Heavy Duty TLT

How's the new shocks? Got any new running video? I'm waiting on a few things, then I hope to get my Juggernaut running again and test the enclosed differentials...

To fix it, I designed and 3D printed a template, to drill holes. The holes were supposed to land between the seem (I missed one 😅), then I brazed the seem with solder, which also filled the holes and act as keys to lock the two compounded gears. 😊 I hope the gearbox holds up this time, waiting on driveshaft then I hope to test the limited slip differential finally!!! 😬

Also… how tough are those Tamiya gears!!? When the post broke, it locked up the gears inside the gearbox, and broke loose the aftermarket pressed in hardened steel gear!!! I was able to spin it off by barehanded!!!

Found the culprit to the clicking noise in my Juggernaut’s drivetrain… This post that one of the gear shaft stakes into broke, which I didn’t realize in my first investigation. I don’t think super glue would be enough to fix it, so I dammed the post and poured ABS plastic slurry (making sure that it’s not going to interfere with the gears) which shortens and supports the post, hoping that it should make it stronger. 😬

Initially, I didn’t want to change the suspension links in my Juggernaut, but the round aluminum bars/tubes looks so much cleaner! I might do that since I have a mini lathe to make them now. 😊 If I ever get another Juggernaut, then I’ll keep that completely stock… maybe… 😅

There was a fitment issue, but I remedied it with some milling to the shaft and the brass hex drive. The diff had to move about 2mm to one side to make the clearance for the diff covers. There are o-rings on the inside which are pressed against the beveled gears to keep the fluid contained.

Along with my Juggernaut limited slip diff project, I’m also working on a limited slip for the Clodbuster. Here’s a couple of pics of the prototype.

Oh man! That’s so cute with short wheelbase. Any running videos? Where’d you get the STL file for that body? 😬

Here’s the cross section of my design in Fusion 360 which shows the channels for the o-rings.

The holes for the shafts have two o-rings with 5.5mm internal diameter. And the two halves sandwiches a 29mm ID o-ring. I haven’t had a chance to test it yet though. If things works out, I’ll have them printed in aluminum. I’ll get some made and will probably sell them. 😅

Project sealed diff continues…

You wouldn't want to have to refill the diff gear housing every time it leaks out, it'll lose it's effectiveness to limit the slip of the diff, also the small bottle costed me $11-15 USD. You're right, the axle housing would hold whatever leaked, but if you build enough pool on the belly of the axle housing, you wouldn't want the thick silicone grease on the drive gear (the gear with the "D" shaped hole), it would severely slow it down, which could strip something in the gear terrain and/or burnup the motor(s). Also, I had used really thick bearing grease prior to using the 60K silicone grease that I showed in my video, and it escaped and oozed out through the seam and the shaft holes when I was simply twisting the shafts opposite of each other. I didn't mind too much that it leaked out, because it was a similar grease that I was using to lube the drive gear. This time with the O-rings and form-a-gasket that I'm using, I didn't see anything come out when I did the same test. So hopefully it'll work. I will use a different "form-a-gasket" in the future (watch my video to understand what I'm talking about), I'm using this type for now since it stays liquid, and I need to open and close the diff gear housing for inspection, etc. Unfortunately I'm really busy at work lately, and don't have much time on the weekdays to work on my hobbies. If any of you decides to do this experiment, and get it to work properly, please share it here. For now, I hope you all stay tuned.

I'm throwing some ideas to make the differentials actually hold fluid inside to limit the slip… I’m replacing the internal E-clip with an o-ring, and also placing an o-ring in the groove behind the beveled gear in hopes of making the hole where the shaft goes through sealed. The seam will be another story, so stay tuned for that. Unfortunately, I came up with this idea of replacing the e-clip with an o-ring after I made my videos… https://youtu.be/P8RAWn5Oy6E?si=EGrLx-y4e_S4aiSD

Here's mine...

I'm not so sure, if you watched my latest video I showed that I tested the gearbox by gripping on the driveshaft and there was nothing slipping in there, and I even had all the plastic gears during the test. I rebuilt the differential, I did see some wear on the spider gears and beveled gears, but when I put it together and tested them by hand they seem to work just fine. The gears on top of the axle are all also fine, I thought maybe the drive gear that has the D shaped hole rounded out, but that wasn't the case. I can't tell until I fully put her back together, but there are some things I want to do with the axle housings to strengthen them a little, and also I want to do something with the diff housings to try and fully seal them so they can hold fluid better, and limit the slip. The grease I packed in them are mostly gone. I hope you all stay tuned...