Subie Boys , Lovey80 Resto

rtcb65 · Post by **rtcb65** » Fri Dec 04, 2009 5:55 pm

Front calipers mounted. Rear ones color coded to match the front. Pedal box fitted out ready to go in. L cross member in place ready for the gear box. The square M.Y. throttle cable mount hole moded for the ej cable and fitted. The battery box is started and on it's way.

rtcb65 · Post by **rtcb65** » Fri Dec 04, 2009 5:57 pm

And one more pic that didnt fit in last post. View from rear , looking at the battery box.

riksta · Post by **riksta** » Fri Dec 04, 2009 8:38 pm

looking good duys.

Rik.

chridk · Post by **chridk** » Fri Dec 04, 2009 9:57 pm

That battery box looks the goods boys, nice work

lovey80 · Post by **lovey80** » Sat Dec 05, 2009 8:02 am

Steve you are a FREAK! Love the work all round boys. Really starting to pick up momentum now. Counting down the days until I see Scrappy again!

Cheers

Chris

vincentvega · Post by **vincentvega** » Sat Dec 05, 2009 10:30 am

awesome sheet metal work as usual.

Thalass · Post by **Thalass** » Sun Dec 06, 2009 10:00 pm

I hate to be a party pooper, but if I recall correctly a battery box has to be able to contain the battery(ies) for a certain gee force in various directions. I can't remember the exact numbers. It's less for negative gees, highest for forward and rearward impacts. As great as this work is, would the box stand up to it?

Of course that could be for electric cars with 300kg battery boxes. One 12v starter battery might be different. Or at least would be easier to contain in a crash.

Once again, great work guys!

rtcb65 · Post by **rtcb65** » Mon Dec 07, 2009 7:10 am

Thalass wrote:I hate to be a party pooper, but if I recall correctly a battery box has to be able to contain the battery(ies) for a certain gee force in various directions. I can't remember the exact numbers. It's less for negative gees, highest for forward and rearward impacts. As great as this work is, would the box stand up to it?

Of course that could be for electric cars with 300kg battery boxes. One 12v starter battery might be different. Or at least would be easier to contain in a crash.

Once again, great work guys!

Hey Thalass,

I cant be certain if the battery box will fit all the specs you have mentioned , but it is strong. I would hate to hit my head on it , lol, and as it is only for a gel pack deep cycle to run a fridge , it should be ok. The main battery is still under the bonnet , mounted on the opposite side , on a mirror image mount.

last celtic warrior · Post by **last celtic warrior** » Mon Dec 07, 2009 7:51 pm

The battery compartment is stronger than it needs to be. It's hand formed from 1.9mm sheet steel, with gusseting ribs and floor ribs to protect the battery from possible off road impacts. If it's TOO strong, it would be like welding an anvil into the frame.

Tortional, impact and deceleration forces are taken into consideration in desgning the ribs and general shape, whilst being mindful of the effects this addition will have on the original crumple zones and vehicle systems (suspension, exhaust, fuel tank etc...). A lot more thought went into this than you can see in the finished work, as is the case with most of the work we do. And certainly a lot more has been considered than when the manufacturer designed the battery mount in the engine bay...

rtcb65 · Post by **rtcb65** » Mon Dec 07, 2009 8:57 pm

Today Ross and i went Brisbane way to pick up the motor ( Ej22 ), Gearbox ( L series AWD D/R with a few changes to it and the computer and loom.

A big THANK YOU goes out to Jeff at Crossbred Performance for all the help in sourcing out the parts for us.

Matt · Post by **Matt** » Mon Dec 07, 2009 9:54 pm

Nice find on the gearbox mate! i have been chasing one of them for years, and never found one! Also i will playing santa on Friday at this stage!

vincentvega · Post by **vincentvega** » Tue Dec 08, 2009 9:52 am

Gen2 motor. nice

much smoother and better on fuel than the early motors.

YouTube · Post by **El_Freddo** » Tue Dec 08, 2009 3:56 pm

I also see that the AWD L box is in an EJ box's casing... Good move there! I'm looking for a casing to do the same thing again

Seeing the EJ in that pic reminded me of when I was getting my parts together for the EJ conversion - it was exciting having the EJ22 in the shed, even though I knew I was a while away from having it running or in the car for that matter! I bet you guys will enjoy installing one of these into an MY!

Cheers

Bennie

rtcb65 · Post by **rtcb65** » Tue Dec 08, 2009 7:45 pm

El_Freddo wrote:I also see that the AWD L box is in an EJ box's casing... Good move there! I'm looking for a casing to do the same thing again

Seeing the EJ in that pic reminded me of when I was getting my parts together for the EJ conversion - it was exciting having the EJ22 in the shed, even though I knew I was a while away from having it running or in the car for that matter! I bet you guys will enjoy installing one of these into an MY!

