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 231/300 Doubler build 
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I finally got around to working on my doubler and thought I would post some pics up.

I ordered the D&D machine doubler kit (Haven't received it yet though). Link HERE

The kit comes with an adapter plate to mount the 231 crawl box and the Dana 300 together...

Image

A clocking ring for the 300...

Image

A 4340 thru hardened intermediary shaft. It's normally a 23 spline shaft but I ordered a larger one for more strength along with a new input shaft for the 300 from http://www.jbconversions.com.

Image

And finally the kit comes with a block off plate to weld in and a new shaft for the planetary shift fork to slide on...

Image

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Fri Nov 16, 2007 5:06 pm
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The only thing you keep out of the 231 for the crawl box is shown below...

Image

You need the front half of the 231, the ring gear, planetaries, planetary carrier, the sun gear, the input shaft, and the low range shift fork. If you buy the Mad Rooster kit you'll also have to keep the orginal shift fork shaft and modify it.

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Fri Nov 16, 2007 5:06 pm
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For my doubler I'll also be using the internals out of a 241 since they're beefier.

The 241 has a 6 gear planetary vs. the 231's 3 gear setup...I'll also be welding the pins in so they won't try to get loose and elongate the holes.

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The sun gear in the 241 is also stouter looking so I'll be using it too.

Here's the 231 sun gear...you can see if necks down for some reason and I really don't like the way the teeth are cut.

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Here's the 241 gear...it doesn't neck down and I like the way the teeth look much better.

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Here's a comparison shot of the two...

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The 231 is on the left...the 241 is on the right.

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Fri Nov 16, 2007 5:07 pm
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The only thing else I have done right now is the modification to the shift fork range selector.

Here it is stock...Notice how it has slots for 2high, 4high, neautral, and 4low...

Image

Since I only need 2high (planetary won't be engaged) and 4low (engages planetary) I went ahead and cut two of the peaks out so I don't have to unnecessarily shift thru them for no reason.

Image

I used a flapper wheel (on my Milwaukee :mrgreen: ) and some 320 grit sandpaper to make shure the selector pill would slide on the surface nice and easy.

Image

Here it is installed back in the case.

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Fri Nov 16, 2007 5:07 pm
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That's as far as I am right now. Updates will take a while though...

I've got to wait on the kit from Duffy to get here so I can get is welded up.

Then I've got to wait to get my Dana 300 from Brian in January before I can finish the rest of it though.

Before I install it plans are upgraded front and rear outputs for the 300 along with the already ordered input and a set of Lomax 4:1 gears thru JBConversions.

The result will be a case with four different gear ratios available...

1:1
2.72:1
4:1 &
10.88:1

If you wanted to do this and not do the lomax you gear ratios would be as follows...

1:1
2.62:1
2.72:1 &
7.13:1

All in all it will be significantly cheaper than an Atlas 4sp, have better ratios I think, and should be just as strong. Hopefully I'll never bust it anyway...

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Fri Nov 16, 2007 5:08 pm
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I'll also be coming up with something very special for the shifters. ;)

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Fri Nov 16, 2007 5:23 pm
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This is a good write-up, Jim.
I'll use it for my doubler, when the time comes.

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Fri Nov 16, 2007 7:20 pm
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Jim, good job. You really didn't need to grind the teeth of the shift fork, I don't even notice them shifting mine, you still have the same amount of throw either way. You can come get your tcase if you want it before Jan its taking up space in my garage.


Fri Nov 16, 2007 9:37 pm
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terry wrote:
This is a good write-up, Jim.
I'll use it for my doubler, when the time comes.


Thanks Terry!

I've seen a lot of people ask questions about this setup and I don't think I've ever seen a very specific write-up...so I'm trying to be as detailed as possible along the way.

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Fri Nov 16, 2007 9:47 pm
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brianho13 wrote:
Jim, good job. You really didn't need to grind the teeth of the shift fork, I don't even notice them shifting mine, you still have the same amount of throw either way. You can come get your tcase if you want it before Jan its taking up space in my garage.


Thanks Brian.

I realize I didn't have to grind the teeth off but I figured since I had it all down I might as well. I know it won't change the throw either but it will make shifting it a little easier. Plus, I think it's a nice little touch nobody but me will know about once it's together (and you guys now I guess... :mrgreen: ).

As for the 300, I'll just get it in Jan. if that's alright with you.

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Fri Nov 16, 2007 9:50 pm
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Color me impressed.

Rev

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Fri Nov 16, 2007 11:09 pm
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Now its time to sac ride Jim! :mrgreen:

Nice work so far brother.

