Go Back   Great Lakes 4x4. The largest offroad forum in the Midwest > 4x4 Talk > Ford Tech
GL4x4 Live! GL4x4 Casino







Search
Reply
 
Thread Tools
Old December 29th, 2006, 06:41 PM   #1
etvaugha
Newbie
 
Join Date: 12-28-06
Posts: 19
iTrader: (0)
How to build a doubler

Want a final crawl ratio of 85 with 3.73s for your Ranger, Explorer, or BII? Want to laugh at people with 5.13s? Here's how to make a doubler case out of a BW1350 that will go in front of the existing BW1354

What you will need:


12"x12"x1/2" sheet of steel plate
BW 1350 manual shift t-case
RBV (ranger-based vehicle) 4x4 output shaft
6 3/8" grade 8 bolts, 1.5" long 16 pitch thread
Transfer case skid plate

Obviously you'll need shop tools like a grinder, drill, etc. and products like RTV, brake parts cleaner, JB weld, etc. You need a 3/8" tap and a 5" hole saw. If you plan on lengthening and shortening your driveshafts yourself, you'll need a chopsaw and a welder. You'll also need a nearby shop with a metal lathe and a arbor press.

The first step is to take the 1350 case and take it apart/split it. You only need the front half with the planetary set and shifting linkage. The sector shaft and your 4x4 output you'll take to a machine shop and have them do this:



This is the machined sector shaft with a 4x4 output pressed on.

The next step is to cut the front output off of the case.





The planetary set is installed in the case, seeing where to drill holes.




Drilling and tapping holes for bolts to attach case bosses. 5" hole has been cut out. Whew!! My drill caught on fire trying to cut that hole.




Case attached to plate.




All the internals (shift fork, sector shaft, etc.) installed.




Lining up front plate of the t-case that will bolt onto the doubler assembly.



Lines created for the shaving process.

This is not a complete guide but should give you a good idea of the overall process. Enjoy!


Remaining:

Some grinding on the existing 1354 transfer case front
Shave/trim the plate
Make drain/fill plugs
Drill and tap holes to attach 1354 t-case to doubler
etvaugha is offline   Reply With Quote
Old December 29th, 2006, 07:28 PM   #2
larboc
Pirate of Dollar Bay.1TBB
 
Join Date: 10-23-06
Location: Painesdale, mi
Posts: 257
iTrader: (0)
Got it back in the exploder yet? you RBV people and your doublers!

Nice work man, cant wait to see it working.
larboc is offline   Reply With Quote
Old December 30th, 2006, 10:06 PM   #3
Captain Ledd
Ranger Addiction?
 
Captain Ledd's Avatar
 
Join Date: 11-06-05
Location: Davisburg
Posts: 2,065
iTrader: (31)
Thats pretty dang sweet, keep us updated.
Captain Ledd is offline   Reply With Quote
Old December 31st, 2006, 06:05 PM   #4
etvaugha
Newbie
 
Join Date: 12-28-06
Posts: 19
iTrader: (0)
Quote:
Originally Posted by Captain Ledd View Post
Thats pretty dang sweet, keep us updated.
Thanks!

Will do. I'm getting real close to being done. Installation will probably happen this week.
etvaugha is offline   Reply With Quote
Reply
Great Lakes 4x4. The largest offroad forum in the Midwest > 4x4 Talk > Ford Tech
Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT -5. The time now is 08:40 AM.


Powered by: vBulletin, Copyright 2000 - 2012, Jelsoft Enterprises Ltd.
Copyright 2005 - 2012 Cracker Enterprises - Powered by Linux
vB Ad Management by =RedTyger=
Page generated in 0.08537 seconds with 18 queries