Cheers

Bennie

Hey Bennie,

You are on the ball mate, and once again , hit the nail on the head. We got the box fitted with liberty front cases so the clutch is just as simple as , ordering a liberty clutch kit.Thanks again to jeff at Crossbred Performance for that bit of info.
We wont to make the brumby so if anything needs to be replaced in the future, its off the shelf parts. Not a mix match. The box also has the out put shafts to suit a off the shelf brumby front drive shafts. Also has the L series low range , not the awd low range.
Also Bennie, to answer your statement about enjoying the fitting of the ej into the M.Y. , you bettcha i am, cant speak for the other 2, i am as in about 6 months, i am putting one in mine . So it is a good practice run. What we learn doing this one , i can implement into mine.

last celtic warrior · Post by **last celtic warrior** » Wed Dec 09, 2009 7:03 pm

Got the last side hammered out this afternoon and started welding things in place. Starting to look like part of the car now...

YouTube · Post by **El_Freddo** » Thu Dec 10, 2009 6:44 pm

Oh - I thought the battery box was going up against the cab wall as well... Will this brumby be going offroad as that battery box could become damaged if the rear bottoms out on a rock - I know you aim not to damage your vehicle offroad but things happen, that's how I dinged up my fuel tank...

Rick that's the same I'm hoping to do eventually with my L series gearbox wise - but with 4.1 ratio diffs

Just money that's holding me back... And I'm not really keen on buying a complete Liberty box only to use the casing from it. You'll love doing the EJ conversion! I enjoyed doing mine and would not hesitate to do another one. You'll really enjoy driving your subi and paying for the fuel that moves it

Cheers

Bennie

last celtic warrior · Post by **last celtic warrior** » Thu Dec 10, 2009 7:57 pm

Ok, the battery compartment is made out of 1.9mm thick steel, which is thicker than both the chassis and the ute floor, and can stand to cop a nasty dent or two without cramping the battery enough to damage it. In addition to this, in order to dent the floor of that compartment, it would have to be a hard drop off something directly onto a rock or stump, and then, it's strong enough to hold the back of the ute up in the air (even fully loaded). And, if you WERE to drop the car onto something like that, you'd rip the whole rear valance and subframing out of the ute as you roll forward (if you didn't have a good towbar or this compartment). There's plenty of FAR more delicate items under the back of the car to look after, apart from the fact this addition actually GIVES protection to the car's underside.

One point I can see that some people are missing is... THIS IS NOT WHERE THE CAR'S STARTER BATTERY WILL BE. This is just for the extra battery that runs the fridge and camp lights. You could set a grenade off in there and it's not going to have much effect on whether you can still start the car and drive it home or not.

Moreover, The safe little areas left either side of the "huge spare wheel carrier" up against the cab wall, are reserved for the FRAGILE, EXPENSIVE and quite VITAL fuel pump and surge tank units. It's not like the auxiliary battery could fit up in one of those spots anyway, and even if it did, it would be hanging below the level of the floor right where you're most likely to scrape a big rock or exposed tree root (if you've ever looked under a car, you'd know how many scapes and dings they end up with in the floor and chassis sections)...

Rant over... For now...

lovey80 · Post by **lovey80** » Thu Dec 10, 2009 11:50 pm

Steve, the battery box is fantastic and exactly what we talked about (and more). It will serve the purpose of what it was intended for and as long as the Engineer signs off on it then who cares about the rest.................It's certainly not dangerous so its all good by me..... I highly doubt ill ever hit that box hard anyway.

Keep up the good work.

Cheers

Chris

rtcb65 · Post by **rtcb65** » Fri Dec 11, 2009 4:06 pm

Fitted all new wheel bearing seals and straightened abit of the body. Also pulled down the drive shafts and cleaned and repacked them.

YouTube · Post by **El_Freddo** » Fri Dec 11, 2009 10:45 pm

Sorry Steve, I was not meaning to pick a bone with you. I just had it in my mind that the battery box was going up against the cab's rear wall. I understand that the battery in that compartment is not the starter battery, either way it still has the potential to arc out on the lid if it happens to break its clamps. Having it at the back of the tray section makes sense for accessability if you've got a light load, I know with Sunnie that light loads arn't really large and tend to live against the cab's rear wall...

As for engineering I doubt you'd have a problem with getting it past with all the work that's been done on this unit. It's really a piece of work and the boys working on it should be most proud - and that goes for all of the subi examples that leaves their shed. I'd love them to do Sunnie over but I'm not sure they've got the time and I know we've not got the money to have it done...

Can't wait to see the end result - I'm hoping for LOADS of pics

Cheers

Bennie