FJ40 I call Shipwreck

[SuperBuickGuy]

how to get the stator out... heat

and tap

[SuperBuickGuy]

Part 1 of the welder series
as you know, I had the parts for a 200 amp CS130 alternator

this didn't look terrible except the stator was cooked - brushes looked new

the rotor looks new too

the new stator

to get the stator out, simply head the housing with a torch to at least 220

when you reassemble, use the rear housing as the 'press' the other reason to do this is so your field wires go through the case.

it's at this point that you need to think where you want those wires to exit (you can rotate the stator)
for mine, I want it to come out about where the rectifier/regulator plug exits

got a boatload of parts of the last several days. I'm still missing the coolers, transient voltage suppressor, and the voltage regulator... no big deal, I'm also trying to find some parallel connectors and I still need to build a box to house all of this... the next installment will be that.

[SuperBuickGuy]

coming soon

[SuperBuickGuy]

part of my day was this

and I admit I'm working on getting to the comfort level to disassemble and tap the box

did drill and tap the clamp

and ugh
not sure why the grill isn't lined up anymore...

I did set the system to draining - and hopefully that will contain the mess that's coming next

[SuperBuickGuy]

well... game on

mental note again... this pan leaks

pilot holes drilled... there are blank space so maybe it's right

then drilled and tapped twice (first with a taper tap and then with a bottom tap)

aforementioned homemade bottom tap

so fun fact, there are supposed to be 2 sizes of balls here... there aren't... but before I measured I spent a minute trying to determine a visual difference

success?

it even turns


so here's the deal, a complete system is about $2500. That includes a new steering gear. Of course, that isn't a Scout 2 gear - that adds at least another thousand (presuming you can find one that is rebuildable).... so $3500 for a basic system without pump. I have about $425 in this. Was it worth the fear? hopefully.

[SuperBuickGuy]

upgrade complete... even works

[SuperBuickGuy]

drove it, that was interesting

I knew the travel on the cross shaft was 6" but, according to the trailgear website, dana 44 needed 8" travel. It trumped my thought....

nope, needed the 6" one. With that said, I may have just decided to put this ram on my Blazer so it's a no harm no foul (and was what got me to order the 8" one)
ah well, the new one will be here next week I'm sure... by then I should be deep in the welder

[SuperBuickGuy]

In other news, this is progressing

[cstmwgn]

In other news, this is progressing

Those are KOOL crimpers for larger gauge lugs

[SuperBuickGuy]

Those are KOOL crimpers for larger gauge lugs

hardest part was finding copper crimps...

[silver_bullet]

hardest part was finding copper crimps...

Try industrial electrical supply sources.... Grainger likes their stuff tho... A LOT....

https://www.delcity.net/store/Batter...mp-Tools/p_102

https://www.delcity.net/store/Non!In...01870.h_801871

[SuperBuickGuy]

doors on


then pull the steering box.... fudgelsticks... well, what I said did start with an f
I thought I might be missing a bearing. maybe? but somehow a bearing got jammed on the worm gear and carnage ensued


the inside of the other bit doesn't look any better.... but at least I got the holes bored correctly.... winning? yeah, no
I also got the 6" assist. This is a lot better... of course, without a steering box, it ain't much good



so at some point in the near future, I'm going to have to deep dive interchangeability of parts. maybe I'll get lucky (nope) and the hydraulic bit interchanges with something else.
Learnin'

[silver_bullet]

I have confidence in your abilities to get this figured out !

[DanStokes]

Try industrial electrical supply sources.... Grainger likes their stuff tho... A LOT....

https://www.delcity.net/store/Batter...mp-Tools/p_102

https://www.delcity.net/store/Non!In...01870.h_801871

I've used Del City, too, mostly for clear shrink wrap for wire identification. Can't buy it locally. Customer service has been great so far.

[SuperBuickGuy]

I have confidence in your abilities to get this screwed up more !

There, fixed it