Cut-Weld-Drive Forums

Go Back   Cut-Weld-Drive Forums > The VolksRodders Forum > Members Intros and Project Updates!

Members Intros and Project Updates! New member introductions and project updates...
Your ongoing "journals"...


User Information
Your Avatar

Stuff to check out...

Cool stuff you NEED!

Forum Stats
Members: 17,564
Threads: 32,440
Posts: 548,521
Total Online: 1067

Newest Member: Tylerted

Latest Threads
- by 1slo3
- by Bugula

 
Reply
 
Thread Tools Display Modes
Old November 12th, 2014, 11:52 AM   #1
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default AUSSIE 4x4 v8 midengine T2 bus

Gday all. The start the white 1 is mine the yellow my daughter & son in laws. I'm also fitting Their bus with a Subaru EJ22 & subarugears 5 speed box






Last edited by roverv8bay; November 12th, 2014 at 12:48 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 01:16 PM   #2
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

DAY 1. Now it begins the 1st cut & fit. setting the height & location
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 01:24 PM   #3
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

2nd part of the fit was to design & build reinforcing to go under the floor this is made up of 75mm x 75mm angle & 30mm x 30mm heavy wall tube the tube slides into the floor supports & sits on top of the chassis rails & torsion tube. then the motor cradle bolts down onto the angle the whole drive train can lift out as a unit once everything is disconnected




the next is sliding into place really simple way to strengthen the cut out section


all the way home
now for the cradle it is made out of 50mm x 50mm & 50mm x 25mm tube

Last edited by roverv8bay; November 12th, 2014 at 01:44 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 04:36 PM   #4
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

now some tech stuff on the font end stating with the spindle I had to have the top ball joint hole moved out to allow for the camber I then had the engineer doing my machine work run the bus tapered holes out of the stubs to press fit into the new holes in the rodeo spindles this gave me the right size for the bus balljoint & camber nut in the bottom. I had to spread the beam tubes to fit the spindles in so here are some pics to give an idea of what's involved. this is a dummy up of fitting the front diff 2nd week into build

then discovered he need to spread the beams. the angles on the arms where way out of parallel


initial cut to the beam plate revealed the amount it had to be spread


then I made a ply pattern to check for size found a cad drawing on the web & Todd from subarugears modified it on his programme to move the lower hole down the required 80mm & maintain the caster at the same time


I then had the end plates waterjet cut out of 12mm plate
& made up a jig to sit the beams in to assemble


awaiting welding painted to show up in pics



Last edited by roverv8bay; November 13th, 2014 at 01:47 AM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 07:28 PM   #5
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

now to the spindles Holden rodeo modified to suit the bus ball joints






Last edited by roverv8bay; November 12th, 2014 at 07:36 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 07:41 PM   #6
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

the front beam with preliminary set up of the Daewoo power steering rack & pinion this connects to a Mitsubishi L300 bevel box & steering column by facing the rack forward it puts the arms to the rear so simple job of modifying the Daewoo steering arms or using some other brand




bevel box assembly





Last edited by roverv8bay; November 12th, 2014 at 08:01 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 08:09 PM   #7
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Now for the back brakes using Mitsubishi pajero disc assemblies this is a very simpl to modify bolt on conversion the pajero bearing carrier housing requires machining on the inside a approx. .05mm to clear the bus carrier it has also had the same amount removed you will see in the pics how much was removed by the casting marks left where the cut was shallow then I hag to find a spacer to go between the 2 housing so off to the local rural irrigation supply shop. these parts are the gold anodised bits in the pics the other part I used was the axle flange of the diff housing. nd then had the bus hubs drilled out to 6 stud offroad size. The VW holes will have to be plugged.

pajero carrier machined


the bus unit 1st cut since been machined down to the face with the chalk dots on it to allow for the spacers


this is the axle flange off the pajero the other flange sits between the bus carrier & this flange


all the parts less bolts & backing plate etc



initial lining up disc & caliper bracket


nearly there just need the extra spacer

Last edited by roverv8bay; November 12th, 2014 at 08:25 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 08:30 PM   #8
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Now for the transmissions 1st the Nissan 720 transfer case simple 2hwd neutral hi 4x4 lo 4x4 modified shifter on case to use morse cable

Toyota Hi Ace diesel 5speed using a Dellow conversions bell housing


this is the bellhousing & McLeod concentric clutch cylinder



to get a 10&1/2 inch clutch to suit the rover flywheel * Toyota spline I used a Daihatsu delta kit 1 problem arose out of this set was the thrust face on the bearing was the wrong sie & nothing available to fit it so had the Engineer make a sleeve to press fit onto McLeod bearing to run against the pressure plate fixed that 1 here is what it looks like



this is the finished modified bearing note the round face on the pressure plate face



the next mod was to the speedo drive I had to have the red drive machined down to fit into the electronic unit out of the Hi Ace box along with a sleeve to adapt into the Nissan trans case



This the early set up of the 2 transmissions now to join them in the limited room available the Nissan use a short drive shaft with slip yoke ^ 2 uni joints I may have to try this later if my 1st concoction doesn't work more on that next



this is the space to fill


these are the parts involved in the drive unit between the transmissions
Hi Ace slip yoke bus axle flange from gearbox cut down bus axle machined to press into the Nissan machined uni joint flange


prior to welding assembled to check length then completed



then it becomes this




and this is where it ends up



the front tailshaft is a standard length commodore
stationwagon. It just has to have a rear diff flange put on the front to replace the slip yoke



