4x4 Off-Road UTV Build Ep.27 - Welding Differential, Changing Clutch, Test Drive
Welding differential in FWD gearbox, replacing clutch and test driving in mud.
This is part of a series of a four wheel drive utility vehicle build to lessen the work load on my trusty 2002 Honda Foreman Rubicon TRX500FA. This partially answers the question "Why?" but for those who want to ask "why don't you just buy a side-by-side instead of building one?" I just want to say - I'm not made of money. Side-by-sides are ridiculously expensive, even the car I drive around daily is worth less (not worthless though!), hell, it is even worth less than my 2002 Honda ATV.
"How much HP will it have?" - the 1.4 litre FWD petrol engine I'm planning on using has 55 kw and this will not change, but the torque will be tripled via the BMW differentials I'm using to transfer power to front and rear axles.
"It will be too heavy!" - this project just like the firewood processor project does not have to float. And a heavier vehicle will handle better anyway when hauling heavy loads.
Stay tuned for future episodes! Thanks for watching!
My other videos: / donndiy
#donndiy #homemade #4x4
Soundtrack:
Pomade - Silent Partner (KZhead Audio Library)
Welding equipment borrowed from Spetselektroodi AS, Estonia:
Fronius TransSteel 2700 welder
Optrel Crystal 2.0 Welding Helmet
Hypertherm Powermax 45 XP plasma cutter
More fabrication videos on kzhead.infovideos
Can't remember if you have built in a handbrake,must rewatch for this but maybe consider a (old) Landrover style one? One single drum on the rear driveshaft.
why that motor on your left does not bother you ??!! :)) It has to be on your right !!
#27
You have what I saw for the Amazon
I love your trick with the cardboard I will probably use it in the future
Disassembling and reassembling a gearbox, it is not given to everyone, it requires courage and especially a lot of patience and here I say respect ✊
Какая природа! Дом у озера! Это просто мечта! Убраться из города, от его суеты и злобы! Автор просто красавчик с золотыми руками! Так держать!
I always thought that US Army mules used back in the 60s would be a simple vehicle for gathering and hauling firewood out of the woods. That is a very useful and resilient Ute, you've built. Great job. Regards, Solomon
💪👍
You have officially gone above and beyond what a lot of other KZhead builders have done in the past. AMAZING!!!!!! Keep up the great work.
Knmlylnb
@@nurfadillah604 ???
When I was in High School an older friend, who was a Heavy Equipment mechanic and a bunch of his coworkers would enter a car in the local Destruction Derby. They used to let me “help” get the car ready, one of their secrets was to weld the plant gears together for a poor mans posi-traction. They placed well every year. They would also fill the rear tires with water. Boy, that was fun! I ended up becoming a mechanic and put my self through college wrenching.
Yes yes yes, it can go anywhere but but does it have a cupholder?... no I think not, guess what..? My car does!! 😄 (I love that it’s so short, wheels on each corner, for steep ascend and descend and sooo quiet.)
A driven trailer you say.. now I get what the PTO is for! Great build. Curious to see what is next. Greetings from the Netherlands, Mark
OOhhhhh now I get it with the driven trailer, you reckon he will use the PTO to drive the trailer , lot of strain on the motor I think . but bloody good idea. Cant wait to see that
Same was wondering what the PTO was for! Now we know! Brilliant idea can’t wait to see that build.
I would have a better chance at removing my own appendix than I would disassembling a gear box. Well done!
removing it is the easy part... putting it back in working is the hard bit
Well, if you're the only medical cadre on a Polar expedition, and you happen to have a mirror and a lot of vodka, that's a given. :))
:-) :-) :-)
@@backyarddodgyness Why would I put my appendix back in? I'm kidding. That's an excellent point! Anyone can take it apart!
Old lady's put together 100,000 price puzzles.
It's really amazing what a small 1,4l engine can do when its power is transferred to the four wheels. Impressive!
The secret about power is how you apply it. You can have a million HP engine, if the power is transferred through dog turd to the ground it will feel like 200 HP.
It isnt a small engine for an UTV A Polaris RZR 800 has 56hp Polaris RZR 1000 has 110hp The 1,4l engine make 75hp that is pretty god
Yes, it seems like a nice and suitable power plant for this machine. Judging by maximum horsepower it's almost overpowered - small (and relative to this project, very heavyweight) farm tractors (with huge wheels in comparison) can work with similar hp. Pulling attachments heavier than Donn's UTV's while their numerous blades or discs buried in soil. Power won't be the limiting factor.
My dad was the best mechanic I ever knew…but even he was afraid of gearbox guts. Love the channel. You are a stone cold genius!
Much obliged!
Fantastic Donn , turned out Fantastic!! Thanks for sharing with us and allowing us to ride along. Fred 🙏🏻🙏🏻👍👍👏🏻👏🏻👋👋
Thanks man!
Hi DONN attention for the welding of the differential since it is not of the classic ironwork there is a procedure respected to be able to weld it correctly, the welding yours have little penetrated the metal it is necessary to heat the satellites and the planets with a torch just before '' they start to redden before welding them and especially let them cool to room temperature beware of possible bearings
I built a similar vehicle some time back and welded the diff without heating it. I've never had any trouble with the welds letting go.
i love these builds he does, sheer genius....
