Good old r tech welder i see you have Mark.

Good units they are i have one of there tigs too.

 

Just sold one on eBay myself, lovely little tool.

 

The things I would make if I had a CNC machine. Thats diff cover is lovely...

Surely, now you've made one, it's saved in the computer and it's easier to make the second?

 

Thanks mate, it would be much easier to make a second one.


Still very time consuming though, no way I could make any money out of it with the equipment I have at work !


Wheels have been painted the correct colour





Can't believe the amount of black wheels at the wheel recon place waiting for collection by blind people

 

Wheels are best in silver.
Looking good.

 

Not a fan of black wheels either.

They're nice though

 

Finally finished bullshitting the outside of the diff cover, just need to get it anodised now...








Now looking at how to sort out drive shafts, might try and adapt these Jag bits to take the standard Cossie ones.

 

looking good keep up the great work

 

I don't like the look of the off the shelf drive shafts to fit Jag diff, plus they are expensive at over Ł800 !


My cunning plan will probably save me bugger all as the steel cost Ł200





Bohler M238 DIN 1.2738 pre hardened with approx. 150,000 psi tensile strength


Should look like this when machined, although the splines turned out to be a pain in the arse to figure out and cost me more cash for a form cutter.

 

I had them on my 3dr when i had one of the first jag diffs in the early 90s, no shit uj joints, just std 2wd shafts.

 

Not done anything with the stub axles, but have gone into work over Christmas to make a new gearbox cross member.




Push start button ad bugger off for a few hours





Flipped over to do other side





Bugger off again for a few hours





Needs chopping out from supporting scrap material and some more machining, but looks nicer and weighs less than the fabricated one.

 

Better than sex. Well really close eh...

 

More Saturday tinkering.







Just need to tidy it up and get it anodised now.

 

Always enjoy your updates Mark.
Looking good.

 

Brilliant work as always

 

I admire your skill, attention to detail and patience. Awesome project.

 

Confession time


Our lathe at work is pretty ropey and to turn the stub axles would have taken an age, so I got a guy up the road to turn them on a CNC lathe for a bit of cash in hand.


Results of the cheating are back.





I now need to cut the splines using a dividing head on a milling machine, problem being our best dividing head is too small to hold the flange on the stub axle.


Round the back of the big surface grinder was a bigger one that has been left there for at east 20 years untouched !


Dragged it out for a look.





After a fair bit of time cleaning and oiling.





Not got any further than that with stub axles as was skimming the rust off drive shafts on lathe at the same time.








Also got my bits back from anodisers, unfortunately the weld shows on the diff cover and I'm going to try and find an oil fill sticker to hide it up.





Anyone know where I can get custom high temperature stickers made ?


I want one that follows the curve of the radius on the oil fill hole...

 

Beautiful work, try Dave username Monster on here as he does bespoke stuff, done a fair bit for me recently and he is brilliant.

 

I'd be giving DMB graphics a shout. Parts look great

 

Amazing work matey,keep it up.

 

All that time pissing about cleaning the old dividing head was wasted


I need to cut 19 splines, the dividing head needs the correct hole circle to do the divisions and this one does not have it, also there are no spares


Only option is to machine the bit where the drive shaft fits, then make an adaptor to fix the stub axle to the small dividing head that does have the correct hole circles !

I need 2 turns and 2 holes on a 19 hole circle to get the divisions correct.

Another Saturday at work sorting the drive shaft fixings...






I want to get the damn thing sat on its wheels this year so it looks more like a real car !

 

You need more clearance inside them 1/4 shafts for the balls in the lobro to move into on full droop

 

Thanks, I'll double check the clearance.


Didn't know they moved that far out

 

Another Saturday at work...


Stub axle bolted to adaptor so it fits in dividing head





Form cutter for splines I had to get specially made





This bit took many hours to do the pair and get the size spot on



All done apart from slot for locking tab.











I had enough at this point and buggered off home, the slots can wait for another day

 

Looks just like mine did, how do you spec the cutter for the mill?

i need to make some splines but have never specced a cutter.

 

Wow is a good word to use here

 

I tried to figure out the profile and gave up


Sent off the Jag stub axle to CR Tools and they sorted it all out for me


http://www.crtoolsuk.com/cutting-tools-sheffield/

 

How much was the cutter?

 

Ł130 + vat


Lot to pay for just making two stub axles !


I just do not like the look of the off the shelf shafts with a UJ one end and CV joint the other and after watching this vid I would be even more wary...

 

I agree, mine back in the late 1990s
Back in 1998

 

got enough space to get the side carrier bolts in ?

 

The bolts have to be fitted before shaft goes in carrier.





Added some more clearance for inside of joint.





If I push the shaft in as far as it will go I still get a witness mark from the grease - fingers crossed there is enough clearance !

 

That's some nice engineering going on there.

 

That engineering work really is stunning.

Must be a great feeling being able to crack open all the nos bits and bolting them on

 

Thanks, I've been hoarding new old stock for years !

 

Cleaning bits in citric acid, stuff works wonders and cleans off old zinc plate as well as rust.












Dried and wire brushed before going in polishing gadget.















All gone for plating now. should be back this week.


Not sure if my rear arches are going to like the 235 rear tyres





Spent the day getting covered in crap cleaning the rear diff up.








Hoping to get some epoxy on it next weekend if the weather is dry before it goes off for rebuild.

 

Looking good Mark. I do a similar process with the bolts prior to plating.
Soak in deox C
Dry off and wire wheel on the bench grinder
Some parts get soda blasted at work and then plating.
Gives and nice even result.

I would have epoxyed the diff that day by next week it might be a little ginger........

 

Went down the shed to check this morning and rust had started coming out of the pores / pits in the surface of the cast iron


Attacked it with Kurust all over





I'll wire wheel it all again and with luck the Kurust will have stopped the leaching !

 

I was going to suggest that its the same with hubs water pumps etc.......

Should be good to go

 

Wire wheeled the diff back to bare metal again and sprayed it with epoxy.


Took it over to a Jag axle specialist on Mersea island for check over / rebuild - going to take 5 to 6 weeks as the guy is really busy.





Got the beam, trailing arms and drive shafts powder coated





Loads of zinc plating, got the platers to mask off parts that would cause issues with bearing fit.







Spent the afternoon assembling drive shafts, buggered up one of the stainless gaiter clips and gave up until I get some more !