Tcase replacement gears from better stock...

**Midnightsun300c** · 10-04-2011, 01:16 PM

Hey Tank,

I thought it would be better to move this discussion to your sections as not to monopolize Ski Wagons thread. Both 007 and I have asked you for an approximate price on this... I'm still interested... Could you answer the following? :

What options in steel grade are there?
What is the relative strength characteristics?
What are the relative costs of the different steel options?
What would be your setup cost/price for producing the first one?
What would be your manufacturing cost/price for each one?
If you had some interested buyers, what would be your best guess at a timeline?
If you manufactured the new gears what would be your quality control measures and assurances to the buyers?

I've got plenty more questions but I'll leave it at that for now...

**SKI WAGON** · 10-04-2011, 01:40 PM

Watching with anticipation.

**tank8289** · 10-04-2011, 03:27 PM

To make things cheaper redesigning the gears inside would be much easier. I'm working on a way to simplify things inside there to reduce the amount of material and smaller weaker parts. Possibly even a chain system like the gcsrt8. I will get info and post up both options and pricing.

**Midnightsun300c** · 10-05-2011, 01:02 PM

Originally Posted by Midnightsun300c

Hey Tank,

I thought it would be better to move this discussion to your sections as not to monopolize Ski Wagons thread. Both 007 and I have asked you for an approximate price on this... I'm still interested... Could you answer the following? :

What options in steel grade are there?
What is the relative strength characteristics?
What are the relative costs of the different steel options?
What would be your setup cost/price for producing the first one?
What would be your manufacturing cost/price for each one?
If you had some interested buyers, what would be your best guess at a timeline?
If you manufactured the new gears what would be your quality control measures and assurances to the buyers?

I've got plenty more questions but I'll leave it at that for now...

Originally Posted by tank8289

To make things cheaper redesigning the gears inside would be much easier. I'm working on a way to simplify things inside there to reduce the amount of material and smaller weaker parts. Possibly even a chain system like the gcsrt8. I will get info and post up both options and pricing.

I commend your enthusiasm and confidence in being able to design and manufacture a complete transfer case however I'm only interested in some new gears cut out of better material than the stock gears. You offered in a recent post that you could cut identical gears out of better steel and I am trying to take you up on that offer. Does the offer still stand? If so, could you do your best to answer my prior questions?

**tank8289** · 10-05-2011, 07:48 PM

The only problem is I don't think stronger material for the gears is gonna hold up on very high hp applications with very hard launches. Although will def make it stronger, might not be the best solution. The bed of the input shaft that connects the input shaft to the front wheels is very very thin and would benefit from a thicker bed as that's where these cases break.

**Midnightsun300c** · 10-05-2011, 08:34 PM

Originally Posted by tank8289

The only problem is I don't think stronger material for the gears is gonna hold up on very high hp applications with very hard launches. Although will def make it stronger, might not be the best solution. The bed of the input shaft that connects the input shaft to the front wheels is very very thin and would benefit from a thicker bed as that's where these cases break.

Opinions vary. I'm betting it will hold up well enough depending on the material.
I guess it is a matter of degree.
-stage 1 = cryo
-stage 2 = better material
-stage 3 = better material and a better/beefier design
I don't think that I'll live long enough for a better/beefier design so I'll settle on better material for now, depending on the cost.
You got some numbers?

**Midnightsun300c** · 10-10-2011, 05:26 PM

From Ski Wagon's thread in the AWD section "The Ultimate AWD Build"

Originally Posted by tank8289

I can cut one off gears but will def be pricey

Not sure what your business model is but you've got a paying customer interested in something that you are offering...should I move on or are you actually selling anything with this vendor license?

**tank8289** · 10-10-2011, 07:17 PM

Sorry I've been really busy lately And hAvent been home. I'm gonna gather up some prices this week.

**Midnightsun300c** · 10-10-2011, 07:21 PM

Originally Posted by tank8289

Sorry I've been really busy lately And hAvent been home. I'm gonna gather up some prices this week.

Thanks, I'll check back next week.

P.S.

I agree with you regarding the hollow gear, it does seem to be the weak link. Maybe you could start with a price to cut that alone.

Regarding your idea to redesign that gear were you thinking of getting the added strength by adding material to the inside and reducing diameter of the input shaft? It seems kind of like choosing between a rock and a hard place doesn't it? Robbing from one to pay the other. If you try to increase strength by increasing the outside diameter of the hollow shaft then you would have to reduce the diameter of the inner planetary gears and the intermediate gear as well as increase the diameter of the front output gear. This would seem the lesser of two evils for gaining overall strength but would require a lot more gears being re-cut and the potential of clearance issues regarding the front output shaft gear. What were your thoughts?

**tank8289** · 10-11-2011, 06:37 PM

I was gonna do exactly that re cut that gear in stronger material and go from there. Redesigning the case I was gonna completely change the whole input style because I am not a fan of it at all. I haven't really chosen what I was gonna do there it was gonna be my last option. I'm gonna start with reaplacin that hollow sleeve and work from there. I will have prices soon.