(CCG Doubler) D20 + BW1354 -> Build thread

[patov6]

Hello friends, I´am Victor Silva (Vicho), builder of the PatoV6`s BW/D20 doubler. This idea was born to address Pato`s concern to achieve a higher Crawl Ratio in his Ranger, but with the idea of changing as little as possible in the rest of the truck (didn’t happen like that…). So, looking into the options, we decided that the best option was to use a Dana 20 Early Bronco transfer case, because of its ruggedness, size and configuration ideal for the Ranger. And opening the the possibility in the future to go into twin stick (…still does not occur, until Pato learns the rest of the combinations… hehe). So we found a D20 in a very good general state and began the task. To keep the length of the package, we chose to use the front half of the case of the BW and make a plate separator that bolted in both cases, so using the same shaft entrance to the D20 and making accommodations for the entrance of the bearing D20. We manufactured the guide and support bearing resemblance to the original set of EB too, once ready for this and taking cases coupled came the task that was more complicated…turning the electric drive of the BW drive to a mechanic. Unable to find another Non Electric donor, we had to produce the elements needed to trigger the whole reducer. For that, we manufacture a shaft that would be able to move the fork. After a couple of tests, this proved that it worked perfectly. So we drilled the case for getting into the shaft, and step down onto the pin and spring that allows it to be in the hi & low position, so we get two boxes work mechanically. Then, we reassembled the whole body into the truck , adjusted the driveshaft and installed the levers. The new transfer cases got just 2" more original length which allows them to be installed without changing any other element as fuel tank, brakes lines, etc…, the result was very good, achieving a dramatic increase in the benefits of the Ranger, and best of all, leaving the minimum alterations onboard.

[patov6]

PICS:

http://img144.imageshack.us/img144/7575/varias2021mediumof7.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/1685/varias20091mediumsm5.jpg (http://imageshack.us)

http://img144.imageshack.us/img144/184/varias2020mediumqf9.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/4379/caqfglshmediumgx9.jpg (http://imageshack.us)

http://img144.imageshack.us/img144/2414/cas9avcpmediumsb3.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/3497/varias20092mediumhc9.jpg (http://imageshack.us)

[sweetsride]

Good right up except for one question for you, did you use the stock shaft from the BW case and did it go stright into the D20 case with no mods?? or did you make a new "stub" shaft to combind the 2??

More info on that you be great!!


Thanks
Kris

[patov6]

More pics;

http://img131.imageshack.us/img131/826/varias20093mediumii5.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/2541/varias20095mediumua0.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/2820/variastaller20020mediumie3.jpg (http://imageshack.us)

http://img131.imageshack.us/img131/2286/variastaller20021mediumlt9.jpg (http://imageshack.us)

[patov6]

http://img131.imageshack.us/img131/2738/variastaller20022mediumyf5.jpg (http://imageshack.us)

http://img131.imageshack.us/img131/1091/victored5.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/6602/camn8n9emediumwu2.jpg (http://imageshack.us)

http://img201.imageshack.us/img201/3939/victormediumyt4.jpg (http://imageshack.us)

http://img144.imageshack.us/img144/7278/victor17mediumkd4.jpg (http://imageshack.us)

http://img131.imageshack.us/img131/4636/img0040iz4mediumyr3.jpg (http://imageshack.us)

http://img144.imageshack.us/img144/1390/img0039om6mediumjf0.jpg (http://imageshack.us)

[Jim Oaks]

http://img131.imageshack.us/img131/2286/variastaller20021mediumlt9.jpg

Pato, where did this shaft come from?

[patov6]

Youtube test:

http://www.youtube.com/watch?v=gyTANAdI62A
http://www.youtube.com/watch?v=PntkssdtbFE
http://www.youtube.com/watch?v=E_IKBg6tVLE

[Jim Oaks]

Why didn't you use the 'electric' part of the BW case?

[Vicho]

http://img131.imageshack.us/img131/2286/variastaller20021mediumlt9.jpg

Pato, where did this shaft come from?
Hi , This shaft was made welding the outputshaft of the BW and the input shaft of the D20.

[Vicho]

Why didn't you use the 'electric' part of the BW case?
Because the electric system is installed at the BW rear...using the D20 in this position, we can´t use it, is a better choice to use a non electric BW case to this doubler .

[Vicho]

Good right up except for one question for you, did you use the stock shaft from the BW case and did it go stright into the D20 case with no mods?? or did you make a new "stub" shaft to combind the 2??

More info on that you be great!!


Thanks
Kris
:icon_thumby:

[Vicho]

a couple of pics installed.

http://http://img174.imageshack.us/img174/3203/paseogaseoducto08070600zt2.jpg (http://imageshack.us)

http://img444.imageshack.us/img444/8112/paseogaseoducto08070600ft9.jpg (http://imageshack.us)

http://img158.imageshack.us/img158/2601/paseogaseoducto08070600io3.jpg (http://imageshack.us)

[4x4junkie]

I've been waiting for this post for a long time now. Glad to see it. :)

How did you seal the shift lever shaft where it comes through the BW case so the oil doesn't leak out?

[4x4RangerGuy]

Me parece excelente Vicho, hace un buen trabajo. Cuánto tiempo duró este proyecto? Los videos son buenos también.

