TehRaydarlover's AWD Lover

[TehRaydarlover]

hey cool - never seen that type of VC either. Makes you wonder if there's any center VCs like that!

Yeah that would be awesome to find one like that. After seeing this one, I have two center VC cut open that I'd like to try and modify with a removable end. I have an idea of how to do it but we'll see if it works out. It'd be cool to "easily" test out different viscosity levels for the silicon fluid.

[TehRaydarlover]

I finished the diff rebuild write up on the previous page, let me know if I F'd something up or need to clarify anything. :D

[TehRaydarlover]

I'm in the process of stripping off the undercoating in the "problem areas". I always knew my car had some rust on the underbody but this is kind of shocking. I'm honestly surprised the drivers side spring perch didn't just collapse. If anyone has any rust free patch panels... I'm in the market :/ I don't want to live in the midwest anymore... #justixthings

[TehRaydarlover]

Little up date on things, I bought a parts car from NM to cut out all the rust patch panels I need. Also bought some new body panels and some rims, kind of keeping things under wraps for now, hehe.

[TehRaydarlover]

Finished up another little side project. A rebuildable viscous coupling. First started with cutting a burnt out one open on a lathe.


The basic idea was to add an extension to the VC barrel for the addition of an o-ring groove and a snap ring groove. After taking a few measurements I mocked everything up in autocad. I rough machined the ring from CA40 420SS and welded it to the VC.



The cover that was removed from the VC was machined to the max ID of the stator plates. Then the VC extension was finish machined for a 0.001"-0.003" loose fit to the cover. Then the o-ring and snap rings were added.



And whala, a rebuildable viscous coupling

[audiquattrot]

oh man was wondering what was going on with your build....that rust sucks! I wish we didn't have to drive on salted roads, but thats just the name of the game.

I just coated the undercarriage of my car w/ Formula 3000. hoping it will help even just a little from this winter.

[Julien]

Great build thread, loving the engineering work

[TehRaydarlover]

oh man was wondering what was going on with your build....that rust sucks! I wish we didn't have to drive on salted roads, but thats just the name of the game.

I just coated the undercarriage of my car w/ Formula 3000. hoping it will help even just a little from this winter.

Yeah it was pretty shocking and depressing when I stripped everything down, but now I've got all the panels to make it new again. I'm going to strip all of the undercoating off and paint everything in this industrial epoxy we use on salt water pumps at work. should hold up well haha.

Great build thread, loving the engineering work

Thanks!

[TehRaydarlover]

Fill hole has been drilled, reamed, and tapped for a 3/8 NPT plug. I also made the custom 0.070" o-ring. Hopefully next week I can pressure test everything and put it together for real.

[stonea]

Man its been a while since I've seen this thread. Great work, we need more ix love on the forums.

[Nisse Järnet]

Nice work!

[TehRaydarlover]

Thanks guys!

I added a small anti-rotation pin to the cover. There shouldn't a lot of torque put on the cover with in service but just in case, I wanted to make sure it couldn't go anywhere.

[burkey001]

hope you enjoy my ID1000 fuel injectors via ebay

[TehRaydarlover]

I'll try to use them to their full potential haha!

[TehRaydarlover]

Custom O-ring made


Pressure test was a success! I'm not sure how much pressure I tested it at but shop pressure is 125psi. I just cracked the valve for a second and let it sit overnight. Still was pressurized in the morning. :D


I filled the VC last week after work. Ended up using roughly 3 parts 100,000 cs and one part 60,000 cs silicone fluid. Unfortunately, I only have the one picture, my hands got covered with silicone haha. My method was to add silicone slowly as I added plates to make sure every plate had a film. I used a hand press to push the plates down and squeeze out the silicone as I added more plates. I kept having an issue where when I pressed the plates down the center sleeve would rise up with the silicone, disengaging the first few plates in the bottom of the VC. Had to be very careful to push it back down with out turning it and having the splines get misaligned. With all the plates and spacer rings installed I put the cover on and installed the snap ring. I made sure it wasn't over filled by leaving the fill plug out and removing any excess silicone. Some thread sealant on the pipe plug and its all ready to go. I'm going to try and reassemble the transfer case this weekend with all new bearings, seals, gaskets, and of course the "new and improved" VC :D