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A little tig welding advise needed

I dont wanna fry ye old motor mounts,lol,if I havent already ,its either this or drill out the CM:haha: sux!
 
Ill see if I can explain this to where you can understand it.

I have run into this before, being off by just a quater inch or so and this is what I do. Jack the tranny/t-case up till there is a couple inches between the mount and the adapter feet. Pull the rubber mount up off the crossmember so that it can move around to line up with the adapter feet. Then run the bolt through the crossmember and tranny mount and there should be enough play between everything to get the bolt started into the adapter. Once the bolts are started lower the tranny/t-case back down and it should cause everything to line up. Then you can tighten your bolts.

I dont know if my motor mounts flex or if my crossmember is tweaked a little but every time I have removed my crossmember or tranny mounts on my dd this is what I had to do to get it back together.
 
Got all the crossmembers in and everything today,,,found a bent spot on the frame , thats what was causing me all this trouble. Now I just need to figure out how to ~work~ my 205 :D:haha::waytogo:
 
forward is 4 low / n / 2 high / 4 high .

best mods to do to it are twin stick shifter setup and modifyed shift rails.
 
Got it ,thanks. One thing tho, had the shift boot off and saw that in 2hi while driving,,,i could see the front shaft partially spinning. More so when I got on the gas , is this normal?
 
Thanks. I guess its= FINALLY TIME AFTER 1 1 /2 years of fixing ,to go wheeling!:thumb::waytogo: I cant beleive it!
 
TheBeast_88K5 said:
For real... Get a mobile Tig welder to do it! :D
Simple, and should be relatively cheap. :dunno:

I would be worried about the strength of that Trans' Case... :eek:
If you follow us around, and it's that weak anywhere else, it's gonna break.. :whistle:




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*This is one of the few forums that supports it! :D
Click to expand...
Ok guys so, question. I'm having a mobile tig welder out soon to fix this. I have the case out and everything, the hole got bigger and now its more like a half moon,and my question is this...After he's done with the welding, I'm going to be left with a rough blob of aluminum right? What's the best way to - shape the new aluminum? I will have to shape it with a good dremell tool or a file? Any advise appreciated!
 
he should fill it all in to 1 solid mass.

then you grind flat / or file flat.

install adaptor for template to drill new hole. then drill it and tap it out.

if hole dosnt go threw then start with a reg tap then finish with a bottom out tap.

good lube and slow and steady when tapping the hole.
 
sweetk30 said:
he should fill it all in to 1 solid mass.

then you grind flat / or file flat.

install adaptor for template to drill new hole. then drill it and tap it out.

if hole dosnt go threw then start with a reg tap then finish with a bottom out tap.

good lube and slow and steady when tapping the hole.
Click to expand...

Yup, thats a good Plan!, will be the strongest way to go!
 
Man you have bad luck lol. Curse these old rigs. So i was thinkin.... I know i know. If these 205s are so heavy and only supported by 4 bolts why not run some type of support like my 208 has from the bell housing to the tc? Or some type of hanger? I think avery got some hanger from trail tech fab to hold his doubler up that just bolts right on... May be worth looking into so you dont have this problem again.
 
Deuling said:
Man you have bad luck lol. Curse these old rigs. So i was thinkin.... I know i know. If these 205s are so heavy and only supported by 4 bolts why not run some type of support like my 208 has from the bell housing to the tc? Or some type of hanger? I think avery got some hanger from trail tech fab to hold his doubler up that just bolts right on... May be worth looking into so you dont have this problem again.
Click to expand...
That is not why he broke it.
It was missing the top 2 bolts and I gave him a couple of pairs to try, one was too long and only threaded for 1" and he tightened it too much and thenon threaded part was forced in the hole and popped it off.
 
imiceman44 said:
That is not why he broke it.
It was missing the top 2 bolts and I gave him a couple of pairs to try, one was too long and only threaded for 1" and he tightened it too much and thenon threaded part was forced in the hole and popped it off.
Click to expand...
It was my fault, I broke it :D laugh and learn! :D:waytogo:
 
If the guy welding it is good you should not have to much to clean up and remember that AL is soft so go slow. A file is your best bet and when drilling ues a good sharp bit on a lower speed and consistant pressure as not to load up the tip and end up putting yourself off center for the tap.
 
Deuling said:
Man you have bad luck lol. Curse these old rigs. So i was thinkin.... I know i know. If these 205s are so heavy and only supported by 4 bolts why not run some type of support like my 208 has from the bell housing to the tc? Or some type of hanger? I think avery got some hanger from trail tech fab to hold his doubler up that just bolts right on... May be worth looking into so you dont have this problem again.
Click to expand...

My 84 CC has a support bar that runs form the bell housing to the 205, similar to what the 208's have. Even thought that is not how it broke support is never a bad idea, but he had the bracket that bolts from the 205 to the frame now.
 
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