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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 27 Aug. 2021 at 9:51pm
We were so fortunate to be able to wheel at Southington Off Road Park the day before the Willys Spring Reunion.  Seth made this awesome video.  We are hoping for a bunch more flatfenders to join us next year before the reunion.  https://youtu.be/k0FQ8s5aDFw
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 27 Aug. 2021 at 10:05pm
Had a great time at the reunion!  Here's Grasshopper and my brother's 51CJ3A there.




Roy let me take his Jeep for a spin around the hotel.  Let's just say curbs were not a problem!



Edited by Barry S - 27 Aug. 2021 at 10:49pm
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Barry S View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 27 Aug. 2021 at 10:45pm
The next event was the Bantam Festival in Butler PA.  So of course more work on the Jeep.  At Southington I ripped the exaust system loose.  Luckily Jeff had some wire.  I wanted to stop catching the tail pipe every time I dropped off a ledge, so a little heat and a little elbow grease... and it doesn't catch any more.  Plus by not being pointed at the ground the tailpipe doesn't kick up near as much dust for the jeep behind me to choke on!




At Bantam to be allowed to run the trails and obstacle course you are required to have front and rear tow points.  Grasshopper had the remnants of a tow bar attachment from a PO.  Rather than start over I just used what was there. 





Had to fabricate the rear one.  Tested my welding skills.  Not pretty but it's strong.




Replaced spring shackles...Again!!!  Going to go to M-170 type with the extra plate next time.


Last mod before Bantam.  Removed back seat to make room for a storage box.  Used seat bolt location to install rivnuts that will anchor the box or the seat.






Had an awesome time at Bantam.  Over 2000 jeeps but only saw 2 other flatfenders in a sea of plastic.  I ran their trails and obstacles all day Everyone seemed to notice the old iron.  Definitely didn't bother with the mud pit though - too much to clean up.
 
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 27 Aug. 2021 at 10:53pm
Brown Santa brought me gears!!!  Game On!  Thanks Jeff!





Edited by Barry S - 27 Aug. 2021 at 10:56pm
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 27 Aug. 2021 at 11:57pm
Back to the transfer case project!  First I need to finish clearancing the inside of the case.  I marked the areas with blue dyechem.


Then went to town with a die grinder.


It took 3 test fits before I was happy.  Best to go slow - it's harder to put material back on!

These are the areas I had to clearance on this small hole D18.  



Checking clearance with a light inside.


Intermediate gear in place and turning free!


Not being real familiar with the D18, I had a little trouble figuring out the spacer Jeff included. I figured out that it had to prevent the front bearing from interfering with the output gear because the old gear was large enough to let the bearing bump up against the snap ring.  The new gear is way smaller and has a deeper recess before the snap ring so the spacer has to fill that space for the bearing to bump up against.  After conversations with BobW and Jpet I learned that the other reason for the spacer is to move the bearing out away from the new larger intermediate gear.  The other thing that was throwing me off was that the spacer ID was a little too small to go over the splines to the snap ring groove.

  
In this photo the old output gear is on the right with the bearing in front of it. The recess on the new output gear on the left has a recess that is deeper and also too small for the bearing to fit into. The spacer goes in there up against the snap ring.



Here is the other interference point. The new intermediate gear is .120" wider than the old one.  It is also larger in diameter.  That means that the bearing would have to move outward .120" to maintain the same clearance.  That is roughly the thickness of the spacer Jeff provided.  Bob was able to maintain the clearance by adding an extra thrust washer with the 2 locater tabs on the ID.  I tried that but the stock thrust washer thickness is .113" leaving the bearing .007" closer to the new gear.


I decided to use the spacer Jeff provided but following his advice I had to increase the ID of the spacer to fit over the splines to bump against the snap ring.



This is the correct position of the spacer.  The order of assembly is: output gear, thrust washer with the 2 locator tabs on the ID, snap ring, spacer.  Whatever thickness of spacer you choose, the same amount must be taken off the flange on the front bearing cap to keep the shaft in the same position.  The spacer I am using from Jeff measures .118" so that is the amount I am planning to remove from the front bearing cap flange as long as there is still enough left to insert into the case to correctly locate it.



