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Joined: Nov 2019
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Rob82 Offline OP
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Made some progress today. I got the top half of the transfer case milled out. There is still lots to do on it but this was the hard part. It took just under 4 hrs of machine run time to change the cast slab to this. I have the file ready to do the bottom part tomorrow If all goes well.

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Rob82 #610105 28/12/19 11:52 PM
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Tricky Dicky
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Tricky Dicky
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This is amazing stuff Rob thanks for the update keep them coming. What will you fill the small voids in the casting with out of interest.


2009 4/4 Sport Henrietta
1999 Indigo Blue +8
2009 4/4 Sport Green prev
1993 Con Green +8 prev





+8Rich #610106 28/12/19 11:57 PM
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Rob82 Offline OP
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Originally Posted by +8Rich
This is amazing stuff Rob thanks for the update keep them coming. What will you fill the small voids in the casting with out of interest.


Those will be filled with the TIG welder, I may look into using a tin based alloy as they are not structural. The filler has to be conductive so I can powdercoat it if I want to. The better I get at casting the less that will happen as well.

Rob82 #610108 29/12/19 12:05 AM
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Originally Posted by Rob82
Originally Posted by +8Rich
This is amazing stuff Rob thanks for the update keep them coming. What will you fill the small voids in the casting with out of interest.


Those will be filled with the TIG welder, I may look into using a tin based alloy as they are not structural. The filler has to be conductive so I can powdercoat it if I want to. The better I get at casting the less that will happen as well.

Thank you for the explanation.


2009 4/4 Sport Henrietta
1999 Indigo Blue +8
2009 4/4 Sport Green prev
1993 Con Green +8 prev





Rob82 #610120 29/12/19 08:02 AM
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Great thread.
Following with interest. smile


Graham (G4FUJ)

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Rob82 #610125 29/12/19 09:00 AM
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+1.Great stuff


JohnV6
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Rob82 #610220 29/12/19 10:33 PM
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Rob82 Offline OP
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I managed to get the bottom half of the transfer case milled today. Did a test fit and it looks good so far. I now have a bucket of aluminum chips that can be re-melted into the next part lol. Now it's back to the lathe to make the extensions so I can weld them on. The hardest part of the transfer case build is over now.


[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]
[Linked Image]

Rob82 #610224 29/12/19 11:20 PM
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Great progress thanks again for the update, you have a lot of us hooked on your project.


2009 4/4 Sport Henrietta
1999 Indigo Blue +8
2009 4/4 Sport Green prev
1993 Con Green +8 prev





Rob82 #610275 30/12/19 02:31 PM
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I am glad someone posted the link to this thread in the three wheeler section as I did not know it was here. Agree with all the comments. Very impressive and keep the updates flowing.

What part of PA do you live in? I took my Morgan around the state in the fall with my dad on his Harley. Lots of great roads and things to check out.


2017 M3W Sport Green
2Sharp #610328 30/12/19 09:41 PM
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Rob82 Offline OP
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Originally Posted by 2Sharp
I am glad someone posted the link to this thread in the three wheeler section as I did not know it was here. Agree with all the comments. Very impressive and keep the updates flowing.

What part of PA do you live in? I took my Morgan around the state in the fall with my dad on his Harley. Lots of great roads and things to check out.


I am south west of Pittsburgh. Lots of great rides in my area.

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