Chief mechanic for Mad Max. Superb work from start to finish
Excelent buggy.Nice gob Mr. outstandung.😀😀😀
Me crying 1st half of the video has I would NEVER attempt that in a million year! Good job🤜🤛
I would give 5 thumbs up if I could. I cannot believe he got through that monster differential gearbox, did his weld mod and got that thing back together properly. What a freak show of engineering.
Just so you know, you didn't need subtitles - your english is very good. Hello from Australia
2:19 Another brilliant idea! Must remember that for my next dis-assembly.
👍
Donny once again = outstanding. I am a tipple ASE master tech in the states and you have skills that i have seen seasoned tech not have! My hat off to you sir!👍
Much obliged!
Brilliant result!. Pls fix the exhaust leak (at least it sounds like one)... reminds me of an old paddock basher that I had that used to give me headaches until I fixed the exhaust. Looking forward to the final look and panel design.
Super
Road? Who needs a road! Climbs like a Billy GOAT,! Awesome 👍👍
Fantasic build. Must have been very rewarding to drive. Off road performance looks really good with the locked diff.
It is rewarding.
Now thats a proper UTV! Cheers from Alaska!
For most of Alaska I think I would want a Hovercraft just ride over everything water, ice, snow, mud, pavement you name it.
It would be great to have manual dif locks..😉 but - I know, for non-solid surfaces it doesn't matter. Respect, nice to see such of great job done.
Awesome job !.. We need you for the Zombie apocolapse..
Well done, my friend!! Five giant stars for you! Art
Не перестаю восхищаться! Одна зима, .. и новое транспортное средство. Есть буксировочный крюк. Теперь будет на чем дрова возить в зимний период.
At least you've proved that you can easily dismantle things when needed.
Brilliant, can’t wait for the PTO trailer!
We'll see how long those LSD's last when you really get into mudding. Seems to do fine with open diffs too. Coolest diy UTV build on yt right now
A switch to torsen diffs would help a long way I guess (:
@@RubenKelevra It is so light I don't think it will ever be a problem. Half the idea is a budget build is what you already have in a wreck so spending big $$$$'s on diffs for it kind of defeats the purpose a bit.
it is also for working i think
@@valfahr126 indeed. He intended it as a replace to his current bike like atv for hauling wood :)
@@koolkar55 well, he wants to tow wood with It and probably also clean snow. So a diff-lock is kind of mandatory.
Well done Donn, as always a brilliand presentation !
Nice to see that everything works as you thought it would and you enjoy your work.
Hi Donn, it's obvious that your abilities have no limits. The UTV you build is like you, you just can't stop it. My sincere compliments my friend, FANTASTIC !
Thank you!
At 7:06 I held my breath when you lifted the stack of gear cogs, I didn't know they were all connected!!! Great build, well done.
I learned a lot from watching your videos. My father and I have been working on my tracked vehicle together and its been a great time.
Very cool!
One of the best homemade projects on you tube.
Cheers man!
OUTSTANDING! Even more outstanding when we get to see you build in the shop we also got to watch you build. Best channel ever.
Well deserved test/fun run!! Enjoying this a lot 😁
Solid piece of kit, very well played indeed. All you need now is a 540 PTO on the back end 😉
Awesome 👍👍👍Thanks for sharing
This is 20x more robust than any Polaris ranger/rzr or kawasaki gator. This is the side by side farmers really want.
Your channel is more educative, best of luck🇳🇬
I am amazed the at the builds, tear downs and rebuilds you take on and Master. Great Job and a fun watch. Great Work
Awesome! That clutch return spring thing and all the cables you have! I’ll tell you that many use boat cable to do what you’re trying to achieve and it is all sealed and safe and keeps working perfectly for years! I hope this helps it did help me when I was told about it! However use hydraulic anytime you can it’s the ultimate! Also put your radiator in back at an angle away from you and everything getting all the wind it can with your electric fan! You will be amazed and much cooler!
dude, im happy i part of this project and journey. Thank you for sharing awesome content
Cheers!
Most amazing results from all your labors, rockon Donn !!
Yeah, she's a climber. Niiiice, Donn. Can't wait to see how you make the trailer.
🤘🤘
Сколько терпения, старания и упорства!!!
AWSOME little rig Donn!!! Nice work my friend.
This is the episode I’ve been waiting to watch since like forever. You have done what ten thousand viewers on you tube would like to tell you how to do what you are doing wrong without actually ever doing anything remotely close to what they are talking about....... I apologize for going there. This is a terrific video. 👍
9:55--- мне это напомнило кадры из серии про Трансформеров,когда Оптимуса Прайма ремонтировал чувак-самодельщик,после того,как Оптимуса изрешетили снарядами... Все ждал момента,когда из кузова этого UTV вылетит ракета и проделает дыру в стене гаража...!))))))) Классная работа,Донни!! Респект,лайк!!! Ты реально--"Мастер-золотые руки"!!
