My Senior design project - a "Swamp Thing" tracked vehicle clone

[strantor]

I used 1/4" thick laminated safety glass - same as a car windshield. The cost was $170.

Thanks. Where did you get it? Do you order it a specific size? Does it require rigid mounting? I ask because I've wanted to put a windshield on my buggy for some time but not sure what direction to go. I've used lexan/Plexiglas in similar situations in the past with poor results. It becomes scratched and hard to see through in short order. Windhield glass is much better in this regard but I am nervous about flex in the fame of the buggy snapping a glass windshield. I know it to be very impact resistant as I've tried breaking a windshield with a hammer before and had it bounce right off, but the flexing is a different thing that I don't know about.

 

[Garauld]

I ordered it from a local glass shop. I made the frame 1/8" larger in all dimensions and just glued it in with RTV silicone rubber.

 

[Garauld]

I picked up the used NV231J transfer case case the other day and promptly disassembled it for inspection after I got home. It appeared to be in very nice shape. I had planned to remove the front output shaft and chain to save weight if I were to install it. As I mentioned in an earlier post, I plan to invert it and use it as a speed increaser (ratio = 2.72:1). I measured it up and modeled it in cad to verify it will fit within my tub frame. The attached image shows what the planned installation would look like. I think it fits nicely. I plan to shift it using a small linear electric actuator hooked up to the shift arm. I measured the required torque to shift it at about 100 inch-#. A few magnetic proximity switches could be used to light up leds on the dash to show what range it was switched to.

 

[Garauld]

Today I started making up the TC support brackets and laid out the planned arrangement of the linear actuator that will be used to shift it. All the parts I need to install it and make it functional are on order. I hope to get it running before the next major snowstorm.

 

[Xfaxman]

 

[Garauld]

Today I started on the "transfercasearectomy". I pulled out the seats, steering controls and the driveshaft. I then set the transfer case into the approximate location to check for interferences. Over the last few days I mocked up a test harness to check the operation of the linear actuator that will be used to shift the tc gear ratios. Yes, that wiring mess actually works!

 

[ArlyA]

And of course, I am following as to how this latest modification goes. :thumbsup:

 

[Garauld]

I spent the weekend making up the two new driveshafts for the tc installation. Have a looky. The biggest pita was making the jig to align the two shaft ends as shown in the first image. After welding I straightened both driveshafts to about .005" tir. That should be close enough. :thumbsup:

 

[Garauld]

Today I collected the speed changer parts and attempted a dry run before freezing my arse outside installing them. This rats nest worked just fine.

 

[Garauld]

Here's a photo of the installed speed changer setup before I put the floor plates back in. The system works as planned. I hope to take it for a quick test drive before the big storm comes thru Wed.