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BigJimny Meet 2019 (17 May 2019)

BigJimny Meet and off-road driving day



20TH OCTOBER 2019

BOOKING NOW CLOSED


If you have booked you will shortly receive joining instructions- See HERE for discussion


Noggin and Natter - pre-event chat - Old Bell at Grazeley (part of hotel) 7:30pm 19th October

× Are you building a Mud Monster or a Pavement Princess??
If so you can have your own thread in this section.
This section on other websites has led to arguments and contention. People are posting pictures of their pride and joy and therefore CONSTRUCTIVE comments only please!

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

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04 Sep 2019 17:42 #213145 by Daniel30
Nice..... ;)

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04 Sep 2019 17:45 - 04 Sep 2019 18:08 #213147 by S200KYS
Thanks Guys...

Just need to drill / cut the mounting slot on the little arm and then test fit it before carrying on...

It just needs tidying up a bit as my welding was not up to scratch :( ... eyesight is bad :(

Is It Sunday Yet? ;)
Last edit: 04 Sep 2019 18:08 by S200KYS.

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04 Sep 2019 18:57 #213152 by jackonlyjack
Looking good Dave will do the job :)
Dare i say the only thing i would do different on the lower bend angle
i'd cut the pointy corners off weld in 2 triangle plates to make it hug the box more :whistle:

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04 Sep 2019 19:54 #213154 by S200KYS
I’ll have a look when I test fit it on Sunday... ;)

Is It Sunday Yet? ;)

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08 Sep 2019 21:25 - 08 Sep 2019 21:34 #213303 by S200KYS
Bit more today...



I cut the slot for the sonle mount side of the cradle and then ground and sanded the mount, and then test-fitted the transfer box back in it...



And then under the car for the first time All good!



Nicely tucked up between the chassis rails and a nice angle to ride over anything high enough to get near it!

I just didn't fancy one of those big flat plates under it?... :sick:



And then tapped the breather...



And inserted the elbow



And then hung the cradle and props up from S200KYS's waffle boards to paint them...

Between coats as the paint was drying, I thought I'd fit the...



JimnyBits fuel tank guard..

BUT!



The old (X-reg) Jimny decided to fight back! LOL :lol: and I ended up drilling both the rear bolts out! :(



The fronts came out fine though, and were replaced with new bolts...



The rears had nuts fitted in the voids behind though...



In in the end though! B) Much better protection for the fuel tank!

A second coat of paint, and...



Everything's all ready for reassembly, hopefully Wednesday...?

Is It Sunday Yet? ;)
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Last edit: 08 Sep 2019 21:34 by S200KYS.

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09 Sep 2019 09:46 #213323 by zukebob
Dave. What size tap did you use for the breathers on the transfer case?

I started out with nothing & still have most of it left

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09 Sep 2019 15:05 - 09 Sep 2019 15:06 #213332 by S200KYS
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" ;)

Is It Sunday Yet? ;)
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Last edit: 09 Sep 2019 15:06 by S200KYS.
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09 Sep 2019 15:12 - 09 Sep 2019 15:14 #213333 by S200KYS
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

Is It Sunday Yet? ;)
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Last edit: 09 Sep 2019 15:14 by S200KYS.
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09 Sep 2019 16:07 - 09 Sep 2019 16:09 #213334 by S200KYS
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 B)
.
.
.
Quite chuffed with that... my eyesight still needs some work for welding though :( I might invest in a new helmet?...

Is It Sunday Yet? ;)
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Last edit: 09 Sep 2019 16:09 by S200KYS.

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09 Sep 2019 17:17 #213336 by Lambert
You do do good work even if you're suffering from complications. Nice!

Dreadnaught (black 2011)
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09 Sep 2019 17:57 #213337 by S200KYS

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:

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09 Sep 2019 18:02 #213338 by Riccy
B) 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?

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