Hi there a lot of work there but worth it real nice 4x4 buggy you built.
Amazing job
Works great mister. I must say that you def have alot of skills and confidence to tear into that drive unit. Bravo !!! Im getting antsy to see what kind of body panels you com up with You have certainly ROCKED THIS BUILD!!! Casanova PA loves it !!!
Haha, thank you!
Perfect, now we need to see some air and going sideways 😉
Must be your summer there Donny looked like a beautiful day when painting. Our winter here in OZ 4deg - 10deg C at night (brrrrrr Chilly) 25deg C during the day. Love ya work Mate. Billy J. Queensland, Australia
Yup, it's getting warmer here finally. It was around 24 degrees celcius when I painted the gearbox cover.
Next time on Donn diy i build a fusion powered tank with rail gun and PDC.
That is a seriously capable off-roader, Donn! Well done!
Cheers man!
Grandpa: "Donny, what a mess you made in the field!"
Donni's own land, he knows what he's doing!
I was thinking about his Grandfather’s comments too when he was playing in the mud.
@@polesinuasi7660 Do you know him personally? I believe it’s his family’s land that he lives on.
I've enjoyed the series thus far! Great Job! I can't wait to see it finished!
Great job I have not seen many people with your gifts Keep up the great videos Thanks
Noice. Sounds like the engine needs valve adjustment though. By the way, these gearboxes sometimes lose fifth gear because the nut gets loose, so you also did a bit of preventitive maintenance there. Really enjoying your channel, absolutely awesome
There's a kit online that gives you a locking plate. You have to grind a flat on one of the sides and it gives you two tabs that lock the nut in place. It's also something you can easily order on your own from any laser cutting company, it's essentially a D hole plate with two two tabs sticking out past the nut's sides. IF you ask me, this is something that should've been factory. That excess thread left, is clearly more than enough and the modification to the shaft's threads poses no risk to the integrity of the whole affair. Cheapening out at every corner, manufacturers are.
My local mechanic has a large sign in the garage declaring: "No Internal Engine Work". Thank you for being braver than them.
I got lucky. It is a tricky task to disassemble and reassemble a gearbox. Patience and taking notes really helps, and paying close attention to what goes where.
Очень большая и отличная работа👍👍👍 супер
Spasibo!
Que quilombo hermano. Buen laburo!
Very nice job you have done on this machine. It's always a pleasure to watch and learn from you
Awesome. I love the build and upgrades
Amazing build there. Very impressive, it seems very capable, as well as cool AF 👍
That sir, is a beast of wonderful abilities. Well done.
Very well built! You mentioned that you will modify the BMW differentials too, i think welding the rear differential will be good, but i think welding the front differential will make it hard to drive around corners
I think you're right.
Well done!! Thanks for great videos!
My absolute FAVORITE fabrication channel on You Tube! Truly awesome builds, Donn! You're not only talented, you're GIFTED with your skills. Please keep the videos coming! :-)
That's awesome mate,cool buggy. Cheers from New Zealand!
Cheers man!
Even the mechanics in the audience are impressed. Good job is a very understatement, but good job.
Cheers man!
Amazing project. Perfect 👌👌👌👌👌👌😍😍😍😍.
Good job Donn! As i always say, you're a true inspiration. I'm glad that when i was looking on how to make my own throttle cable end that it brought me to your channel. It must be very satisfying to be driving this project and seeing it work perfectly.
I'm happy to be the source for inspiration. Cheers!
That thing is amazing. To get a little more grip when one wheel breaks loose and you stop moving apply the brakes a bit to force the open differential to transfer power to the wheel with traction. It’s a trick to compensate for open diffs.
Yup, I have tried it on my ATV's front axle and it works great.
Awesome Machine.. It does really well in the mud..
Awesome work! Keep on 👍
I always use cordless drill with clutch on weakest setting to chase threads, both inside and outside ones
You made it great! But the next could be a solid axles project?
Somehow I knew you take this build to a whole new level. Outstanding. I am truly amazed and pleased. Your TIG skills are getting much better. Your welds are beautiful.
Cheers. I really love TIG welding.
Real engineering skills! Congrats to you!
love the way it looks...pure mechanical...would leave it looking like it is...awesome.
The King of the Hill! :-D Great job! :-D
I was wondering how well that strut suspension would work. Looks like it works pretty good. Great job! Look forward to your videos.
Very nice should go anywhere with no problem !!! You have come along way very nice work !!
Looks like it's going to be a beast, from the front it reminds me of the old jeeps...
very very very good!!!🔧🔧🔧🔧🔧🔧🔧
Hello from France, great try! unfortunately there is still a lot of finishing to finish but I trust you because you do wonderful things. Good continuation.
That are the test I was waiting for! Love it
The taste of glory!!! Well done!
LOL knew it bud. glad this is finally happening.
I love it. Perhaps in Gen 2 a little more ground clearance might be useful.
Super awesome work and install 👍
Amazing playground you have there, Donn!
Congrats, have followed the build from the start!!!
Cheers!