clstolten
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No. The seal for this setup is in the transfer case to trans adapter.
CK5
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Linked 74 K5. Rental house driveway build.
- Thread starter clstolten
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No. The seal for this setup is in the transfer case to trans adapter.
clstolten
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Thanks man. If you have the means, you should buy a welder and start welding.
clstolten
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Tube Bender
I need to get this thread back up to date. A lot has happened since I last posted. Early in the year I picked up a JD model 32 bender. I dont have a place to hard mount it to the floor so I had to put it on wheels. I built a stand for it that had big casters, and also had adjustable pads to level it out during use. The pads are adjusted via .75" acme threaded rod that I got for cheap from enco, along with some acme nuts. The pads are steel with rubber glued to the bottoms. I got them from mcmaster carr. I also picked up a swag hf cylinder mount and hf cylinder. Here is a pick of the almost completed stand prior to mounting the bender:
Took this picture the night my garage flooded last June. You can see the cranks on the threaded rod. They fold over when not in use. Had to add tennis balls after my girlfriend sliced her shin open on one of the threaded rods.:
Being able to level this thing out has been very helpful. I have a tube clamp with a flat surface for a magnetic level that I use for a point of reference as I go from bend to bend. Works really well. The only die I have so far is 2", and the hf cylinder bends it fairly well. It is sometimes a b*tch to return the cylinder to a compressed state. If I had to do it again, I would probably buy the jd hydraulic cylinder and use an air over hydraulic pump. I also picked up a hole saw notcher for notching the tube.
I need to get this thread back up to date. A lot has happened since I last posted. Early in the year I picked up a JD model 32 bender. I dont have a place to hard mount it to the floor so I had to put it on wheels. I built a stand for it that had big casters, and also had adjustable pads to level it out during use. The pads are adjusted via .75" acme threaded rod that I got for cheap from enco, along with some acme nuts. The pads are steel with rubber glued to the bottoms. I got them from mcmaster carr. I also picked up a swag hf cylinder mount and hf cylinder. Here is a pick of the almost completed stand prior to mounting the bender:
Took this picture the night my garage flooded last June. You can see the cranks on the threaded rod. They fold over when not in use. Had to add tennis balls after my girlfriend sliced her shin open on one of the threaded rods.:
Being able to level this thing out has been very helpful. I have a tube clamp with a flat surface for a magnetic level that I use for a point of reference as I go from bend to bend. Works really well. The only die I have so far is 2", and the hf cylinder bends it fairly well. It is sometimes a b*tch to return the cylinder to a compressed state. If I had to do it again, I would probably buy the jd hydraulic cylinder and use an air over hydraulic pump. I also picked up a hole saw notcher for notching the tube.
I should read stuff between the pictures 
nvm
nvm
clstolten
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Yeah, it was a rough day. The worst part was the garage is half of the basement and when I opened the door in to the rest of the basement, I had a small tidal wave going on. Good thing it is a rental house.I should read stuff between the pictures
clstolten
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Roll Cage
This is the start to my roll cage. The cage is made of 2" DOM steel tube. Welded to the body where possible, and then bolted to the frame.
top is now bolted to the cage up front. Windshield frame is also tied to the cage.
with paint
This is the start to my roll cage. The cage is made of 2" DOM steel tube. Welded to the body where possible, and then bolted to the frame.
top is now bolted to the cage up front. Windshield frame is also tied to the cage.
with paint
That's what I'm talking about!! Bad A! 
Crap....Just what i needed...Another cool build!!!
Nice so far, I'll check to see how things progress.
Subscribed!
Nice so far, I'll check to see how things progress.
Subscribed!
clstolten
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Alright, sounds good. I checked out your build. Looks good! So, Canada has more to offer than just the Trailer Park Boys. Haha. I love that show.
clstolten
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Got a doubler
OK, so I decided I should install a doubler. Found a new never installed ORD doubler with a th400 NP203 on craigslist. If anybody is interested in the ORD modified advanced adapter and factory long spline 32 spline NP205 input, let me know. I will give you a deal on it. It would be cheaper and easier than finding a 4l80 to NP205 factory adapter.
