ive just spent the past 2 hours reading about the adventures of a bad*ss named crash and his tools. crash, you are the living embodiment of customization, and gibby, you are the commander of a new cross-bred ORV(and a top-notch one at that). chev'otas never die. wow.

wow. just wow.

 

SPanks

BTW, the rear winch is just about done, and has turned out better than I expected. Will have a bunch of pics up tonight (headin out to catch more stuff on fire )

 

WHAT HE SAID---GIBBY AND CRASH---YOU GUYS ROCK! :rockband: :drum:


AND

 

HUH???

 

I can keep a rig from going up in flames, but myself, I gotta get a handle on that (whats wrong biggy, did I scare ya,lol)

 

Oh, so YOU were going up in flames. That makes me feel better. HAHAHA

I better be careful or the biggy nickname might stick.

 

So, since the the front bumper is now complete, its time to dig into the t-cases, the one part of the job I really wasn't looking forward too.. But here are the isses with it. There is a kinda light gear clatter to it, there it ATF in the 203 and 205 and there is a leak at the 203-205 adapter, but not where they mate to either case but at the extension tube thats welded in between the 2 halfs of the adapter (on the 203 side of it).

Look at the 90w(looks a little red, huh)



I also found this, the zert fitting on the front driveshaft smacked the tranny pan, and peeled it off the driveshaft

 

SO I ripped both t-cases out and dissassembeld the adapter. Here is the weld on the 203 side.



So I inspected the adapter, and I found a few issues.If you look closely, you can see fractures in the weld(203 side)



I also found fractures on the outside of the adapter on the 203 side.



I also inspected the 205 side of the adapter and I found the crappy weld also fractured.

 

I've read in several places that motor oil goes in 205s, and not gear oil. Is there any truth to that?

 

BTW, those are NOT my crappy welds...

My crappy welds look much more like giant boogers!

 

So I cleaned the surfaces up and removed material where neccessary and crankd the welded up, and burned the piss outa the adapter.



I welded as much as I could, and added a couple gussets to help the weight support and to just make sure this wasn't going to happen again.



And here is the 205 side of the adapter.



So once the adpater was repaired I went thru the 203 to inspect it for any gear/bearing issues plus I replaced the input seal on the 203 (only way atf is going to get into the cases). I also popped the inspection cover on the 205 and took a peek and it all felt good. So I fully assembled both cases and stuck them back into the rig. I took it for a drive and the gear noise seems lessoned(I also added hyperlube) and didn't notice any leaks, so we are good to go.

 

Did you have to replace the seal on the output of the transmission as well?

Much NICER welds. If I break that sucka now and should be SHOT!

 

There is no seal on the tranny output

 

If you use motor oil, the t-case will go POOF (too light of an oil).

 

So since that was out of the way it was time to go to the rear of the rig. SInce gibby got a new winch for the rear of the rig, he wanted to have the old one put into the rear. He also got a universal winch plate to help in the install. So I mocked the general location of it and started buildin stuff
I planned on 2 mounts being on the rear crossmember(one the spare tire used to go on). I welded a couple areas where the 2 sections of the crossmember overlapped to help keep the crossmember from wanting to seperate/rip apart. I also took a piece of metal and welded it close to the distance of the crossmember to help distribute the forces across the crossmember.





I then ran 2 short stringers using 3/8x2" verticly to the winch plate and then tacked it all into place.



So now those 2 mounts were figured out it was time to start the other mounts to the bumper. But first the bumper had to be "fixed". It was shoved over to the passenger side so it would hit the tailgate. So using the "goldbar" method I fixed it up



And now its perfect

 

So since I know where the bumper belongs I grabbed some tube and bent up two more mounts.






And here is how the other 2 mounts turned out.





This thing should hold up pretty good since the 2 inner mounts are triangulated and there is some seperation from the inner/outer mounts. To fail it would have to theoreticly twist the rear bumper plus have the 2 forward maounts fail but I don't think any of it will happen under normal use. But be warned gibby don't use that winch cable as a tow strap as very hard torque loads will be hard on it.

 

Here is the mount for the soloniod box



As you can see its as high as I could get it.



And still be able to hook a remote to it.



But I am also wiring it up for an in cab switch on the center console

 

And here is how the whole thing turned out







Its tucked up as far as I could get it so the cable would not rub against the bottom of the bumper but in the end I am really happy with how it turned out. So now all that is left is to run the main power cable to the front and run the wires to the center console.

 

SWEEEET

Can you throw on a little loop for the hook? That way I can still use the receiver.

I should have a couple of shackle mounts on the bumper somewhere anyway.

 

D A N G

Crash, I knew you were good but, man oh man. If I have any money left over when you get done, which I dont think. But I am also doing farless than Gibby is. I am in need of some bumpers. I was going to try them my self. Well at least try. I am going to need a tube bender and all that fancy stuff to even try and make them half as nice as yours. I do like the rear winch mount/bumper set up. High and tight. It is higher than the air tank. So Gibby or is Biggy, when you hear a BOOM, dont worry, it's just a bunch of HOT air.....ROFLMAO. I know when it comes to my rig, you will get some free shots at me...yellow...I know. But I dont care either.

NICE WORK CRASH FAB!