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

Nice.....

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

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

I’ll have a look when I test fit it on Sunday...

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?...



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 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! Much better protection for the fuel tank!

A second coat of paint, and...



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

Dave. What size tap did you use for the breathers on the transfer case?

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?...

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?

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?