1G Designing and Fabricating transfer case cover/brace

[SasaniFab]

I have been thinking about this for awhile now and Ive decided to make my own out of 6061 or potentially something stronger like titanium. Im fully aware you can purchase these from frontline and magnus but Id figured what the hell. One of my ex gfs best friends father has his own machine shop with several cncs/ lathes etc and he loves doing prototyping and designing. He has alot of scrap aluminum and titanium for us to work with. I plan to start work on tuesday. Ill be sure to keep updating id anyones interested. I forgot to ask, does boostin make a 300m output shaft for the transfer case? I looked on the website and couldnt find anything.

 

[lasthope05]

It's pretty easy to make your own. 1/4" mild steel plate with 2 45° bends to go down to the tailshaft and some standoffs. Look at Jeff Bush's transfercase brace. Very easily duplicated.

I wouldn't trust aluminum unless it was very thick.

 

[SasaniFab]

The frontline brace is made out of billet al yes? Most of the people ive talked to have said that most of the strenght needs to be at the cover as the bearing surface rides there... otherwise its just for stiffining purposes.

 

[lasthope05]

Well he says his brace has hit 100s 1.2 - 1.3 60fts and never broke a t case. If his design is good enough for 7s, it's good enough for me.

Also it's the flexing/twisting of the case that allows the gears to spread and crack the cover. The way i see it is to prevent the flexing from happening in the first place and you won't have that problem.