Fitting a rock lobster (SJ) transfer box in a Jimny...

Thank you Dave. I appreciate the info.

Martin. Thanks for your info too. The truth is that I was only looking for the overall length of the SJ shaft so that I could confirm authenticity when I purchase one here. In the Philippines the surplus part vendors will sell parts from SJ410s, SJ413s, JA11s along with a host of other Suzuki flavors and tell you that it is what you are looking for. The fact that there are (at least) 2 SJ shaft lengths will make it more difficult. At least having that knowledge will help my search.

Welcome mate

That was so easy I will ask another favor. This will be dependent on whether you remember at the time.:laugh:

When you have your transfer case in position, would you take a measurement from the transmission output to the transfer case input shaft flange. If you can get that, later, and with your permission, I will add the same dimension for an auto transmission. At least I will after I finally get all of the parts I need. Hopefully the information will be useful to people who find this thread later.

zukebob wrote: . The fact that there are (at least) 2 SJ shaft lengths will make it more difficult. .

Its not a great issue, spacers etc. can sort that. I was just pointing it out.

However, if you are offered parts from early SJ410 then these have "skinny" props, probably from the LJ Series, I would avoid these if possible. They are very thin.

Just looking back at the photos of my previous Jimny build...



This was the Samurai intermediary prop with a 12mm prop spacer added, and that's the gap left...

Not much time today, it's my usual day off in the week, but I've got to take our youngest daughter to the airport this afternoon to resume her dance contract in Malta, so not enough time to work on the buggy today, but a couple of hours to mess about with props?... :woohoo:

I started by disappearing under the buggy to measure it's intermediary shaft as Martin had got me worried especially as my donor Jimny is an old X reg model of 2000 vintage... all ok though, it's 46cm as measured previously...



So I took the Jimny intermediary prop I got from James... marked the middle of it, and then measure 4cm back on either end, to remove a 8cm section, and gingerlly cut one of the lines I had marked... hoping props are hollow?...



Yup, as hoped made of tube



Which is 32mm ID (Internal Diameter)...



Onto eBay and start searching for a tube sleeve insert... I found a couple of sellers but both had the message to say they were away and not processing orders immediately (impatient me!) but then I found good old Tom "pipe-bender" had pieces listed of the right size So I ordered the minimum length of 50cm, even though I only need about 16cm... it's 31.75mm diameter (imperial 1.5") and~2mm wall, so should slide nice and tight into the inside of the prop tube (which is 32mm)

So...



Cut the prop to length... about 8cm shorter, so it's a bit longer than the Samurai prop, to save running a spacer in it



And then drilled four holes in both halves of the prop and bevelled the edges ready for welding up when the insert tube sleeve arrives hopefully before the weekend... I paid an extra £3 delivery for a 24 hour courier...

Inserting the sleeve will keep the prop perfectly straight, allow me to puddle weld through the holes onto the sleeve inside, and I'm hoping it won't need re-balancing as a result...?

Then grind the welds "flat" (or slightly rounded actually!) and repaint the middle of the prop... sorted!