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Modifying Shift Rails

Discussion in 'The Garage' started by Smitty, Nov 19, 2005.

  1. Smitty

    Smitty 1/2 ton status

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    Can anyone point me to some instructions on modifying the shift rails of a 205 for the doubler kit?
     
  2. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    there was several articals if 4 wheel & offroad a couple of years ago that explained about how to do it. i modified mine based on that. had the grind shop at my machine shop grind it. they did a very clean job. its never been installed though so i dont know how well it works. they said their's worked very well though. also the article was a bit vague on spicific dimensions. they showed several pictures of the modified shaft so i calculated the scale of the shaft and the grind points in the picture in percentage to come up with what i thought was a pretty good value to give me the right dimensions. they did theirs on just a bench grinder by hand and it worked fine, so i think mine being precision ground with very good surface finishes and clean transitions will work just fine too. i can take a picture if you would like and give you the dimensions off my shift rail and pics of the articles too.
     
  3. Smitty

    Smitty 1/2 ton status

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    Sent a PM with my email address. Thanks for the help.
     
  4. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    Shift Rail Pic.

    keep going down for pics
     
    Last edited: Dec 10, 2005
  5. Smitty

    Smitty 1/2 ton status

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    All I'm seeing are red x's. Someone let me know if it's my computer.
     
  6. Stomper

    Stomper ΜΟΛΩΝ ΛΑΒΕ GMOTM Winner

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    This is what I used as referenceBadDog's web page

    Worked like a charm...



    ps. I can see the pics in this thread
     
  7. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    keep going down for pics
     
    Last edited: Dec 10, 2005
  8. Smitty

    Smitty 1/2 ton status

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    The links work great for me! Thanks for all of the help!
     
  9. gman454

    gman454 Registered Member

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    work for me to
     
  10. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    these should be better pics of the shift rail mod with better digital caliper readings that you hopefully you CAN see. radius is 3/16. first pic is 2.200, 2nd is 2.350, 3rd is 2.825, 4th is 3.125. second pic is the end of the rad to the flat. third is ofcourse the other end of the flat.
     
    Last edited: Oct 6, 2007
  11. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    the other end pics, rad is same 3/16. shop compareter shows 19 deg 43 min. that probably does not have to be exact, we just ground the figures i calculated. first pic is .625 in case you cant read it. 2nd is .800.
     
    Last edited: Oct 6, 2007
  12. jekbrown

    jekbrown I am CK5 Premium Member GMOTM Winner Author

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    well heck, now that I have all the critical dimensions I think I'll knock out a 3d model on autocad. Doesn't someone in the 4x4 world machine brand new twin-stick-capable shift rails for a decent amount of cash? Doesn't look like rocket science to me... and the amount of material is pretty small too...

    very cool machine you have there, wish I had one! :o

    j
     
  13. rdn2blazer

    rdn2blazer 1 ton status Premium Member

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    as far as i know, no one does, but i could. we can even heat treat in house too. damnit jek now ya got me think'n. :D im going to go check Rockwell hardness right now.
     
  14. backyardbuilt

    backyardbuilt 1/2 ton status

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    JKW offroad is selling them for 90$
     
  15. afroman006

    afroman006 1/2 ton status

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    Uhhhh...check the latest product review. I dont feel like looking to see what company it is but they sell a complete twin stick kit with brand new shift rails. Myself, I'll be busting out the $15 harbor freight grinder to get the job done, whenever I get around to doing it...
     

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