Talk Morgan Forums Community Vehicle Talk (non-Morgan) M3W Homebuild

Last night I worked on the Input shaft for the transfer case. Material started out at 2.5" dia x 6" lg. and turned down on the lathe. Both shafts are now ready for key ways to be done on the mill with the rotary table. I still have to finalize what spline profile and count I want to use and mill those on the input shaft but otherwise they are ready to be heat treated.

I also sent out for quotes to get the intermediate housing plates laser cut (profile only) as they are a bit large to fit on my milling machine for that operation.

Last pic is an "Exploded View" of the internals for the transfer case to show how they will go together.

This weekend I welded up the form for the transfer case castings, poured and decked them. Lots was learned in this process as well. Next step is to make the toolpaths for milling them out into a functional transfer case housing. I am hoping to have the transfer case almost complete by the time I go back to work in the new year, will be a challenge.

Pretty amazing work, thanks for sharing your efforts.

The only bit I don't get is given the skills and engineering handywork how come you are not over-employed and able to pay for the M3W, you seem very skilled.
(You don't need to answer, everyone has their own world, I am just amazed with your skills you cannot afford the M3W!)

Thanks for the update you are very talented, this is by far the most adventurous engineering project we have seen on here

LOL, Yeah I would love to have a real M3W in my garage. I have a wife and 2 kids to take care of (love them dearly) and in my area the salary just isn't there like it would be in a big city. Employers love my skill set and resume but none will pay really well for them. It's taken me about 10 years to acquire the shop tools I have most of them are older than I am and needed refurbishing to make work. My shop has been equipped by doing side jobs with the support of my wife and a couple lucky finds. I can't buy my dream, but maybe, I can build one close enough to it..

Thanks for the kind words.

Amazing skills you have. Looking forward to seeing your progress.

Really nice work! Melting and casting aluminum is yet another skill set you have mastered. I like your design philosophy, I had a Guzzi powered JZR with an electric reverse and engines with perfect primary balance make life much easier. I really wish Morgan had used a 1400 cc Guzzi motor instead of a 56 degree Xwedge that needed the compensator lash up that we live with.
Good job!

Thanks, I have far from mastered the casting process. The JZR is cool looking for sure, They are scarce nowadays though. The guzzi is a good engine and seems pretty common in the "classic" style builds. I absolutely didn't want an electric reverse, especially with the terrain and weather around here.

I honestly believe the Morgan setup would work in my application because of the smooth pulses of the BMW Boxer engine. If I had access to one I would love to fit it up just to see how well it does in comparison. With my design intermediate housing it's simple enough to experiment with.

I have the CNC files almost ready for the transfer case, and will hopefully get them started this weekend. Gotta keep the wife and kiddos happy too though lol.

For Morgan there is a previous, though indirect, history of negotiations with Moto Guzzi for the supply of engines and other components for a proposed series of 100 replica 3 wheelers to be built by Tony Divey at Triking. The concept was to build them for the 100th anniversary and a prototype was partially completed but the management of the day at Moto Guzzi was completely uncomprehending about the potential of the project and offered the required components virtually at the dealer price for a complete finished bike. This, plus Tony's failing health, scuppered the project.

Even with all the good will in the world Guzzi is not an engine supplier and the costs would be undoubtedly higher than the S&S, but given this rather bitter history I doubt that Morgan even considered using Guzzi engines.