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K10: Built HP60/241-205 Doubler/tons of tube
- Thread starter Avery4jc
- Start date
Everything I've read says they're great for street and sand. I think they might get a bad wrap because guys run them in rocks/mud and hate how they work so they just give them an overall crappy review. I got them for really cheap though so I'll run them and see how they do.
U-bolts and some tube flanges showed up yesterday so I'll get the new longer u-bolts put on tomorrow.
Finished up the pivot point for my shifters at work today. Made some bushings then machined some little nylon spacers so they don't rub on each other. Couple snap ring grooves on the ends and it's good to go. Also shortened it up a little since I didn't need it as long once I figured out where they were all going to ride.
I have a dinner to go to tonight but when I get home I'll be burning the midnight oil to get the linkage busted out so the cases can go in the truck tomorrow.
Finished up the pivot point for my shifters at work today. Made some bushings then machined some little nylon spacers so they don't rub on each other. Couple snap ring grooves on the ends and it's good to go. Also shortened it up a little since I didn't need it as long once I figured out where they were all going to ride.
I have a dinner to go to tonight but when I get home I'll be burning the midnight oil to get the linkage busted out so the cases can go in the truck tomorrow.
Made some good progress tonight after dinner. Should be able to wrap it up first thing in the morning and then move onto getting the cases in the truck.
I need to gusset and burn in the threaded bushing then make a couple small tabs for the underside of the three shifting bushings for the other little joints to bolt to. I picked up some material to make the actual shifters that'll come up into the cab on my way out the door at work tonight. It sure isn't fancy but I think it'll work.
I welded in a little gusset on the front output shift rail, you can see it in this pic.
I need to gusset and burn in the threaded bushing then make a couple small tabs for the underside of the three shifting bushings for the other little joints to bolt to. I picked up some material to make the actual shifters that'll come up into the cab on my way out the door at work tonight. It sure isn't fancy but I think it'll work.
I welded in a little gusset on the front output shift rail, you can see it in this pic.
chevysmithz71
1/2 ton status
Ya looks like it should do the job. do you have to make the xmember too??
Yeah but I have it all planned out and it's pretty simple. Just a support piece for the back of the 205.
HOLY SMOKES IT SHIFTS!
After a crazy long night last night, working today then working tonight again until 11:00 it's finally ready to go in the truck!
It took some tweaking but overall it went pretty smooth. Ended up having to add some gussets here and there to stiffen it up but I'm really pleased with how stiff and positive it feels now. You can feel the shifts through the shifters so you don't fly by gears but it doesn't take a crazy amount of force to shift either.
Tomorrow I need to figure out how much fluid a 205 takes since I'm going to have to fill it unconventionally and can't use the factory plugs for reference. Same with the 241 range box...
Just because I'm excited here's a bunch of pictures.
After a crazy long night last night, working today then working tonight again until 11:00 it's finally ready to go in the truck!
It took some tweaking but overall it went pretty smooth. Ended up having to add some gussets here and there to stiffen it up but I'm really pleased with how stiff and positive it feels now. You can feel the shifts through the shifters so you don't fly by gears but it doesn't take a crazy amount of force to shift either.
Tomorrow I need to figure out how much fluid a 205 takes since I'm going to have to fill it unconventionally and can't use the factory plugs for reference. Same with the 241 range box...
Just because I'm excited here's a bunch of pictures.
chevysmithz71
1/2 ton status
Looks real good. I can see how all the little tabs and adjustments you had to make would take so long. but well worth it
Friggin SWEET! 
K5 Jess
1/2 ton status
x 2friggin sweet!
Well today was make or break day. I had set this weekend as the absolute deadline for getting the doubler in the truck. If it was in by this weekend I would still have enough time before our pismo trip to do exhaust/driveshafts, build the little rear support mount for the 205 and get some break in time on the gears done....
I'm not going to lie, at one point I did say F it and started to call it quits and just kick back and do nothing until after Pismo but my dad stuck it out with me and we got it "done".
Started off bad because the shifters were waaaay off, so I had to take it apart and make all new bends to come up in the cab differently. Then I couldn't get it up in place, then it kept rocking and turning on us, then it hit the floor, then it was just a PITA to maneuver and get the crossmember and adapter bolts in.... but in the end I now have an empty workbench....
...and a 241/205 doubler in the truck...
Luckily it only hit EVERYTHING so I just said screw it and cut most of the floor out. In the end I think it'll be better...
It should be worth it though, once the factory crossmember is replaced with a low profile tube one it'll have a relatively flat belly all with no body lift.
I need to get them filled up (should be fun, I'm going to fill them while the floor is out) then get started on the rear crossmember. It's surprisingly tight with the poly engine mounts and the poly mount on the adapter.
The countdown is on now! Just a few weeks before the maiden voyage!
