Great Dane excavating co.

[Cooper]

This is the transfer case.

[Bo Wallen]

It's not just a transfer case.....it's pure Awesomeness ! Getting closer and closer to move around on its own power.

[Hofabooz]

Hi Cooper


Looking good man looking very good.
It will soon be pushing you and the dog around under its own power.

[Cooper]

should have a esc and motor arriving soon. Have the basics of the driveline done. Still need to weld up and some more details. This is a pic of the spider being machined. Did it in the mill then remove from collet block and part off on the lathe. Rotary table would be nice but don’t have one and then setting up for a simple opp,, I’ll keep with the collet blocks for now.



And some shots of universal.

[9W Monighan]

Get a Hardinge HV-4 5C collet indexer. Look on ebay.
You really don't need a rotary table since you have your CNC mill.

[Zabco]

Very nice, I like the idea of combining set screws with pins to connect the parts. Using thread lock to keep them from backing out? Also, how did you make the slip joint? Broach?

[Cooper]

Originally Posted by Zabco

Very nice, I like the idea of combining set screws with pins to connect the parts. Using thread lock to keep them from backing out? Also, how did you make the slip joint? Broach?

Yes the two joints , one under front frame and one right before rear pinion are broached keyway joints. With this driveline the universal is centered at articulation joint and the driveline is all on the same plane. So I don't need the driveshaft to slip in or out during use. But if for some reason the joints can be easily modified by only clamping on one end and letting the other float. The keyways are cut to length so keys cannot slip out if need be. I don't see needing any expansion/contraction joint on a one plane driveline, but it will not be know until I get a few more steps done. Hopefully tomorrow after all holiday events are done I'll have it spinning. I still need to cut gears from gearstock. Top and bottom transfer gears are boared and keyed, the two center gears I'm going to cut the shafts all in one with the gearstock. I'm waiting on a better fitting collet to arrive so I can machine the gearstock. I can center it in a 4jaw chuck with some soft shims so not to damage the gear but indicating it would be a pain in but. That's why I am waiting on a better sized collet, then I can use the collet blocks or even just the collet to hold it while lathe work.

[Zabco]

Thanks for explanation. I agree that your particular setup doesn't need to slip back and forth during actual use and your two spline setup will work fine. Just noticed it in one of your pictures and was curious as to how you made it. I look forward to seeing the rest of this amazing build. Thanks very much for sharing.

[9W Monighan]

Originally Posted by Zabco

Very nice, I like the idea of combining set screws with pins to connect the parts. Using thread lock to keep them from backing out? Also, how did you make the slip joint? Broach?

I would assume he is stacking another cup set screw on top of the ones with pins to lock.

Cooper, Get a soft collet and bore it to fit your gear diameter.

[Cooper]

Transfer case done along with drive shafts. Also made a attachment plate for mounting motor to gearbox. Waiting on some gearstock to make a one piece coupler from motor to gear inside gearbox. Went with a fairly low kv motor that is sensored for easy start up and soft transfer of power to drivetrain. Using tekin rx8 esc with a 1400kv motor on 3s voltage. That gets a reduction in the gearbox of 4:1, 4:1, 3:1 then into transfer case all 1:1 then into axles with a 3:1 differential. Very similar to the haul truck. I think I used a 1900kv motor on that set up. With this machine I’m more looking for the motor to spin up closer to full speed while keeping machine slow and smooth power.

[Cooper]

And that last pic, the motor and gearbox are underneath that plate. The 4 black bolts are some of the gearbox mounting hardware. Bunches of room on top and to the back for hydraulics and batteries

[Cooper]

Made split couplers for the driveshafts. Makes it easier to set the transfer case and line up. I still need to cut the keyway in them.

[Cooper]

Connected to the shafts and keyway cut in.

[Cooper]

Pic of the drivetrain

[skeeter]

RW, at this pace, you'll have er up & runnin before next weekend!

[Cooper]

Received more gearblank today. Cut a one piece pinion and coupler to go from motor shaft to first stage of gearbox. Now I think I can think about getting her to move .

[Cooper]

Originally Posted by skeeter

RW, at this pace, you'll have er up & runnin before next weekend!

I have been getting a lot of other projects to pile up, wanting to get this one done and working!! Have a screening plant to build and get this loader running material . Also have the springtime work to start doing. More life work and less time in shop .

[Cooper]

Oh and another thing I did was to center drill a hole in the pivot joint pins. This will allow to properly align the universal joint with center of articulation. For it to function proper alignment is pretty critical. Straight no problem, but would bing during articulation if not lined up.



This is a 3/16” drill poked through centerline hole to line up with spider pins in universal before tightening the other set screws and couplers.

[9W Monighan]

Ahh pinion wire is so nice to turn on the lathe isn't it.

[Efroeh]

Originally Posted by Cooper

I have been getting a lot of other projects to pile up, wanting to get this one done and working!! Have a screening plant to build and get this loader running material . Also have the springtime work to start doing. More life work and less time in shop .

I really look forward to watching what you come up with for a screening plant. I would bet it's going to be awsome.