BUILD YOUR OWN "ROCK-CRAWLER"

Gunta · Post by **Gunta** » Fri Nov 04, 2011 2:43 pm

You are making me jealous

THROTTLE-BOY · Post by **THROTTLE-BOY** » Wed Nov 09, 2011 6:39 am

:) Got stuck in yesterday and started looking at the fitment of the transferecases.....this is going to still take a bit of "Kopkrap" as I need to make an adaptor Between the NP205 and NP203. The Np203 fits between the gearbox and the other case to make up the "Doubler" which will give a first gear ratio of over 200:1 in "Crawl gear".....

Got all the airsprings plumbed in last night and the system works perfectly.

I now have control of each airspring, they can be inflated and deflated in seconds giving many ride configerations at the touch of a button.....Gotta get this Rig finished so I can Wheel it !!!

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Mr_B · Post by **Mr_B** » Wed Nov 09, 2011 8:42 am

I'm beyond jealous already... and be aware there's a growing group of lurkers watching this thread with keen interest... yes you Ford/Jeep boys, you know who you are!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Wed Nov 23, 2011 8:11 pm

Well I got the drivers side B-pillar brace welded up and dressed both and fitted them in position. Thats one more thing off the list of things to do.
Next thing on the build is the Exhaust system.....this is the fun part ! I have a bunch of 42mm mandrel bent tubes and some 76mm that will go to the box. A friend gave me a Borla racing box from the States that I'll be fitting. I got the flanges water-jet cut and they still need to be port matched to the heads so theres no flow restrictions. This will be a fully TIG welded system so it should come out good looking as well !

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THROTTLE-BOY · Post by **THROTTLE-BOY** » Sat Nov 26, 2011 7:24 pm

Got stuck in on Friday and removed the rear temporary air-spring posts so the rear tubes and fuel tank could be fitted......

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honneysett · Post by **honneysett** » Sun Nov 27, 2011 12:17 pm

Hi see you got 404 mog axles, Where did you get the disc modifications for it or did it come with the diffs. Have some under a 1956 CJ6 Jeep and it came with drums, would like to change them perhaps run smaller rims at the moment running stock mog rims with 12.50 -20 tyres.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sun Nov 27, 2011 8:16 pm

I'm also running drum brakes at the moment ! I put a set of 15" rims on the diffs but I have plans to fit a set of discs later. I had a set of inners laser cut with the Mog P.C.D and then welded them in before making the bead-locks. I have some ideas for the disc brake conversion....

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Hoppy · Post by **Hoppy** » Mon Nov 28, 2011 8:32 am

Is that the T case with the disconect on the rear propshaft? What ratio will you be running in the T case?

THROTTLE-BOY · Post by **THROTTLE-BOY** » Mon Nov 28, 2011 4:45 pm

Thats the NP205 casing in the pic....I have already done the twin-stick conversion to the selectors of the box that will be the same as the rear disconnect.
The 205 has a 1.98:1 ratio and the NP203 is about 2:1. The gearbox I'm using has a "Granny" first so with the whole combo takes the ratios to over 200:1 in first.
With the twinstick set-up you can run 2x4 front in high,low and crawl....2x4 rear in high ,low and crawl and 4x4 in high ,low and crawl. I'll be doing a set of cutting brakes on all 4 wheels and have pnuematic cyl for the Mog mechanical diff locks as theres already air on board.

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Mr_B · Post by **Mr_B** » Mon Nov 28, 2011 4:58 pm

Dang... hopefully I'll see this beast in action one day!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Mon Nov 28, 2011 5:16 pm

I can't wait myself.....I'll have to come visit and drive over that flat mountain You guys have down there

Post by **Mud Dog** » Mon Nov 28, 2011 11:05 pm

Awesome project Mark!

Taken quite some time but it seems to be coming together now!

(Just don't cut any corners in the final thrust to get it finished.