I'm not going to lie, at one point I did say F it and started to call it quits and just kick back and do nothing until after Pismo but my dad stuck it out with me and we got it "done".
Started off bad because the shifters were waaaay off, so I had to take it apart and make all new bends to come up in the cab differently. Then I couldn't get it up in place, then it kept rocking and turning on us, then it hit the floor, then it was just a PITA to maneuver and get the crossmember and adapter bolts in.... but in the end I now have an empty workbench....
...and a 241/205 doubler in the truck...
Luckily it only hit EVERYTHING so I just said screw it and cut most of the floor out. In the end I think it'll be better...
It should be worth it though, once the factory crossmember is replaced with a low profile tube one it'll have a relatively flat belly all with no body lift.
I need to get them filled up (should be fun, I'm going to fill them while the floor is out
) then get started on the rear crossmember. It's surprisingly tight with the poly engine mounts and the poly mount on the adapter.The countdown is on now! Just a few weeks before the maiden voyage!
Damm. Way to go!!!! Looking good!
Looks awesome Avery!
Keep it up.
Keep it up.
Looking really good Avery... I like the tenacity and attention to all the the little details.
I have to ask though.... Why was the Doubler a prerequisite for Pismo? Don't most people run around in 4HI anyway?
....it's also possible that I just don't have any concept of deadlines and getting stuff done by a target date. Which is why I won't be at BlazerBash until 2019.
-G
I have to ask though.... Why was the Doubler a prerequisite for Pismo? Don't most people run around in 4HI anyway?
....it's also possible that I just don't have any concept of deadlines and getting stuff done by a target date. Which is why I won't be at BlazerBash until 2019.
-G
andyblack
Registered Loser
Awesome work dude. You put in some late nights and hard work and it paid off. Everytime I see your doubler, it always freaks me out a bit because the front output is on the left side. Then I remember that you have a Ford type front axle.
If you want a good idea about how to build a sick crossmember for your doubler, check out mrdrinksalil. He made an awesome one for his doubler, but I think his was for a 205/203 with the passenger side front output. It would be cool if you could make something like that though. And paint it electric blue.
If you want a good idea about how to build a sick crossmember for your doubler, check out mrdrinksalil. He made an awesome one for his doubler, but I think his was for a 205/203 with the passenger side front output. It would be cool if you could make something like that though. And paint it electric blue.
Looking really good Avery... I like the tenacity and attention to all the the little details.
I have to ask though.... Why was the Doubler a prerequisite for Pismo? Don't most people run around in 4HI anyway?
....it's also possible that I just don't have any concept of deadlines and getting stuff done by a target date. Which is why I won't be at BlazerBash until 2019.
-G
Because I needed to get to driver's drop for my front end and I dont want to make driveshafts twice so it all needed to happen in one shot.
Awesome work dude. You put in some late nights and hard work and it paid off. Everytime I see your doubler, it always freaks me out a bit because the front output is on the left side. Then I remember that you have a Ford type front axle.
If you want a good idea about how to build a sick crossmember for your doubler, check out mrdrinksalil. He made an awesome one for his doubler, but I think his was for a 205/203 with the passenger side front output. It would be cool if you could make something like that though. And paint it electric blue.
I've seen his and it's really nice. Mine wont be that complicated though. I really just need some support for the back of the 205 for now.
I don't know why I still cringe when I see you hack the sheet metal on this truck, its pretty moot at this point... 
Oh and so I get the finishing the doubler for the deadline/drivers drop axle, but do you really need a doubler? Like Greg said, Pismo is all full throttle dune running, why go through all the trouble of setting up triple sticks when any drivers drop t-case could have worked for you? (Not trying to put down your bling, just currious)
Oh and so I get the finishing the doubler for the deadline/drivers drop axle, but do you really need a doubler? Like Greg said, Pismo is all full throttle dune running, why go through all the trouble of setting up triple sticks when any drivers drop t-case could have worked for you? (Not trying to put down your bling, just currious)
I don't know why I still cringe when I see you hack the sheet metal on this truck, its pretty moot at this point...
Oh and so I get the finishing the doubler for the deadline/drivers drop axle, but do you really need a doubler? Like Greg said, Pismo is all full throttle dune running, why go through all the trouble of setting up triple sticks when any drivers drop t-case could have worked for you? (Not trying to put down your bling, just currious)
Good question, I don't talk about it as much on here but the local guys I wheel with don't like Pismo so when we go wheeling its trails up in the sierras where low gears and control are the key. This truck is transitioning into a trail rig and once its how I want it I'll buy/build a go fast rig for taking to Pismo. This truck is fun but really not all that great in the sand. We're thinking more of a 2 seater front engine mid travel buggy for going fast in the sand.... But that's a ways off.
