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Frequent flyer Gold
Posts: 1092
   
Location: An island off southern Tasmania. | This is a medium term project, here are some thoughts.
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | More pics
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | I have the K frame in an engineering house in Geelong for some fabrication work.
I cut up a shell from a wreck to use as a Jig.
here are some pics....
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Are any of the AWD magna parts compatible |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | I have used the auto and transfer case as well as front driveshafts from a Magna.
I acquired the entire rear axle assembly...waste of time...but I got some ideas from it.
I might use the main driveshaft which is sitting in the workshop...but it needs a cut and shut extension.
Will be going to the US in a few months on a shopping mission.
I will be doing the GT and TMR eventually.
Also have a new black VRX project car in the shed...it's a manual transmission unit. |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | would you ever concider, after completing your cars, selling a kit of some sort |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Today I authorized payment to air freight 120 kilograms to be air freighted by DHL ex Michigan.
That is the Endeavour rear assembly....cost $1800...freight? $1600US...import costs $700.
So...$4100 for the rear axle...comes in $1500 under budget thanks to the aussie dollar being nice and high against the USD.
Should be here in 10 days.
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Where did you source the rearend from? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | wsbtt - 20/8/2011 23:41
Where did you source the rearend from?
Michigan, USA |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | did that include the diff centre and axels |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Was checking out th AWD boxes, by any chance would the four speed Endeavor box be a better box to use, looking at the tranfer case differences, looks like the Endeavours output shaft is higher on the gearbox than the magnas, maybe to clear the rack.Goin off the endeavor pics looks like the tail shafts sit pretty high in the tunnel and both the 380 and endeavors front crossmembers are identical as well except for the rack of corse??????????????????
Edited by wsbtt 21/8/2011 16:27
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | wsbtt - 21/8/2011 16:24
Was checking out th AWD boxes, by any chance would the four speed Endeavor box be a better box to use, looking at the tranfer case differences, looks like the Endeavours output shaft is higher on the gearbox than the magnas, maybe to clear the rack.Goin off the endeavor pics looks like the tail shafts sit pretty high in the tunnel and both the 380 and endeavors front crossmembers are identical as well except for the rack of corse??????????????????
yeah...but one big problem...it's LH drive...so all that goes out the window and custom K-frame required.
which is where I am going..... |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Yeah its LHD , its the rack thats different but the K-frame looks the same to me |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | some goodies on their way now from cincinnati. |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | what have we aquired???????? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | wsbtt - 25/8/2011 12:48
what have we aquired????????
a pallet of endeavour bits |
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | tail\drive shafts, maybe even a gearbox?????????
By air freight?
Edited by wsbtt 25/8/2011 15:12
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Posts: 18
Location: Sydney Australia | wow you have a huge budget for this! |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Okay....It's 2am and i finally got the endeavour rear axle fitted up to the 380.
IT FITS!!!!
As we all suspected the PS41 chassis is common between multiple platforms....and right down to the last millimetre.
The 2006 endeavour rear axle frame just bolted straight in.
A couple of small issues...the stabiliser bar rubs against the additional strenghthener on the underside of the spare wheel well...but a nudge with arubber mallet will fix that.
Also the fuel tank tunnel is about 25mm too shallow.
In that area i face a dillemma...will i re-weld and modify the fuel tank or will I just rip it out completely and go down the Liquid LPG injection path?
too many options....but anyway there you go...finally been proven to be a go-er!
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380-Endeavour axle mock fit up.JPG (218KB - 552 downloads)
380-endeavour rear axle test fit up.JPG (203KB - 561 downloads)
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | you can see the recesses in the tank to make way for the tail shaft and exhaust in the endeavor underside pics,maybe you can aquire an endeavor tank on your janurary trip, looking good anyhow, only a minor hiccup hey |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | There is progress? |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I am very interested in your experience. What do you plan to do with the fuel tank? I'm just trying to do a full drive. However, I use a part of the Outlender 2006. I wrote to you on the site in the US. I think I have the same problem. Very interested in your solution to this problem. |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Stayer...I am flying to the US in January.
If you need me to get you something please tell me.
The Americans have trouble sending us things.