)

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sat Dec 03, 2011 7:18 pm

It has taken some time but I worked out the other day that We(M&P FABWORX) have built 5 serious compertition vehicles and the first right hand drive JK Jeep with a 6.4 Hemi called Genesis inbetween working on 2 Crawlers as well.Then theres the diff mods, 4-links ,odd roll-cages and go-carts that still had to be looked at

and all this after a full days work as all this is after all a "Hobbie",passion ....Drug .....call it what You may !

I landed up re-doing the rear 4-link about 5 times as it had massive anti-squat. Far more than I was happy with .....the anti-squat is now acceptable and the whole Rig will lauch off the line as expected ....without spilling a Beer!

I added some essential bracing on the rear off the Rig on Friday and this will add considerable strength to the "B" pillar section and also control all of the stresses from the rear suspension that will be transfered to the whole frame work. The roof has also been strengthened with extra triangulated bracings that will give the drivers cell maximum strength in the event of a decent roll.....which off course I'm not planning at all

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legend35 · Post by **legend35** » Sat Dec 03, 2011 8:45 pm

O no Mark.I dont think that flat mountain of the capies is challenging enouth for that RIG of yours

Looking very good

Post by **Mud Dog** » Sat Dec 03, 2011 10:11 pm

Awesome build, Mark.

There's only one thing your that rig might be short of, and that's rear wheel steer for those tight obstacles, but even without it, it's going to be a formidable contender.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sun Dec 04, 2011 4:25 pm

legend35 wrote:O no Mark.I dont think that flat mountain of the capies is challenging enouth for that RIG of yours Looking very good

Nay my bra ....those dudes will flip if you even touch their bergie!!! :wth:
I had a rear Mog diff in the back..... but I don't think my style of driving would have mixed too well with a rear steer ! I'd probably roll it on a level piece of road

I have a spare diff for a rear steer set-up and theres space provided for turning on the cage as well .....thats plan B!

Post by **Mud Dog** » Sun Dec 04, 2011 7:08 pm

THROTTLE-BOY wrote:
legend35 wrote:O no Mark.I dont think that flat mountain of the capies is challenging enouth for that RIG of yours Looking very good
Nay my bra ....those dudes will flip if you even touch their bergie!!! :wth:
I had a rear Mog diff in the back..... but I don't think my style of driving would have mixed too well with a rear steer ! I'd probably roll it on a level piece of road I have a spare diff for a rear steer set-up and theres space provided for turning on the cage as well .....thats plan B!

Just checking to see that you thought of everything.

Hoppy · Post by **Hoppy** » Mon Dec 05, 2011 9:14 am

i am not that fond of rear steering, makes it to easy and it looks more like a construction machine.

Post by **Mud Dog** » Mon Dec 05, 2011 2:22 pm

Hoppy wrote:i am not that fond of rear steering, makes it to easy and it looks more like a construction machine.

Me neither .... as far as I'm concerned, it makes the rear drive a weak point. But the guys that set up / lay out some of these extreme courses purposely include a tight obstacle here and there because so many okes with pipe cars have rear steer nowadays.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Mon Dec 05, 2011 10:57 pm

Mud Dog wrote:
Hoppy wrote:i am not that fond of rear steering, makes it to easy and it looks more like a construction machine.
Me neither .... as far as I'm concerned, it makes the rear drive a weak point. But the guys that set up / lay out some of these extreme courses purposely include a tight obstacle here and there because so many okes with pipe cars have rear steer nowadays.

I agree the front diff in the rear doesn't work when it comes to strength!!!
I've seen some drivers with all the bells and whistles take so bloody long in an obsticle that you can see the grass discolour as the season changes. BORING as hell , :evil: thats why theres cutting brakes for tight turns and roll-overs when you don't make the turns,after all we aren't driving grocery getters !!!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Thu Dec 08, 2011 6:17 am

Loaded the Crawler yesterday and took it home....I've got some holiday work to be done on it ....

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ChrisF · Post by **ChrisF** » Thu Dec 08, 2011 6:30 am

Mark if you dare put foot on Table Mountain - PLEASE call me first .... I will be there with my cameras to record the event :)

but I have to agree .... this little hill on our voorstoep wont offer much of a challange to that beaut of a machine.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Thu Dec 08, 2011 6:35 am

I'll call You first Chris.....I have already entered the Rig into an Extremeshow next year June out here in the Vaal so the clock she is a ticking !!!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Tue Dec 13, 2011 10:15 am

Got back from a great week-end at Moegatle and also got my complimentary voucher for a Roll,Recovery and pin-stripping !