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terry wrote:
Fullsizexj wrote:
They feel alot heavier than that when you are holding it up with 1 hand and feeling for holes with the other

Thanks for the classic "out of context" signature quote! :lol:


Jim wrote:
I've got a small one, but we're already friends...and I live in TN.


Sat Nov 17, 2007 3:43 pm
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Let's not get too far ahead of yourselves....



All he's done, so far, is ground down two teeth on a detent and rebuilt half of a NP/TC.



When he's married the two TCs together, and finished the write-up, then I'll saddle up.
Besides....... Didn't brian already do this? :mrgreen:

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Sat Nov 17, 2007 3:52 pm
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Jim wrote:
I used a flapper wheel (on my Milwaukee :mrgreen: ) and some 320 grit sandpaper to make shure the selector pill would slide on the surface nice and easy.

Image



terry wrote:
Let's not get too far ahead of yourselves....

All he's done, so far, is ground down two teeth on a detent and rebuilt half of a NP/TC.



He obviously doesn't know what he's doing. He used the wrong tool. Everybody who knows, knows your supposed to use a Dewalt griinder.

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Sat Nov 17, 2007 4:52 pm
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hadfield4wd wrote:
He obviously doesn't know what he's doing. He used the wrong tool. Everybody who knows, knows your supposed to use a Dewalt griinder.


Who said I knew what I was doing?

:flipoff7:

Dewalt makes a grinder? :lol: I think they should stick to the carpentry stuff and leave the metal working tools to Milwaukee.

:mrgreen:

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Sat Nov 17, 2007 5:42 pm
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He can build all he wants, I'll still give him shit til he actually wheels.

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How many calories does masturbating burn? I don't think I took long enough to call it cardio, though.

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Sat Nov 17, 2007 9:26 pm
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I was impressed he could write that much.

Rev

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Sun Nov 18, 2007 2:54 pm
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Jim wrote:
Before I install it plans are upgraded front and rear outputs for the 300 along with the already ordered input and a set of Lomax 4:1 gears thru JBConversions.


whats the coin on that? $1500?

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Jim wrote:
seanr wrote:
I guess marring a girl because she put out and had big tits isn't a great idea

You're only supposed to promise to marry her.

I really don't wheel... I just pretend to. :blaze:


Mon Nov 19, 2007 12:19 pm
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Ramsey wrote:
He can build all he wants, I'll still give him shit til he actually wheels.


big X2 on that one...

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Jim wrote:
seanr wrote:
I guess marring a girl because she put out and had big tits isn't a great idea

You're only supposed to promise to marry her.

I really don't wheel... I just pretend to. :blaze:


Mon Nov 19, 2007 12:20 pm
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Opie wrote:
Jim wrote:
Before I install it plans are upgraded front and rear outputs for the 300 along with the already ordered input and a set of Lomax 4:1 gears thru JBConversions.


whats the coin on that? $1500?


I'll have about $1600 in it total. Really, I'm going to be in it cheaper than that, though, considering I made money on the jeep I bought just for the 231tc. Plus, you don't really have to do the lomax and you could probably get by with just the upgraded rear output.

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Mon Nov 19, 2007 12:32 pm
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Opie wrote:
Ramsey wrote:
He can build all he wants, I'll still give him shit til he actually wheels.


big X2 on that one...


You all will just give me shit about something else then...

:razz:

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Mon Nov 19, 2007 12:33 pm
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No shit, what else would I do.

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Jim wrote:
How many calories does masturbating burn? I don't think I took long enough to call it cardio, though.

Jim wrote:
'Let's not turn this rape into a murder.'


Mon Nov 19, 2007 1:33 pm
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Ramsey wrote:
No shit, what else would I do.


:circlejerk:

Practice pivoting?

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Mon Nov 19, 2007 3:28 pm
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Jim wrote:
Opie wrote:
Jim wrote:
Before I install it plans are upgraded front and rear outputs for the 300 along with the already ordered input and a set of Lomax 4:1 gears thru JBConversions.


whats the coin on that? $1500?


I'll have about $1600 in it total. Really, I'm going to be in it cheaper than that, though, considering I made money on the jeep I bought just for the 231tc. Plus, you don't really have to do the lomax and you could probably get by with just the upgraded rear output.


I think my total converion was only about $700 didn;t do 4:1 in either case (still plenty of gear). and I did the 32 spline outputs on both ends.

my 300 was free though.


Mon Nov 19, 2007 6:09 pm
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Who did you go with for your 32 spline outputs?

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Mon Nov 19, 2007 6:11 pm
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