Re: Kenworth 850 Off Highway
 

It is getting really interesting now!

Kerst

Re: Kenworth 850 Off Highway
 

One more small update. I struggled a bit to get the axles drilled out true but it's all done now. I installed bronze oilite bushings but I may put bearings on the outside end if it looks like it needs it.

http://i1293.photobucket.com/albums/...ps3faf5d5d.jpg
http://i1293.photobucket.com/albums/...ps4fbd6a18.jpg
http://i1293.photobucket.com/albums/...ps90121446.jpg
http://i1293.photobucket.com/albums/...psd0b5fe2a.jpg

Thanks for lookin!

Re: Kenworth 850 Off Highway
 

Those axles look great!

Kerst

Re: Kenworth 850 Off Highway
 

Reg, if the axles pushed you out of your comfort zone, I can't tell. I know they aren't quite done yet, but it looks like you knew exactly what you were doing the whole time. I'll bet you had every step planned out in your head, before you even began. I might have missed it, but are those the Savage differentials?

Re: Kenworth 850 Off Highway
 

Good eye Nate!

Re: Kenworth 850 Off Highway
 

Bead blast really changed their appearance. :eek:

Now how did you rifle out the axle bores? You use the mill or lathe? Take any set up pics of that?

Re: Kenworth 850 Off Highway
 

I used a lathe and a 4 jaw chuck but sorry no pics. It was my first time using a 4 jaw chuck but it went fairly well. The first drill bit I used wandered off a bit causing me to say some bad words and grow a few more grey hair. I was lucky enough to have drilled them out undersize to begin with though so with some creativity I managed to fix the crooked bore. Now comes the part that has me worried...making the pinion carrier:(.

Re: Kenworth 850 Off Highway
 

I wondered about that... once a hole is drill, how do you change its projectory over the length? ...small bits have so much flex to them.

Re: Kenworth 850 Off Highway
 

I drilled in from each side toward the center so luckily I only had the issue with the one axle tube. I installed bushings that are 3/8 OD so by drilling in very slowly with a 9.5mm bit I was able to get the larger bit to cut straight(almost) and in the end be able to press fit the bushings. Its a few thou out but you can shove a single axle all the way through both sides. It just doesn't turn as nicely as the other axle but I think it will be fine. When you put an axle into the diff gears from each side it spins freely. It definately made me sweat for a while though. I have way too many hours into these housings to wreck one now.

Re: Kenworth 850 Off Highway
 

I think you have CNC mill there that you aren't showing us, you say it's all manual but:rolleyes:... lol


Keep the updates coming:)!

Re: Kenworth 850 Off Highway
 

Haha, Thanks Madda!

Re: Kenworth 850 Off Highway
 

Increadable, could never imaging doing an axle from a piece of stock material!
With your skills in welding I was supposed to see axle welded together from different pieces. And that you could get the bore it straight, thumbs up.
Like that "cheese plate, do you have a pic without anything on it, guess have to do one of these, looks realy handy.
Dan

Re: Kenworth 850 Off Highway
 

That's the one thing about machining the more complex parts. The ones that have so many steps, and take so long to make. The pressure to not mess it up, raises exponentially, every time you reclamp for the next stage of machining. :D

Re: Kenworth 850 Off Highway
 

I think the worse part is when you spend hrs manually on the lathe for the 1st op only to mess it up in seconds in the cnc mill by forgetting a decimal point on z depth :(

looks good Reg . I see you can do abrasive machining too :p

Re: Kenworth 850 Off Highway
 

Haha, Abrasive machining is what I'm best at!

Re: Kenworth 850 Off Highway
 

A few minor updates.... I changed to bearings on the outside when I made the fake brake drums-backing plates. I have started making the rear leaves too but I haven't made much more progress.

Dan, Here is a picture of the plate that my father-inlaw made for me. It has an MT2 taper on the back to center it and is held down with 3 T nuts-allen bolts. I asked him last night if could make me a larger one sometime so hopefully he will. It would be nice to have a little more surface area.

Reg

http://i1293.photobucket.com/albums/...psf28029c6.jpg
http://i1293.photobucket.com/albums/...psb56836ff.jpg
http://i1293.photobucket.com/albums/...psc0d40a72.jpg
http://i1293.photobucket.com/albums/...psc779af46.jpg
http://i1293.photobucket.com/albums/...ps7aa7c109.jpg
http://i1293.photobucket.com/albums/...ps4a77b0c7.jpg

Re: Kenworth 850 Off Highway
 

Wow Reg ..looking good..you and this guy have a little in common
https://www.youtube.com/watch?v=oOkmKkvC-PE

Re: Kenworth 850 Off Highway
 

I would say very little. That guy has built a masterpiece...my own, not so much. Did you see the other stuff that guy has built? WOW!

