Max’s Roxor Build

[Roxasuras]

Planned obsolescence my friend

 

[Max A.]

Today I was able to got my proof of concept done to where I’m confident my plans will work.

With the box placed where I wanted it I realized that there may be a fairly simple way to mount this box to the frame.

The unused shackle mounts that I decided not to cut off while I was cleaning up the frame lined up pretty close to where I ultimately wanted to be.

I used the plasma table to make centering spacers, ran a bolt through the center and into the lower mount of the box. It worked perfect. The box clears everything and there is plenty of room to pass a shaft through the window in the roxor front crossmember. It is tucked up nice and high, out of harms way. I will still skid plate it.

I am now going to work on making a permanent relocation solution using the shackle center as my point of reference. Once all mock up is done I’ll switch out this old box for the new PSC hydro assist box.

Man my roxor looks like a mess in these photos. I’m going to give it a good power wash and repaint before Moab in a 2 months.


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[Roxasuras]

Looks like you have a good plan,

 

[Kake America]

That almost looks simple now! Just kidding love your confidence and the improvements your making

 

[Max A.]

Blew up my little commuter car. No time to waste with the alternative being a 10mpg gas 2500 truck… slapped a junkyard motor in it and we are back on the road. 40mpg when gas is $4.40 a gallon is nice.

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[Max A.]

Made a template of the 2 patterns that I need to combine. Transferred that onto a 1/4 inch piece of plate. It hand cut it to fit inside the frame but the final product will be produced on my plasma table. I should be able to run this prototype for a while before I finalize a kit if I decide to go that way.

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[Roxasuras]

Blew up my little commuter car. No time to waste with the alternative being a 10mpg gas 2500 truck… slapped a junkyard motor in it and we are back on the road. 40mpg when gas is $4.40 a gallon is nice.
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You need to make this an off-road machine

 

[txroadkill]

You need to make this an off-road machine

Too small. Go big or go home

 

[Max A.]

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[Max A.]

Fun little lathe project tonight. Turning a roxor leaf spring bolt into a steering shaft adapter. One down one to go.

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[MaXXis85]

slippy fit to make it work!!

 

[Max A.]

Documenting part numbers In case anyone needs this in the future.

Borgeson 114931 Steering U-Joint, Stainless Steel, 3/4DD X 3/4-30

And

Borgeson 450036 Steering Shaft; Telescopic; Steel; 36in. Extended Length


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[Max A.]

This project is a pain in the a$$!


Made the final plate. Had to adjust from the mock up because the XD PSC box was a little bigger and contacted the frame. The center hole rom the unused stock shackle hanger no longer worked. I got a chunk of aluminum to put on the lathe and machine out a eccentric press in insert to lower the box. This also was used to position the box so that the pressure and return lines had space to connect behind the winch plate.

The box now lined up perfectly with the pass through for the steering shaft.

I drenched everything in lock tight so we won’t have any bolts backing back out. There won’t be an easy way of tightening things up after all the lines are installed.


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[Max A.]

I was getting only 1 turn lock to lock out of the steering wheel. This would make fore some very twitchy steering at speed. I also compressed the suspension to see how close the pitman arm would be to the tie rod ad full compression as the wheel base grew. It was too close for comfort. Leaf springs only keep the axle in a general area. They tend to do funky things sometimes and I definitely don’t want linkage contact or a broken sector shaft.

I figure I could kill 2 birds with one stone. I did the overwhelmingly complex math to figure out that the pitman arm could be shortened a little over an inch to correct the arm throw. I now get exactly 1.5 turns in each direction and the added inch or so of clearance on the linkage is a welcome bonus.

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[Max A.]

Next is tackling the pump mount. I wanted to keep it in the same location and drive pulley as the stock pump. The PSC Toyota pulley was the right size Vbelt and should spin fast enough for the pump to work efficiently.

I stared at this thing for 2 days before I came up with a mount in my head. Then in was down to the basement to draw it up and press print. Here is what I came up with.

The tensioner was made with a pretty simple concept. A threaded piece made on the lathe with a bolt hole that would bolt to the the factory tensioner plate on the motor. The pump side would float on the threads with a tightly machined tube with a mounting tab attached to the pump via the unused bolt holes on the bottom. Double 1/2-13 nuts will tension the belt and lock it in. A 31 inch belt (15310) worked perfect.

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[MaXXis85]

Most folks would stack washers to make a sleeve. Mr Fancy with his Lathe!

 

[txroadkill]

Most folks would stack washers to make a sleeve. Mr Fancy with his Lathe!

And yet others would use a stack of nuts and washers….

 

[Max A.]

Reminds me of the conversation I had with the guy that bought my grand wagoneer.

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[Max A.]

That was an alternator mount . Moving on up in this world.


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[txroadkill]

You ever thought about fabbing up a york compressor mount for on board air?