Last edited by roverv8bay; November 13th, 2014 at 01:37 AM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 09:59 PM   #9
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Now for the rear differential & drive shaft the diff centre is out of our commodore it's IRS the tailshaft is an axle 1/2 shaft out of a Nissan 180b it has been shortened down to fit in the space required I'm using it for the slip yoke foe limited movement between the transfer case & diff


The rear mount now to build something nice to replace the temporary set up


I will post pics of the 2 side by side to show the difference in length

tis is the front mount for the rear diff it bolts to the side of the chassis rails the mounts are designed to hang they are original Hi Ace gearbox mounts. nothing is welded yet that will be the final job once everything is in place



this is the adapters made up to bolt the bus CV to the h
Holden diff flange simple & retains the VW parts line





fitting up


Last edited by roverv8bay; November 12th, 2014 at 10:25 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 11:03 PM   #10
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

the next problem was lack of room for standard exhaust manifolds or off the shelf headers. So making my own using mandrel bends takes some sorting for the left due to the firing pulse but right side straight forward this is the left side so far



roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 11:07 PM   #11
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

this is 1 of the few body mods being carried out on the bus front & rear arch flares



roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 11:34 PM   #12
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

one of the easiest jobs is converting to power windows using 3 series BMW. the hardest part of the job is getting the mechanism out to change it over
I have a video on youtube under albert norley can't load onto here

Last edited by roverv8bay; November 12th, 2014 at 11:55 PM.
roverv8bay is offline   Reply With Quote
Old November 12th, 2014, 11:58 PM   #13
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

rear suspension spacers to allow for the CV spacers & extra width of the diff centre. These can also be used to lift the rear with out resetting the torsion bar splines the plate is 12mm also used if I want to move the hubs back to better align the axles with the diff









Last edited by roverv8bay; November 13th, 2014 at 12:07 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:08 AM   #14
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Front suspension in place to work out the lift achieved with out adjusters before check the height against the crate


don't look at the camber the beams hadn't been located & welded when pics were taken had to set it up to get the wheel sie sorted out for the Engineer doing the report for our registration authority we have to have the build inspected in stages to make sure it meets the safety requirements to be used on the street



Last edited by roverv8bay; November 13th, 2014 at 12:16 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:17 AM   #15
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Cooling system 2 thoughts on this subject
1 is mount the radiator in the rear engine bay


2 mount it up front & make the bus ugly


Last edited by roverv8bay; November 13th, 2014 at 12:20 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:25 AM   #16
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Now the back. The rear tyre rack is off the same model rodeo as the spindles it fits with a nudge between the rear chassis rails. I have to notch the brackets to move it up 40mm & trim the brush guards behind the wheels then simple job of bolting up I extended the carrier but don't like it so going to return it to original & move the mounting hub over to suit






Last edited by roverv8bay; November 13th, 2014 at 12:37 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:40 AM   #17
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Owing to the lack of room for the alternator I'm mounting it on the right hand head at the back. It will connect to the front pulley by an aluminium shaft running in bearings mounted to the inlet manifold & top of the timing case. sorry about pic quality.




Last edited by roverv8bay; November 13th, 2014 at 12:44 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:48 AM   #18
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Due to the lack of space up front I will be blanking the waterpump off & using a Davis Craig electric mounted behind the motor. along with a remote oil filter & cooler to help with heat control. The oil system will carry an additional 3litres of oil through the lines etc
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 12:50 AM   #19
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

For the shift side of the transmissions I'm using a Toyota Tarago shifter for the gearbox a L300 Mitsubishi for the transfer case & Hi Ace hand brake lever. they are all mounted in a cut down checker plate tool box






I have cut 5 inches out of the box since this pic was taken to move the shifters back


Last edited by roverv8bay; November 13th, 2014 at 01:07 AM.
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 01:09 AM   #20
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Had a visitor hate these damn things not venomous but just make me feel sick
roverv8bay is offline   Reply With Quote
Old November 13th, 2014, 01:12 AM   #21
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

Random pics of the motor layout & intrusion into the load bay


mockup mounts for location

this will give you an idea how far the box sits above the floor





sump to be cleared slightly




Last edited by roverv8bay; November 13th, 2014 at 01:26 AM.
roverv8bay is offline   Reply With Quote
Old December 4th, 2014, 02:12 AM   #22
roverv8bay
Forum Member
 
roverv8bay's Avatar
 
Join Date: Jul 2013
Location: Nambour Queensland Australia
Posts: 23
Default Re: AUSSIE 4x4 v7 midengine T2 bus

G'day all. back on track after a while with shoulder issues I have set up the front end to start designing the front diff mounts & fitting power steering rack





picked up a freebie fuel tank long range out of a range rover


Last edited by roverv8bay; December 4th, 2014 at 02:26 AM.
roverv8bay is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT -8. The time now is 08:02 PM.


Powered by vBulletin
Copyright ©2000 - 2023, Jelsoft Enterprises Ltd.
ALL text, images, graphics and content herein are Copyright 2002 - 2020 Three Pugs Design - Cut Weld Drive Forums