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Started working on the branches for the Crawler yesterday as the week-end has given me new inspiration to get this Rig done soon !

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witmamba · Post by **witmamba** » Tue Dec 13, 2011 1:07 pm

Hey Mark - any more pics of Moegatle???
Stop being stingy and post those peekchaz!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Tue Dec 13, 2011 3:28 pm

What a Rip at Moegatle.....Friday night at 6 started a night-drive and got back to camp after 12.....after puttin No7 on its roof in a donga that had the gearbox oil running over us while still in the Rig. Saturday did a couple of really cool serious obsticles and landed up at "SledgeHammer" and "Propshaft Alley".....got through all that with not many casualties.....drove again till into the night.
Sunday was the real day we all waited for..... The Rock it'self.......

Theres enough Rock there to keep any crawler busy for a while......Drove most of the rockcrawl comp obsticles and then went on to run the Tsogwe Trail......
I love the Tsogwe trail as We helped lay it out a while ago .....it's about as rough as a Rhino's nutsack and theres almost a 100% chance of some or other RockRash.....As expected No7 took a bad ass line and I landed up on dislodged rock the size of a coffee table that pushed the Rig on it's righthand side standing at about 70 degrees on only the right front wheel facing down the mountain side......Now that was the highlight of my trip

Revved that 8 plug till the oil light came on !!! After about a half on hours recovery we got loose and down the mountain we went.....I'll do it all again any day .....great crowd of guys and a magic place to wheel !

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witmamba · Post by **witmamba** » Tue Dec 13, 2011 3:40 pm

Jis, I'm sorry I missed it. Was looking forward to going along. Glad you guys enjoyed it though.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Tue Dec 13, 2011 10:50 pm

Hansie You would have had a good time had You come....Planning a "Shake-down" week-end for the Crawler when its done at Moegatle for some testing ....will let You know ahead of time !

Spent an hour or so on the branches today and they are already taking shape.....one more tube to fit on the left bank....this past week-end really motivated me for this project !

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Post by **Mud Dog** » Tue Dec 13, 2011 11:20 pm

Looking good! I see you're planning on 8 into 1 .... would have rather done two pipes myself. Not a lot of space to get to the bolts, but thank goodness for ratchet handles!

Great work! Keep it up!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Wed Dec 21, 2011 10:00 pm

Finished the left sides branch today and will get the rest of the system fabbed up tommorow.

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ChrisF · Post by **ChrisF** » Thu Dec 22, 2011 6:58 am

Mark looking at those pics I have bad news for you !! DONT bother bringing that rig to Cape Town - driving over Table Mountain will be less exciting than going down your driveway !!!!!!!!

Man, you guys are insane in the most fun way possible !! :)

witmamba · Post by **witmamba** » Thu Dec 22, 2011 7:39 am

Those branches look mean! - you won't buy that setup over a Midas counter....

THROTTLE-BOY · Post by **THROTTLE-BOY** » Fri Dec 23, 2011 12:57 pm

You Guys crack me up....Got the exhuast almost complete by last night , still have the last bend or two and then the Borla box. I have a feeling this Beast is gonna be 'Offensively' LOUD.....That should take the guess-work out of were the Dwangs hitting the fan !!!

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THROTTLE-BOY · Post by **THROTTLE-BOY** » Fri Dec 23, 2011 7:49 pm

Crawlers Exhaust done and dusted.......now theres about a days work left to TIG weld it all up and dress everything. If this system sounds as good as it looks I'll be happy !!!