Re: Kenworth 850 Off Highway
 

RCP57-this is some very nice work you are doing here. I have been watching this from the beginning and I enjoy these kind of builds--I am impressed!!!!

Re: Kenworth 850 Off Highway
 

I wish I had a father-in-law that knew how to machine stuff like that swiss cheese plate, Reg!

The drums on the axles really add a lot. Looking good.

Re: Kenworth 850 Off Highway
 

Yeah it is nice to have his help every now and then especially when it comes to tooling. He has helped me out a lot by giving me stuff out of his toolbox. We haven't spent much time on the machinery together though which is mostly my fault. He has offered but our schedules don't work out all that often and I'm really pig headed and want to figure stuff out on my own(usually the wrong way). I know that I'm weird but I like to be by myself a lot haha! He might come over this weekend though to help me build another hydraulic pump so that will be cool if he can... I need to finish the 630D....

Reg

Re: Kenworth 850 Off Highway
 

Wow Reg its coming along quite nicely. Axles look great! Keep up the awesome work!

Re: Kenworth 850 Off Highway
 

HAH! that's funny! I can relate, I greatly dislike ppl noise too. ;)

Re: Kenworth 850 Off Highway
 

I spent a little time here and there over the last few days and managed to get the rear suspension done. The leaves need some prettying up but I will do that later on when I finish the axles. I made up my own link bars and TIG'd them together. I then pressed the pins and rubber bushings(hose) in. It seems to flex nicely but not an unrealistic amount. At least I was finally able to see it roll back and forth on it's axles! Now comes the tricky part...finishing the gear train!

Thanks for looking!

http://youtu.be/LS6eurJgOYY

http://i1293.photobucket.com/albums/...ps13f3a463.jpg
http://i1293.photobucket.com/albums/...ps0fbae9d6.jpg
http://i1293.photobucket.com/albums/...pse8f9bbf0.jpg
http://i1293.photobucket.com/albums/...ps62767b6c.jpg
http://i1293.photobucket.com/albums/...ps935ed819.jpg
http://i1293.photobucket.com/albums/...ps009b825e.jpg
http://i1293.photobucket.com/albums/...ps9392754f.jpg
http://i1293.photobucket.com/albums/...psb69cdb8b.jpg
http://i1293.photobucket.com/albums/...ps4ae9e2c9.jpg
http://i1293.photobucket.com/albums/...ps11c6b01d.jpg
http://i1293.photobucket.com/albums/...ps64ece3b6.jpg

Reg

Re: Kenworth 850 Off Highway
 

Very very nice I luv it man that thing is big:eek::D

Re: Kenworth 850 Off Highway
 

Hmmm, I'm seriously gonna have to consider getting a tig welder... no way could I ever mig such parts together like your link bars without destroying them. Great Show again Reg. :cool:

Re: Kenworth 850 Off Highway
 

Reg you have done some very nice work here keep it up. Ed

Re: Kenworth 850 Off Highway
 

The suspension detail is amazing! Don't know if I'd have the nerve to try making axle housings - but your results are really great. Yes, it is a good feeling to roll it around - just got the motor and driveshafts finished on my Payhauler - another step forward.

Enjoying your build immensely.

Ken

Re: Kenworth 850 Off Highway
 

Always amazed on how well you tig weld all of your parts. Keep it coming.
Making the rears sure looks great.

Re: Kenworth 850 Off Highway
 

Reg,

Looks great, what material are you using for the axles?....and I noticed you pressed bushings in, are they bronze impregnated? I probably overlooked those posts. I like the custom stuff like this. Keep up the fine work. Colin

Re: Kenworth 850 Off Highway
 

This is a one-of-a-kind rig! A lot of rigs claim to be "custom", but this is as true to that as you can get! Excellent work, I can't wait to see more! :D

Re: Kenworth 850 Off Highway
 

Reg, looks like you're working full time with model building, when not checking forum every day, I have to go back a page on your tread to see what's happend since last time.
Those axle bars looks very good, with that rubber inside it's just like the real ones.

