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Dual-T case Adaptor done on the cheap....First Update...

Discussion in 'The Garage' started by dhdescender, Nov 18, 2003.

  1. dhdescender

    dhdescender 1/2 ton status

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    I'm currently installing my motor and driveline into my K5, and I wanted to finish my Dual T case adaptor before I have to cut new driveshafts.

    I started with:

    1 TH400 NP203 Style
    1 TH400 NP205 Style
    1 NP205 for TH400
    2 NP203's for TH400
    1 TH400 -> NP203 Factory Adaptor Plate
    1 TH400 -> NP205 Factory Adaptor Plate

    I took the measurments off the face of the 205 factory adaptor, and recreated the face onto a 3/8" plate. I then cut a 3/8" plate for the NP203 side, andcut the retaining ring for the aluminum housing that retains the 203's intermediate shaft and bearings. I also cut the slot for the anti-rotator shaft into this plate.

    I called WMS, and they quoted me $60 for machining the factory shaft down to the spec's I require.

    So far, for a dual Transfer case adaptor, I've spent $20 on steel, and will spend 60 on resplining. The intermediate shaft may not be *quite* as strong as the ORD solid shaft, but I'd say a Dual Transfer case adaptor for $80 wasn't a bad deal! The adaptor plate will be 3" Face to face. Bear in mind, I don't have to pay for labour, because I'm trading my labour (Aluminum TIG welding) for their machinework.

    I'll post pics as I get them coming. It isnt the prettiest sob, but it will certinally get the job done. I plan to replace the welded 3/8" version with a solid aluminum job like the ORD's once I find how my tolerances worked out for me.
     
  2. jekbrown

    jekbrown I am CK5 Premium Member GMOTM Winner Author

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    so when is ur version going to market? /forums/images/graemlins/grin.gif

    j
     
  3. dhdescender

    dhdescender 1/2 ton status

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    I'm going to look into production costs....can't say If I will go that route or not yet. I'll talk to the machinist who produces my bike products and see what he thinks for cost.
     
  4. earl87gta

    earl87gta 1/2 ton status

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    How is this coming along got pics yet?
     
  5. dhdescender

    dhdescender 1/2 ton status

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    I've moved onto billet aluminum adaptors with 10 center holes to allow many clocking locations.

    [​IMG] This is my TH400 To NP203 adaptor. I can also use it as one side of my NP203 to NP203 adaptor. I'm not going to bother with two range boxes, because I installed my own 3:1 kit into my NP203.

    I'll post pics of the original adaptor, but I've already started to CNC the new one...which is much more entertaining.

    [​IMG]

    Once I get my shaft back from WMS, I'm taking it to a local gear shop and getting copies made out of solid stock and then hardening it. /forums/images/graemlins/thumb.gif /forums/images/graemlins/thumb.gif
     
  6. earl87gta

    earl87gta 1/2 ton status

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    Thats nice,
    Im doing the 205/203 and have been thinking abought getting the shaft from some one and then making the rest of the adaptor but I havent had a lot of luck finding good pics of the adaptors to use to figure it all out.If only I new some one close but with one to look at It doesnt seam like they would be that hard to make in the steel vertion.
     
  7. Thumper

    Thumper 1/2 ton status

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    Well, that looks like a nice job. You do realize that if you were to build a gen 1 type of doubler setup (ie 10 spline stuff) you would sell a bunch of em as long as the price didnt include research and developement costs for the last 10 years. I would be very interested in a setup for a 10 spline sm465 to a 203/ 205 t cases. That would be awesome... if the price was decent.
    You should take a poll on the different demands for the setups and see the reactions. Id figure there would be lots...

    Keep it up!

    Mike
     
  8. dhdescender

    dhdescender 1/2 ton status

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    I'm just going to have to pick up a 27 and 10 spline input and see If I can fit it all in 3", I have a feeling it may be a bit longer. But I can just add a spacer between each adaptor...easy as Pie!
     

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