I've had a few questions about this stuff, it should probably be somewhere else besides my stagnant build thread haha:
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.
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.
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.
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
And whala, a rebuildable viscous coupling
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.
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.
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.
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
And whala, a rebuildable viscous coupling
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