Thanks for that pic, will do one, looks handy!
Dan

Re: Kenworth 850 Off Highway
 

Once again, nice work Reg! The radius and torque rods look good. Question though....is there supposed to be one more rod, running parallel with the axle, that ties into the chassis frame rail? I've never seen a Kenworth like this, so maybe they don't have them? I'm not sure of the proper term for a rod like that, but I think they call panhard bars in the rock crawling world. The truck is looking great! Standing on it's own feet.

Re: Kenworth 850 Off Highway
 

Thank you very much...yes it is BIG!

Thanks Joe, I would say that TIG is great for our hobby. With a little practice even a guy like me can turn out some decent stuff and there is virtually no fumes and never any sparks/spatter.

Thanks Ed, complements like yours keep me motivated!

Thanks Ken!....so where are the pics of your Payhauler????? I love that build!

Thanks very much. It makes me think that I'm doing something right when someone like yourself is impressed.

The axles are made from cold rolled steel, the housings are aluminum. Yes the bushings on the inside are bronze oilite.

Thanks, No matter what hobby I have pursued in life I have always rathered to build versus buy. Partly because I have yet to win the lottery...Ah, who am I kidding if I won I would buy more machinery!:D

Yes Dan I have been pretty much working on this full time(ten hours today). I'm obsessed at the moment! I'm going back to work finally next week so I have been pushing myself to get as much done as possible!

Nate Thanks! These trucks don't have a panhard bar. The earlier trucks(848-early 849) with underslung springs did have them but appearently they had too many roll overs so Kenworth went to a different suspension setup(the same as Hayes and Pacific) with overslung springs. I guess the spring pack is enough to keep the axles centered:confused:.

-----------------------------------------------------------------------
OK, Todays update... well actaully it's been a couple days. I FINALLY almost have the front diff finished. I need to weld the gears to the shafts and do a little more prettying up to the housing but it works. I have started the rear diff too but I'm still waiting on the ring and pinion....AND MY MILL DIED! I'm not sure what happened. I shut it off because I was done for the day, then I changed my mind and decided to drill another hole(this is just like riding a motocross bike, never say just one more lap cause thats always when you crash hard). I flipped on the master switch and nothing happened. It seems like there is a blown fuse or something. No magic smoke escaped and there is power to the mill. Anyone have any ideas? BF30???

I didn't take many pics of the process....but here is a little vid of it spinning...

http://youtu.be/Wrq2KidK3JA

http://i1293.photobucket.com/albums/...psb385580a.jpg
http://i1293.photobucket.com/albums/...ps2cc36873.jpg
http://i1293.photobucket.com/albums/...ps05a5a630.jpg
http://i1293.photobucket.com/albums/...ps284dfe29.jpg

Reg

Re: Kenworth 850 Off Highway
 

Oh man, Reg, after seeing your axle in this mostly completed state, I think I'm just going to throw in the towl with my build! That looks awesome.

Sorry about the mill giving you problems. I guess if you have digital multi-meter, you need to see if you have in coming power first, and if you have some fuses, you need to check that they are good. Just pull the fuse and do a continuity check - meter set to ohms. Not to familiar with your mill. Does it have a speed controller? Maybe you just have a bad push button or switch?

In anycase get it going so you can continue with this incredible build!

Re: Kenworth 850 Off Highway
 

I don't think you need to throw in any towels. Unless you want to throw them my way for when I cry myself to sleep knowing that my mill died:(. It has a brushed motor with variable speed. Power is getting to the switch but I'm not sure about anything beyond that. I read in the manual that it has a fuse but it doesn't say where it is. It just tells you to have it serviced by a tech:confused:. It still has over a years warranty on it so I won't go too crazy until I speak to the dealer. It probably won't be anything simple knowing my luck but I have my fingers crossed.

Re: Kenworth 850 Off Highway
 

Great Job Reg that's exactly what I'm doing with my truck rears but in a smaller scale :eek: . you ware the mill out already ?:eek::p

Re: Kenworth 850 Off Highway
 

That looks nice!

Kerst

Re: Kenworth 850 Off Highway
 

Reg very nice work on the rears like I said before this a real scratch build. Ed

Re: Kenworth 850 Off Highway
 

I found the fuses and they were blown so I drove around town until I found a place that had them(Sunday sucks for buying obscure stuff). I came home and put them in, turned on the main switch and everything lit up. I then turned the emergency stop switch...still good. Hit the green button and pop, bye bye fuses. I guess something has fried in the board. Hopefully I will hear back from the dealer tomorrow.