Dave's la(te)st buggy build...

Hiya ZukeBob! That's a great name

I used the original tap from Martin's kit - www.bigjimny.com/store/breather-kit-suzuki-jimny-2.html

I drilled the breather in the transfer box out to 9.5mm and then used the same tap as the acle breathers as I used the same size elbow in the transfer box...



I experimented first in an old aluminium body lift spacer block (the same one that was used to beat the front bearings out! ) and drilled and tapped it several times before I was happy to move onto the actual transfer box -



And did that when I was fully happy...

After first buying the wrong size elbow, I ordered a 3/8" one thinking it would be near 10mm, when I actually wanted a 1/8" size? Weird BSPT sizing, the kind folks sent me this chart -



So that I could buy an elbow with a longer thread -



To take 8mm OD / 6mm ID tube, so they all connect up to the 5 way manifold shown with it... so that's

1. Rear Axle
2. Front Axle
3. Transfer Box
4. Gearbox
5. Goes to the top of the snorked for them a ll to breath freely.

Hope that helps?

I'm not exactly sure of the tap size though... Martin might tell you?

Dave "ZookBOB"

Some more photos...

This is the original breather cap still in situ =



And when you prise off the cap you're left with -



And I then drilled it down to this -



And then tapped out to take the breather elbow -



Ta-Da! -



That might help some people searching in future.

Tags - Jimny Origina; / Stock Transfer Box Breathers Tap Thread Elbow

Wit ha spare hour this afternoon...









You can just make out the cutout for the drain in the third and fourth photos...



And I set of my (ZookBOB) HD 10mm bolts and rubber bush stack mounts
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Quite chuffed with that... my eyesight still needs some work for welding though I might invest in a new helmet?...

You do do good work even if you're suffering from complications. Nice!

Lambert wrote: You do do good work even if you're suffering from complications. Nice!

Why thank you kind sir

Hmmm, I though Do Do’s were extinct? :lol:

Nice one Dave! That transfer box bracket looks a sturdy thing.

Do you have one of the automatic welding masks? They make it loads easier when set properly. Mines a SIP and has a few handy adjustments. Just wish it had an airline feed tho.

Your optician might be able to make some special glasses for close work, worth an ask?