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Post by **Mud Dog** » Fri Dec 23, 2011 11:22 pm

Mark, educate me! As I understand, a branch is intended to create equal lengths of pipe for all cylinders .... that doesn't seem to be the case here ..... or am I looking skeef? I also notice that both sides are different. You've gone through an awful lot of effort to create that setup ...... an explanation please, I'm confused.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sat Dec 24, 2011 12:53 pm

Over the years I've built many high performance exhaust systems and it's dyno proven that the size of the primary tubes are more important than the length of the primaries. The ideal length for a 4 into 1 design for a 350 Chevy is between 32 and 36 inches long....the size of the primaries and length both contribute and can be tuned to where the motors torque band will be in conjunction with the chosen cam....the longer the primary tubes the lower the torque band will be and keeping the primary tubes smaller will benifit higher gas speeds and improve the "Scavenging" effect of the exhaust system. This will prevent spent gasses from re-entering the cylinder heads and contaminating the fresh fuel-air mix......the scavenging effect also helps draw the fresh mix into the cylinder head.
I placed my motor off center by 60mm for many reasons that will be necessary later in the build.....more space on the drivers side as this will be a left-hand drive Rig....( throttle ,brakes and clutch),the transfere case off-set weight including prop weight and angles of aproach to the Mog diffs. The passenger sides tubes are fabricated on a vertical plane compared to the drivers side as space in the frame was limited ....so yes it looks different on the pics.If You've ever built a Rig from scratch you soon learn to plan the whole Rig out in your head .....making sure that what you put in today won't foul something tommorrow ! I hate doing anything twice so I've I've learnt to rather think everything through carefully ......5 hours of planning and 1 hours work !!!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Tue Dec 27, 2011 5:19 pm

Got the Borla Box fitted ,the fuel cell is in position and the radiator has been put in place to check for any clearance issues......none so far . Now I need to make up some permanent mount brackets and weld on some aluminium bosses to the side tanks fo final fitment. I got some 32mm 316 stainless steel tubing and bends for the radiator piping to the motor.

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witmamba · Post by **witmamba** » Wed Dec 28, 2011 7:38 am

Taking shape nicely - glad to see you reaping the fruits of staying at home in December

THROTTLE-BOY · Post by **THROTTLE-BOY** » Wed Dec 28, 2011 9:22 am

Hi Hansie ....I take it You are back at work already.....that sucks Boet ! I've done more this past week than I've done in the past 2 months on that Rig and it's starting to take shape!

This thing must run early next year !!!!
I got my bead-lock bolt protectors fitted. They are CNC machined from aircraft aluminium and I had them "Gun-coated" for added protection in the rocks. They serve 2 purposes.....firstly to protect the cap-heads and secondly they add exrta traction on the rocks when you are on your side and trying to get out of a bad situation.....and usually into a worse one !!!

The first pic is with the washes only befor the change over !

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Post by **Mud Dog** » Wed Dec 28, 2011 4:48 pm

Looking smart! Getting anxious myself now to see the rest come together!

witmamba · Post by **witmamba** » Thu Dec 29, 2011 1:55 pm

Really awesome work!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sat Jan 07, 2012 7:28 am

Thanks Hansie....started planning out the dash for the Rig with some cardboard templates. This still needs to be fabbed out of aluminium so theres a bit of planning still before the first cutting gets done !

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witmamba · Post by **witmamba** » Sat Jan 07, 2012 7:33 am

Looks good, it won't bugger around too much with your view of the wheels/ line of sight.

Post by **Mud Dog** » Sat Jan 07, 2012 7:35 am

..... Taking shape! .... Pun intended!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sat Jan 07, 2012 8:35 am

witmamba wrote:Looks good, it won't bugger around too much with your view of the wheels/ line of sight.

Not at all, theres as set just on the centre-line of the stearing where the dash will drop at an angle so the front wheels can be seen. You must come visit the shop in next week.....it's going back on monday. Will We see on Sunday ?

witmamba · Post by **witmamba** » Sat Jan 07, 2012 8:42 am

:? :|

THROTTLE-BOY · Post by **THROTTLE-BOY** » Mon Jan 09, 2012 8:23 pm

Back at work again .....took No7 to the shop for some repairs after Hiedelburg yesterday.....blew another Longfield 30 spline.....so after work today there was a stripshow and this is how looks......

