Fitted grills to my hot air ducts, looks like a target

Plans for the winter months.
The Suzuki transfer box is a well designed and well built, but is not Citroen.
The plan is to use a modified GS 5 speed box.
The Pinion shaft to have drive couplings at both ends. (One end already done in the current set-up.)
The layshaft will be driven through the existing 5 speed pinion with an additional input shaft+ 5th gear/bearing and drive flange.
The big down side is it will be permanent 4x4, and thats prone to axle windup.

Rear end of 5 speed box



Redundant Layshaft.



Lay shaft cut down to make new input shaft

I like your thinking
so i take it you press a propshaft flange onto the ground shaft?

How do you intend to deliver the power forwards?

additionally

just quaife up your diff units!!!!

Actually i got 10 special diff out put shoulders made by Quaife
for the second version of Barbour full lock
Now using a 38 mm spline not 35 as in the 2cv so should be even stronger by about 25%

But as normal not enough time for getting into build the special diff casting ( yet)

keep up the pictures it always makes me smile!

pony

Drive Flanges with splines either Wire cut or spark erosion.
The new input shaft to have spark cut splines external.
The 5th gear to be wire cut with internal splines to fit new shaft, using double roller bear. and lip seal.
Grind down Diff Pinion, Spark Erode Spline to fit with fixed length prop that has internal splined joint with lip seal.

Found a company that will build REAL plated LSD diffs.

Drive Flange (internal splines to fit pinion shaft.)



Drive Flange fitted fits 1100 UJ flanges

Re plate LSD quaife also stock them actually they bought the firm

However dale the Tech boss pointed out to me that Plate type LSD
very quickly go out of adjustment and need to be taken apart frequently to be re set.

and 95 % of people fit a Quaife!

Love the ideas

For your info i think a 2cv top rear shaft has the same spline as your GSA 5 gear!

if this could help

also i am stripping some VIsa 650 boxes so if you need some components i may be able to help

pony

Tech boss Dale should have job title ...."Salesman of the decade" ...

Measured up the positions for input flange and output flange, just enough room

The project transfer box is now on "stop"

The cost to wire cut/spark erode involute splines onto these two parts would be £780 + Vat + shipping.
The old guy who did my last work (£105) has passed away, apparently he worked it the company as a hobby and liked do work for amateurs.

Could perhaps do a friction fit with some welds, but thats not a very good solution.

Why not make it a press fit
then weld the synchro side after pre heating the parts
and you will probably get away with it!

or use the synchro teeth on the gear wheel and synchro hub to engage the gear.
By having the splined part of the hub welded to your shaft
that way you do not have to weld the gear

easy!

pony

Thanks for the input Lou, will go and consider alternatives.....