I was going to use the 2004 4L80 to 241 adapter that came with my transmission, but I wanted to install all 6 bolts from the adapter to the transfercase. A friend of mine had already built up and sold a 4l80 to doubler setup. He told me that ORD had modified his cast iron adapter to include a slotted hole for the missing bolt. I thought I could just slot a hole on the aluminum adapter, but I was wrong. Look at the pictures below to see why.
If I were to slot the hole the aluminum adapter would probably crack and break. Not enough meat on that thing.
OK, so I decided I should install a doubler. Found a new never installed ORD doubler with a th400 NP203 on craigslist. If anybody is interested in the ORD modified advanced adapter and factory long spline 32 spline NP205 input, let me know. I will give you a deal on it. It would be cheaper and easier than finding a 4l80 to NP205 factory adapter.
I was going to use the 2004 4L80 to 241 adapter that came with my transmission, but I wanted to install all 6 bolts from the adapter to the transfercase. A friend of mine had already built up and sold a 4l80 to doubler setup. He told me that ORD had modified his cast iron adapter to include a slotted hole for the missing bolt. I thought I could just slot a hole on the aluminum adapter, but I was wrong. Look at the pictures below to see why.
If I were to slot the hole the aluminum adapter would probably crack and break. Not enough meat on that thing.
clstolten
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The cast iron adapter shown above I found on ebay. Paid more than I should have, but it saved me from having to go to the yard, so I thought. You can see the slotted hole in that pic. For those that dont know, if you try to drill the np203 to match the newer 6 bolt round Chevy pattern, one of the holes is located on a profiled, not flat part of the np203. It appears based on internet research that most people just use 5 holes in this case. I wanted to use all six bolts, and here is how I did it. Slotted the sixth hole on my bridgeport mill.
clstolten
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Here is the proof. All six holes drilled and tapped in my 203 case. Not a poser with only 5 bolts. 
like I said, my research shows that many people run this setup with just 5 bolts without any problems. If you want to run six like myself, this may be an option for you. Heck, you could probably slot the hole with a high speed grinder. Dont need a mill to do this.
like I said, my research shows that many people run this setup with just 5 bolts without any problems. If you want to run six like myself, this may be an option for you. Heck, you could probably slot the hole with a high speed grinder. Dont need a mill to do this.
clstolten
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unfortunately, the adapter I picked up off ebay had a factory machining flaw. the surface that interfaces with the transmission surface was not machined flat. I wish I would have taken a picture of this before I machined it flat. I am certain that if I would have used it as is, the cast iron would have won, and the cast aluminum transmission case would have cracked. Here it is after machining flat.
clstolten
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Here are some pics showing the difference between the aluminum and cast iron 4l80 to transfer case adapters. Not sure when GM switched to the aluminum adapter, but they did save a considerable amount of weight when they did. However, in this application, I think the cast iron is best. dimensionally they are the same as far as the interfacing features go. Here are a few pictures.
However, in this application, I think the cast iron is best. dimensionally they are the same as far as the interfacing features go. Here are a few pictures.
You need to update this thing some more! We need to hurry up and get this thing done so we can wheel this summer. I am more posting this up just so people don't forget about this thread and how Bad A this thing is
clstolten
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Thanks man. I have made some progress on this project. Also, looks like I am under contract to buy the rental house so I may have to change the title of my build. Front coilover hoops are almost complete, bump stop mounts complete, limit straps mounts finished, Thorley headers installed, and the 203/doubler is read to be bolted to the 205 when I get it out of the truck. Here are a few progress pictures of the front end:You need to update this thing some more! We need to hurry up and get this thing done so we can wheel this summer. I am more posting this up just so people don't forget about this thread and how Bad A this thing is
y5mgisi
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Killin it! good job!
Nice!
Sweet Update!!!
Excellent work!
Coming together nicely!
Excellent work!
Coming together nicely!
