Smash2.0 K5 resurrection

Thornbird1 said:
Very cool setup on the cooler. I want to do something similar. How to you fill the system and know when it’s full? Is there a reservoir with a vent or a sealed system?
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I used a small aluminum reservoir as a fill point and mounted it on the firewall. On that system there is no positive way to check the fluid level. Me and the owner discussed it and he agreed that he would just be mindful if it leaks and so on. He thought he had spent enough money and didn’t want to pay for the extra R&D for me to make a dipstick and related components for that. Soooo I just used some math to figure out how much fluid to put into the system so that there would be headspace inside the planetary. Th reservoir being high up on the firewall ( and empty) gives excess oil and oil foam to vent to and dissipate. The system I’m making for myself will have a dipstick integrated as well as the reservoir/catch can vent system. The pic shows the reservoir behind the PSC one on e the firewall. I drilled a small hole in the top so it could vent.
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Neat. I look forward to seeing how you build yours. I added a catch can to mine and a sight tube on the side of the case, cured my puking on the highway and gave me some piece of mind being able to see what’s in there.
 
Going to run 2.5 into 3” single pipe out the back. At the convergence of the 2.5 there will be a 3” electric cutout before the muffler. The muffler is a 3 vector home brew flowmaster to save $$. I had that crap so I just cut it up and welded it.
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wheels came today from US Wheel they are unpainted steel 20x12 with 3.75 bs. Need to dress them up a bit maybe some rock rings that look like mock military bolt rings.
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JayMcJay said:
Great looking drivetrain!
But holy crap, that's a long adapter!
Is there a shorter version available?
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That is a stock length np208 adapter for a SM465. An np205 stock adapter is longer. It works in my application my rear driveline is 40” and the front is 37”. My wheelbase has been stretched from 104” to 116”
 
Gotcha.
I started out wheeling with a CJ5 with stock 84" wheelbase.
I have since moved on to things with low 100's wheelbase, but still sorta cringe when I see 18" of 'wasted' adapter.
I guess when you're in that 116" realm you can soak it up pretty well though.
 
JayMcJay said:
Gotcha.
I started out wheeling with a CJ5 with stock 84" wheelbase.
I have since moved on to things with low 100's wheelbase, but still sorta cringe when I see 18" of 'wasted' adapter.
I guess when you're in that 116" realm you can soak it up pretty well though.
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18”? Nope what your looking at is 7.5 “ of adapter and 6” of 2:72-1 Magnum low box on a np205.
 
pennsylvaniaboy said:
To be fair, ORD does make a 3.5" long adapter.

SM465/D300 adapter

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Yes and in my set up I didn’t see the need to tear down a transmission to install a new output shaft to use a shorter adapter that would make my front driveline shorter. Good research finding that short adapter sport.
 
The fuel cell sits just above the bottom of the frame but still want to get a skid plate in there in case the driveshaft let’s go or a big tree branch you know **** happens. Instead of a big steel plate I made 1”x.120 sq tubing and attached angle to the bottom of the frame for it. That mounting framing also ties into the shock towers to make it into a system that supports the towers from underneath instead of a bar in between them in the bed. A 1/16 diamond plate sheet will cover the framing. The differential is 9” away from the bottom of the fuel cell and uptravel is set at 5-6” up.
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Everything is just tack welded together cause I was low on gas. I just went balls out fabricating stuff. I’m starting to get caught up on finish welding now.
 
Put a Donaldson 2 stage air cleaner in where the AC was. The intake is plumbed into the cowl. This air cleaner flows 1125 CFM clean and full clogged ( according to manufacture specs) 400 CFM. This will handle the dustiest of trails.
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Cut those big holes in the floor to rotate that transfer case up. Took the cut out pieces , added to them and made removable floor covers. There is the stock one, big one over the transfer case and a small one to access the rear driveshaft bolts. Put rivet nuts in the floor so no self tapper screws. Got all this done and forgot to patch up the old t-case shifter hole, dang.
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Put the steering column in and I’m going to use a non tilt so I don’t break the mechanism on the trail. The steering box was moved forward 5” and outboarded slightly so the steering shaft had to make a detour for shock clearance ( mock up shock pictured). The clutch master cylinder was changed to a different style higher on the firewall and the supports under the dash modified accordingly.
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Pierced the firewall for the rollcage tie-ins to the front engine cage. Finished the 85 style cowl conversion
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( this is a 79 tub). Fabricated the sheet metal for the windshield frame ( full convertible). And capped off the holes left be the top removal. Got all the rockslider to roll cage tie-ins done underneath.
 
Getting all the crossmembers in. There is 5 total. Under the oil pan bracing the motor mounts, under the bellhousing to support TJ front of the skid plate, transmission one , transfer case one and behind the transfer case that will support the rear of the skid plate and has the traction bar upper mount.
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