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Got the Crawler loaded this evening and it's to the shop tommorow for some serious afterhours attention !!!

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witmamba · Post by **witmamba** » Tue Jan 10, 2012 9:01 am

Looking flippin' good!!!

witmamba · Post by **witmamba** » Thu Jan 19, 2012 7:37 am

update???????

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sun Jan 22, 2012 11:45 am

No new work has been done on the Crawler......We are busy at work which is always a good thing and M&P Fabworx has 5 Rigs booked in already.....at the moment We're fitting a solid front axle with cross-over steering and 35's into a Hilux that had the independant "MallRat" set-up from the factory. This is going to be a serious Rig as the owner's plans are big and He's also not scared to wheel what He's got !

THROTTLE-BOY · Post by **THROTTLE-BOY** » Tue Mar 20, 2012 8:27 pm

Got started on welding up my branches for the first time today and it was well worth the effort.....theres always someone elses parts that need attention before your own .....heres a pic of the Hilux that had it's IFS yanked out and we fitted a solid front axle with a set of 35's....theres still the Exo, front and rear bumpers and a 4-link later.....the Lexus was fitted by a friend so it's almost time for a good shake-down with this Rig. Still have to build the exhaust system as well......

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Johannes van die See · Tue Apr 17, 2012 3:47 am

THROTTLE-BOY wrote: Heres the diff between a Dana 60 front sideshaft compared to the Mog's
attachment.jpg

Help my gou reg hier asb, is die onderste sideshaft wat gebreuk is die Dana 60 sideshaft en die boonste een die Mog sideshaft?

Post by **Mud Dog** » Tue Apr 17, 2012 7:28 am

Nee Johannes, hulle hoort bymekaar .... dis een kant se stel. Die rollerball cage het female splines binnekant waarin die langer shaft pas ... ander ent gaan diff toe.

THROTTLE-BOY · Post by **THROTTLE-BOY** » Sun Jun 08, 2014 6:04 pm

Well it's been more than 2 years since I last posted anything on this forum......no real reason other than It's been a crazy past 2 years and We've (M&P Fabworx) have built a lot of new Rigs and parts and in doing so have placed our personal Rigs on hold........Proud to say theres been 2 serious National winning Rigs born out of this......Gavin's fastest senior eliminator at Tarlton ......taking National Honours 2 years in a row and Leon's Class 3 National Challenge Rig which was built end of last years and has already had huge results with 3 class wins in a row............

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Now back to my Crawler.... We decided that this year would be dedicated to building our Rigs and getting them completed.....so far alls going to plan. I yanked out the L82 Chevy TPI motor and dumped it with the branches. I bought a LS1 04 Corvette motor......there was way too little space in the original frame and this was the perfect time to chop the front-end of the Rig off and get it redesigned for a 2014

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Post by **Mud Dog** » Sun Jun 08, 2014 9:30 pm

Congrats on the successful builds.

As for your own, looks like the saga starts again, but with a few steps back.

Hangover · Post by **Hangover** » Mon Jun 09, 2014 9:43 am

Come now mark... Share the pics on facebook of the beast...

THROTTLE-BOY · Post by **THROTTLE-BOY** » Mon Jun 09, 2014 9:01 pm

After getting the nose done.......another set of branches had to be built for the LS1

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Mars · Post by **Mars** » Wed Jun 11, 2014 11:26 am

Unbelievable job you are doing! Hope you get the time to finish this project now. Can't wait to see the end result!

THROTTLE-BOY · Post by **THROTTLE-BOY** » Thu Jun 12, 2014 9:34 pm

It was time to truss the rear diff casing to mount the top links and make some space for shock post mounts.......

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Now the real work starts......getting the aluminium body panels done .....starting at the nose which was about the most challenging so far becuase of its shape. This turned out well on the first try and so far it's just the rear quarter panels and the roof left to do .

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I got a set of Toyota Run-X driving lights to finish off the look thats still need some mounting brackets........

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Post by **Mud Dog** » Fri Jun 13, 2014 5:07 am

Nice progress, looking good!!