CAD designs

[Moridinbg]

I will upload CAD designs of some of the stuff that I build for my cruiser here. If anybody wants to share his we might build an index.

1. Gearbox skid plate for LHD 5 speed Diesel

2. Transfer case skid plate for LHD 5 speed Diesel

There are 2 holes that have to be drilled through the gearbox crossmember and 2 are reused.
The holes in the front between the control arms and the ones in the back on the chassis are already there and reused.

An improvement would be to add an access door for the oil drain on the gearbox plate. I might add one in the future, if I smash this one or become too annoyed with unmounting it (4 bolts) when changing oil.


3. Rock sliders
A friend helped me a lot with a model for sidesteps but this quickly diverged to pencil marks on the steel, so I will have to take measurements and update the model before uploading
CAD files for this have been lost unfortunately, so I won't be able to upload that

Two steps - AHC compatible. Passenger side could be made with 3 steps. The AHC accumulator blocks the driver side.

Square tubing would be better for the main beam

 

[Moridinbg]

Might need this slot later

 

[TheForger]

Just requested access to the Drive files. Thanks for putting that together!

 

[Moridinbg]

Check links again. It should not require approval now

 

[Moridinbg]

Tire carrier for the stock rear bumper
Sized to fit a 33 MT tire. Locking mechanism not included.
Solidworks 2021 SP5.1 files.

Needs a little bit of cutting on the corner of the bumper. Sized to keep the tire at a safe distance from the rear door and as low profile, as possible. Keeps very good visibility through the rear view mirror.
You will need a decent tube bender for the tubing, the shape is 3 dimensional.
I made the spindle and the shell on the lathe, the shell accepts 2 radial bearings and 2 seals.

I changed the final build in the end, instead of a rectangular tube with brackets, to hold the tire I used the same tube as the rest of the carrier and a circular sheet.
I added a locking mechanism in the shop, that was never added to the CAD.

I cut waaay too much bumper. The cut has to be 1/3 the size.

 

[Moridinbg]

Drawer system

They extend until just behind the second row seats and are about that high, minus the headrests. This allows for 800mm full extension sliders.
There is a dimensionally accurate cutout of the floor. It extends for about 15cm more, before the seats.

If made from aluminium sheets and steel frame it totals to about 90kg with the sliders.

There are mockups for the sliders in the model, based on
Schwerlastauszug 850 mm KV2-100-H53-L850-LC Lock-in/out von JUNKER - https://www.junker-slides.com/schwerlastauszug-850-mm-kv2-100-h53-l850-lc-lock-in-out-von-junker.html?qty=1 for the main sliders and Schwerlastauszug 850 mm KV2-200-H76-L850-LC Lock-in/out von JUNKER - https://www.junker-slides.com/schwerlastauszug-850-mm-kv2-200-h76-l850-lc-lock-in-out-von-junker.html?qty=1 for the heavy duty kitchen slider.

The model is fully defined and built with mates, but it's my first ever more complex assembly, so might not be optimal. The drawers can be pulled in Solidworks as much, as in the real world.

The big cutout is for a sink that we never used and I regret wasting space for. Not in the CAD is a smaller cutout next to it for a stove. If I ever redo this, I am not doing the sink and putting the stove in it's place.

I enclosed the entire thing with acrylic panels to keep the dust away.

 

[Moridinbg]

And finally, currently work in progress - wheel caps for 3D printing with ABS!

 

[Live to Ski]

just curious: w/r to the structural stuff, was there stress/vibration analysis (can be done in the higher end solidworks)?

 

[Moridinbg]

just curious: w/r to the structural stuff, was there stress/vibration analysis (can be done in the higher end solidworks)?

I have always wanted to do that, but just getting the hang of SW to be able to model those relatively simple designs is taking me enough time.

I was very concerned with the tire carrier - a 33" Toyo MT on a rim weighs about 50kg and the truck rear is bouncing up, down and around all the time.
Alas I just opted to use more material - the tubing is 42mm OD with 3mm wall seamless structural steel (S355) tubing and the sheer amount of experience my friend that runs the workshop has.
In the end I have done about 60k km with the carrier on it, some of it hundreds of kilometres of horrendous gravel road, others just hard wheeling and it's holding up really well.

 

[Live to Ski]

post desgin real world testing beats analysis every time ...well done...enough said

 

[SeventhDurandal]

Alas I just opted to use more material - the tubing is 42mm OD with 3mm wall seamless structural steel (S355) tubing and the sheer amount of experience my friend that runs the workshop has.

In the engineering world we jokingly call this "P=Plenty"

The engineering time required to properly model and calculate/simulate shock loading, stress, vibration, etc, is much more expensive than just overbuilding it. That extra time only pays for itself if your production quantities are very large.