gearboxes and axles

[Steve Kerswell]

So there he is, 4wd kit car with 2.9 of boat anchor and it will not go around corners, " Stevo, what do I do?" chuck in a Rover V8 half the weight, "But how do I keep the 4wd?" well that's a tad more difficult, so what you do is this, get a saw cut off the bell housing, get the Rover bell housing and chop a bit of that off and weld them back together, and bingo you have the full monty, here, just like this !

[Jim (across the pond) Adamek]

Japs continue to take over the auto industry.

[Steve Kerswell]

Back on track, I have hit trouble ! oh oh ! The shaft to the front diff hits the Borg Warner bell housing, more chopping and a bit of planning required, they are talking of off setting the diff further, but I want to keep the shafts as in line as possible.

[Steve Kerswell]

more sawing and filing, I did get to sand the two faces, fell behind today, still waiting on "the engine", have a knackered spare for trying to true things up.

[Dave Adams]

Wondered about this my self getting the input shaft central looks to be a bit of a hassle....

[Steve Kerswell]

Daryl, this V8 thing is rubbing off on me, I'm starting to wonder what I could do with one, or two :-))

Must admit his special Land Rover does sound nice even at tickover.

[Steve Kerswell]

Centralisation jig, to complex to write it all out, but you can see the idea.

[Steve Kerswell]

and this fitted

[James Doulton]

So did you make up the jig using the original bell housing before it was lopped off? And is that the new bell housing being held in place by the jig, using the input shaft as the reference? Is it actually welded or is it just a trial fit? It is starting to look like it was planned!

[Steve Kerswell]

James I said it was complex, here is an abridged version, leaving all the thinking out :-)  The flat plate is a template of the Rover block. Put on with a few bolts, then taking a 2lb. hammer I indented where the spigot bearing was, drilled the centre and found a good fit tube and welded it on good and square. So thats the jig. Engine block mounted on bits of timber screwed securely down. Mt75 offered up with no bell housing, had to drill the spigot bearing to 15mm. So spigot bearing and shaft engaged, reference points from gearbox to the deck scribed. Gearbox out, bell housing offered up with the Transit clutch in place. Gearbox offered up, and leveled all ways. Gearbox is 15mm to far back from reference mark, good, better then being short. Taking the gearbox face as true scribed off 12 mm of Rover ell housing. More cutting and sanding and we are almost there. Reference marks almost right. Then put the two together with the jig and spot weld, with my trusty DC Tig. now need AC Tig to weld it proper. The last photo is how it looks spotted together, the photo makes it look better then it is. As for being planned? I have seen this method done before but abandoned. The real big hurdle is the front drive shaft, it takes out part of the bell housing and the starter motor mount, so I'm looking at a Dave Adams starter motor/bellhousing modification. This has not been an easy job. 3 days of fiddling and trying things, jammed fingers and lots of tea :-) However I can see the light, just hope its not someone with a torch coming at me. Still lots to do, and all I'm getting in return is help to fit the pinto and a Spare V8 Rover motor to play with (I have a Plan).

[Steve Kerswell]

Um, I hadn't thought of that ! Yeah, I don't do technical, just make it happen, head down and charge :-))

[Steve Kerswell]

after a good sleep, common sense has kicked in ! Forget silly engines in silly cars, back to plan A, Pinto and make do. The V8 will be a rebuild and a long think, if this gearbox thing works (if) maybe a 4wd Phaeton, who knows ??

[Steve Kerswell]

I've just read a article on keeping things simple. A Land Rover used to be that, break down 2 days from anywhere and a basic tool kit and a few spares could get it fixed, so I'm hoping the Dutton's will be the same, so I will keep it simple and easy for me to fix.