Edited by Barry S - 28 Aug. 2021 at 12:06am
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Pope891 Quote  Post ReplyReply Direct Link To This Post Posted: 28 Aug. 2021 at 11:38am
Following!
Instagram #flatfenderpope

My Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote stevez Quote  Post ReplyReply Direct Link To This Post Posted: 28 Aug. 2021 at 6:02pm
any chance getting the specs on Roy's jeep?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 28 Aug. 2021 at 6:30pm
Hi stevez, Your probably best off asking Roy.  He's done a great job and takes his Jeep to a lot of military shows.  I have his number but never share without permission.  PM me your contact info and I'll forward it to him. 

Thanks!

-Barry 
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote bobevans Quote  Post ReplyReply Direct Link To This Post Posted: 29 Aug. 2021 at 9:24am
Thanks for the update.  It was great wheeling with you at Southington, thanks for making that happen!  I was also at Bantam, at the "property trails" in my 2A/3A.
'48 CJ2A

'56 DJ3A

'79 CJ7

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Aug. 2021 at 9:47am
Sorry I missed you at Bantam Bob.  I was just there for the day on Friday.  Todd (TN21) was there too but we missed each other as well.  Maybe next year we can coordinate a day and wheel a group of Flatties together.  Old iron can still get r done!
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 29 Aug. 2021 at 5:34pm
Today was welding day!  My brother Ron did the honors - he's been welding on cast iron a fair amount over the last year so I was happy leave it to him.

Cleaning up the weld location.


Heating up the entire case.


Checking temperature.  Ron took the temperature up to over 400 degrees F knowing that the temp would fall while getting repositioned to weld.


He wanted to maintain the case temp around 300 degrees while welding.  He had me continue to monitor the temp. while he welded.  He TIG welded the "blister" on using 309 stainless rod. He tacked the corners on one end and had me hold it down while he tacked the other 2 corners.  Then he proceeded to work in sections.  He kept stopping to peen the welds with a pointed welding hammer to help align the molecules in the metal and relieve stress in the weld. He had to position a wood 2X4 as an arm rest to be able to hold the torch steady.  Couldn't rest his arm on the 300 degree case for long. It was near 90 here today with super high humidity.  Couldn't have any breeze to blow the shielding gas away so this was hot work!


Peening a weld.  Ron did a great job welding the blister on. The only place that was a problem was the small gap between the blister and the mounting bolt ear.  He couldn't get the torch in there to weld so there is a little void.   There is no pressure in the transfer case and the blister is on the top so any gear lube there will just be from splashing.  I'm planning to seal it up with JB Weld.  After the welding was done we wrapped the transfer case up tight in a fiberglass welding blanket and then rolled it into a padded moving blanket to let it cool very slowly.  Should be cool by tonight or tomorrow morning.


Next was to machine the flange on the front bearing cap.  We secured it on the Bridgeport table making sure it was square.


The plan was to remove .117" which is the thickness of the additional spacer from Jeff.  We took it off in .025" passes.  At .100" removed the remaining flange was looking pretty short and I was worried that if we took the other .017" the flange might be too short to engage the case well with the gasket added. I decided to only remove another .013" which totals the thickness of a factory thrust washer (.113").  That left the flange at about .095".  I'll try the extra thrust washer for a spacer and if there is interference between the bearing and the intermediate gear I can always file a little more off the flange and use the thicker spacer.

Milling the flange.  Notice that there was a chamfer at the top edge of the flange to help guide it into the case.


Flange after removing .113".  If it's a struggle to guide it into the case I may file a tiny chamfer on the edge.



Edited by Barry S - 29 Aug. 2021 at 5:42pm
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 30 Aug. 2021 at 8:36pm
Blister welded on.


Should be able to get a socket head bolt in.

