford model 205. most internals are the same. a few are upgrades to a standard chevy unit. By using a few of these parts I was able to upgrade my 30 spline front output to a 32 spline unit. This will allow my driveline yokes to be the same for both the front and rear driveline and allow interchangeability. Just for info.. A chevy T400 205 has a 32 spline Input.. and a 30 spline front output and a 32 spline rear output. Ford units have a 31 spline input and both front and rear outputs are 32 spline.
Now with my use of both... I am 32 spline in all three areas.
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Post by hootie on Jan 26, 2010 21:10:24 GMT -8
On Sunday Patrick and I went to Winton and Maureen's home. Winton gave us the tour of his well appointed shop. Highlights include a few drag race cars,,, several 4 wheelers,, and a great place to work on a rig.. like being able to work in a nice house. Kitchen,,, bathroom,, heat,,, big screen tv,,, and every tool a person could need. What a nice place. Thanks again Winton and Maureen for allowing me to come and enjoy your hospitality and your help on my project. After cleaning up my empty 205,, Winton attached it to his Turrent Lathe. This is the Unit we needed to use to enlarge the input hole on my 205 to fit the new 32 spine input bearing and shaft. Set up is a major part of this type of work and Winton is very smart in this area. measured several times.. worked slow and accurately and finished with a bearing fit that was perfect. Here are a couple pics of the shop.
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Post by hootie on Jan 26, 2010 21:12:37 GMT -8
Here Winton is attaching the 205 to the bed of his Lathe. Patrick and Winton Discussing the project and creating a plan.
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Post by hootie on Jan 26, 2010 21:19:34 GMT -8
After carefull set up,,, The process of enlarging the whole proceeded... Winton watches the cut and applies cutting oil as the cutter carves it's way down through the hard cast iron.
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Post by hootie on Jan 26, 2010 21:29:07 GMT -8
After a nice day at Winton and Maureens,,, Patrick and I headed to Portland to his Auto Repair Shop on 82nd Avenue.. Good Guys Auto Repair. Patrick and his business partner have a nice and well equiped facility. His shop is capable of a wide range of repair and maintenence services. He has 3 bays,, two with lifts.. and ample room to service both personal and business and fleet vehicles.. His clean shop shows that he cares about the details. I would be confident in using his shop for most any repair need. He made me clean and re clean each part of both my 205's so he could choose the best parts for a long life rebuild of my 205. We had hundreds of parts and I was concerned about it all getting back in working order. He was confident in his ability. Here is a pic of some of the parts on the work bench being inspected by Patrick.
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Post by hootie on Jan 26, 2010 21:37:26 GMT -8
Next the assembly of the 205.. Not an easy process and I am glad Patrick was doing it. Experience pays and Patrick had the unit back together in a short amount of time.. And the 205 is done... Patrick is testing the operation in this next photo. And Last... another big THANK YOU To Patrick... who spent nearly 12 hours with me.. ( I know.. he must be crazy ). and Winton for his expertise. I will post the pictures of the complete unit and the installed unit in a short time.. to be continued.. Dave.
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Post by fivendime on Jan 27, 2010 7:47:19 GMT -8
That's looking good! I've only ever tore my model 18 Transfer Case apart and that was a good learning experience. Its great to have such good friends to help, another example of the quality of folks we have in this club!
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Post by hootie on Jan 30, 2010 10:56:41 GMT -8
OK,, here is the finished look of the Doubler. ain't it purdy?
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tonka
Ok to Drive
My Heep
Posts: 256
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Post by tonka on Jan 30, 2010 14:37:55 GMT -8
Looking Good !! When will it be in the truck and ready
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fry
Ok to Drive
Posts: 114
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Post by fry on Jan 31, 2010 12:23:14 GMT -8
interesting, thanks.
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redxj
Ok to Drive
Posts: 105
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Post by redxj on Feb 1, 2010 8:15:18 GMT -8
X2 interesting. Good info thanks
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