[patov6]

Me parece excelente Vicho, hace un buen trabajo. Cuánto tiempo duró este proyecto? Los videos son buenos también.

El proyecto de la Doubler tomo algo de 1 mes. El trabajo de Victor (Vicho) es excelente, en Chile es muy conocido. Gracias!

The Doubler proyect took close to 1 month. Victor´s work is excellent, in Chile he has a very good reputation.Thanks!

PatoV6

[Vicho]

I've been waiting for this post for a long time now. Glad to see it. :)

How did you seal the shift lever shaft where it comes through the BW case so the oil doesn't leak out?
Hi , I put a couple of O`ring in the lever shaft.

[Jim Oaks]

The Ranger has a low of 2.46:1 and the Dana 20 has a low of 2.48:1. An advantage to the Dana 20 seems to be the possible future of twin-sticks. Actually, if I did this with a 1350 I could have all mechanical shifts without any shift solenoids.

I LIKE!

[patov6]

The Ranger has a low of 2.46:1 and the Dana 20 has a low of 2.48:1. An advantage to the Dana 20 seems to be the possible future of twin-sticks. Actually, if I did this with a 1350 I could have all mechanical shifts without any shift solenoids.

I LIKE!

Cool! That was this thread idea!!:beer:

[sweetsride]

hey, thanks for the info, have you had any problems with the stub shaft?? do you build?? did you get it heat treated??

Can you buld one for me?? i got 3 1350 and 2 dana 20s and have been wanting to do this but live in a small town that i dont trust the one and only shop in town that can do this.


let me know

Kris

[Jim Oaks]

I want one too. I was going to do a 1350/1354, but I like this idea.

[metalmacguyver]

how much adjusting to the drive shafts were needed?

[patov6]

hey, thanks for the info, have you had any problems with the stub shaft?? do you build?? did you get it heat treated??

Can you buld one for me?? i got 3 1350 and 2 dana 20s and have been wanting to do this but live in a small town that i dont trust the one and only shop in town that can do this.
let me know

Kris

I want one too. I was going to do a 1350/1354, but I like this idea.

Let us check the costs ;) and if its feasible.
Pato

[dirtraider]

This is sweet, thanks for the pictures

[sweetsride]

metalmacguyver,

The new transfer cases got just 2" more original length which allows them to be installed without changing any other element as fuel tank, brakes lines, etc…, the result was very good, achieving a dramatic increase in the benefits of the Ranger, and best of all, leaving the minimum alterations onboard.

[metalmacguyver]

i read the post. i just dont like assuming things like that the front driveshafts will bolt to the D20.

PatoV6, do they?

[bobbywalter]

how much testing has been done?

[reddog5]

i like this idea too. I was also lookin at the 1350/1354 combo, but twin sticks sound sweeeeet!

[patov6]

i read the post. i just dont like assuming things like that the front driveshafts will bolt to the D20.

PatoV6, do they?

Ranger front driveshafts bolts the D20 yoke (is well written?). The front driveshaft was stretched, and rear shortened (dont remember how much in both)


how much testing has been done?

2 years, with no issues.:headbang:

[351ranger]

Are you planning a more detailed write up on this? I would love to do this.

[reddog5]

me too.

Not to mention the 3.15 crawler gears from Wild Horses you could put in that D20:icon_thumby:

[patov6]

Are you planning a more detailed write up on this? I would love to do this.

No, but feel free to ask whatever you want ;)

[patov6]

me too.

Not to mention the 3.15 crawler gears from Wild Horses you could put in that D20:icon_thumby:

mmm. i didnt remember that :drool:

I remember, somewhere...(i read that , maybe in tech section)...there are 3:15 gears available (dont remember the exact number) for the Dana 20...is that real? or 3:15 is the max? :icon_hornsup: or upper gears are available?

For the toyotas for example, they have 4.7 and 5.7....:mad:

372x513x248x315= 149:1....not bad!:shok:

[351ranger]

I would like to know the total length of the shaft and was it turned, pressed and welded? or was it just welded and the weld turned down. Is the one end from a EB trans output shaft? Thanks!

[reddog5]

Yeah, Wild Horses has 3.15 gears.They run $825.00. Thats as low a gear as i have found , but i just did a quick search.
You might find some lower ones though....

[AKBroncoII]

I've heard through the grapevine that DD will be offering a 1350/1354 to dana 300 doubler. Due out sometime late spring, early summer.

[patov6]

I've heard through the grapevine that DD will be offering a 1350/1354 to dana 300 doubler. Due out sometime late spring, early summer.

A lot of CR. BTW...what is DD?

[patov6]

I would like to know the total length of the shaft and was it turned, pressed and welded? or was it just welded and the weld turned down. Is the one end from a EB trans output shaft? Thanks!

We have no data of the shaft length now (Vicho dont find the scheme). We fabbed a guide to center both shafts, and a 45º bevel to weld them. And yes, is the one end from a EB trans output shaft (D20).

[4x4junkie]

A lot of CR. BTW...what is DD?

D.D. Machine (http://www.pirate4x4.com/forum/showthread.php?t=465032)

[patov6]

D.D. Machine (http://www.pirate4x4.com/forum/showthread.php?t=465032)

Thanks!