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 30 Aug. 2021 at 9:03pm
Good job. Now put the intermediate shaft in by itself and make sure the bores still line up.
CJ2A #29110 "General Willys"
MB #204827 "BAM BAM"

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 30 Aug. 2021 at 9:28pm
Just went out and tried it. It took some pretty good love taps but it went in and back out a couple of times.  Then I tried it on an extra case - I was easier but still took some persuasion.  I'm wondering if  the cast may have moved slightly but hopefully will still be OK.
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 03 Sep. 2021 at 7:45pm
It bothered me that the intermediate shaft went in so hard.  I wondered if I had warped the case while welding.  On close inspection I discovered that the bores were really rough and scuffed up.  I tried working the used shaft around with some rubbing compound. Not much effect.  I didn't have any lapping compound.  Tried some emery cloth not much better and was worried about making the bore out of round.  Ended up using a brake cylinder hone very lightly.  It smoothed the bores out nice and I just went a little at a time and kept rechecking the fit.  Finally I tried the new shaft for fit - goes in with a few light hammer taps on a wood block. Perfect!


Hit the area where we couldn't get by welding with JB Weld inside and out.  



Tomorrow - paint the case then hopefully ready for assembly!
1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote bobevans Quote  Post ReplyReply Direct Link To This Post Posted: 03 Sep. 2021 at 9:49pm
Nice work!
'48 CJ2A

'56 DJ3A

'79 CJ7

And two of them actually run!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 04 Sep. 2021 at 2:38pm
Cleaned, masked, and ready for primer and paint.


Painted up all pretty!  This has been a long project and I am seeing light at the end of the tunnel.  I am so anxious to get started assembling - waiting is like watching paint dry!LOL

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barry S Quote  Post ReplyReply Direct Link To This Post Posted: 11 Sep. 2021 at 11:30pm
So I wasn't able to start assembling until today - my usual MO - the flatfender gathering is tomorrow!
I have been so focused on the gears I ignored all the other parts that would have to be prepped.  Ended up spending lots of time cleaning parts.


I also forgot that my shift rods had some pitting.  Rather than buy new I took them out to Ron's and glass beaded the pitted areas.  Then I coated them with JB Weld and then sanded them smooth. This photo is "before".


All the parts ready to put together.


A trick I sometimes use for square head set screws is to use socket extensions backward.


It took me 3 tries to figure out where to lock wire this and avoid interference.  This is how I ended up wiring it.  I also used blue threadlocker.

Next was to trim the front axle clutch shift rod to prevent interference with the new intermediate gear.  Like Bob and Jeff I had to trim off 3/8".
 


Next the intermediate gear has to go in.  This presented a challenge because of the amount I had to clearance on the inside of the case.  The gear has to be set down into the case and then move over into the clearance area.  I could not stick the keyed thrust washers to the case first and then lower the gear in between them like normal.  I finally discovered that I could stick the front washer to the case then lower in the gear and move it over into place on a temporary shaft.  Then I was able to install the rear thrust washer from the bottom by sticking my hand in through the access cover hole and sliding the washer up along side the gear and engaging the keyway from the bottom.  Then I slid the new intermediate shaft in from the back side pushing the temporary one out.


So this was today's progress.  Everything went together nicely - just the way Jpet planned.  Great job Jeff!  Everything moves smooth and quiet!





The bearing caps are on temporarily.  I have a lot of end play in the front output shaft - to the point that the teeth just touch if I push the output shaft all the way in when the front drive is not engaged.  I am not sure what controls end play on the front output shaft- I'll have to investigate.  I also put in an extra thick shim pack on the rear bearing cap - Its at .018" for now until I can fine tune everything, but its good enough to take to the flatfender gathering for "show and tell" tomorrow!

1947 CJ2A 93664 "Grasshopper"
1947 CJ2A 90729
194? CJ2A 04893/194304
1946 CJ2A 46745
1946 CJ2A 36723
1945 MB   413665
1971 CJ5 8305017 375392 Drive train parts donor
Bantam Trailer T3-C 25487
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