I am looking at how the Endeavour fuel tank sits.
But remember...mine will run propane gas and gasoline...2 fuels...and maybe electric rear wheel drive.
So I only need a half size fuel tank...maybe cut him in half and only leave the fuel pump side? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Stayer. also if you put the transfer drive you will need to modify the front K-frame assembly.
Good news for you my friend...the Endeavour K frame probably fit your left hand drive galant.
I will get many photos when I am in the US and post them for you to help you make a decision.
Stayer, do not bother with the Outlander...waste of time...use the Endeavour...the manual is on this forum for download.
Also...I am called Redblower at other forum. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Redblower, Yes I knew you, so he began to write in your topic, sorry. Why I use the Outlender? In Russia engines only 2.4-liter, no 3.8L. Chassis Outlender 2003-2006 is ideal for 9G - 2.4L. Secondly, Russia has not sold Endeavour. Order of the united states is very expensive. I wrote to you, I have a small car cemetery, and there are details Outlender. I haven't started your project AWD, I gather information. Very much I wait for your photos and solutions. I am planning to start in the spring. |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Just sitting at los angeles airport waiting in the qatas club lounge.
the petrol tank from the endeavour has been checked in as luggage and is now drawing oohs and ahhhs from the xray machine no doubt.....LOL
also got some other rear axle bits and heaps of photos of our endeavour rental car.
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Awesome, will be good to see it all under the 380 and working, good luck |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Had to take a 380 rear trailing arm to be refabricated, they are different on the Endeavour rear end, the kink is vertical to clear the ball joint....and of course the bastards whop sold me the rear axle only sent me one trailing arm...sheesh!!
Should be able to roll the wheels on the endeavour axle on the weekend.
Oner disappointing thing we found is the endeavour does not have a LSd at the rear like the Magna did....looks like I will be fitting a Quaife there....LOL |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | John, I want to give you the information for you. This is on top of the petrol tank. We in Russia have tried to install the fuel tank from Endeavour. He is not placed in the niche of the body. The tank is lower gear, cardan will not fit. But found a solution. Used tank of the Evo IX. Here's a photo 3 of the tank. Far Endeavour, the average Galant, in the foreground of the photo Evo IX. The tank from Evo gets up perfectly. He has tunnel for the pto. Yet explain photos. We took the bottom part of the body and do experiments on it. As you can see this part is standing against the wall. Perhaps you will be useful for this information.
Edited by stayer 8/2/2012 14:43
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | More photos. One tank was cut in half. Is not so simple inside. We thought to make a custom tank. But abandoned in favor of the Evo.
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48ceb18b54ccff25-main.jpg (42KB - 526 downloads)
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Stayer,
Here is the Endeavour fuel tank.
I do not think you have a Endeavour tank.
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | The exhaust pipe runs side by side with tailshaft. |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Here is what it looks like on the endeavour and the fuel tank
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endeavour tank and shaft view.JPG (153KB - 516 downloads)
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | I don't want to argue with you. We have a tank of Endeavour, and he is a great for the body Galant. When you start the installation, you will understand what I said. Good luck to you. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | here is a tank of Endeavour, find the 10 differences from your tank.
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48ceb334d2921620-main.jpg (41KB - 552 downloads)
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | stayer - 8/2/2012 19:10
here is a tank of Endeavour, find the 10 differences from your tank.
Okay I will try him Friday......I hope i do not have the same problem you had, because my rear axle is different to yours? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Sayer....
Of course you were correct.
The Endeavour fuel tank is hopeless to fit in this application.
This is because the Endeavour is higher and the back seat in the Galant is lower, it is impossible to make work.
I have decided to do everything else and will do the fuel tank re-design to fit in with the tailshaft and exhaust.
I meant to ask you, how do you intend to keep the ABS wiorking with your Evo rear axle?
I think the driveshaft to hub sensors are totally different to the Galant, yes? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Here is tonights effort... got the rear end completed now...hubs, calipers, abs sensors and had to have a trailing arm fabricated to the same shape as the endeavour to clear the ball joint.
Thieveing assholes only sent me one with the endeavour rear axle.
She spins and stops and the camber and track is perfect.
Just got to decide on the direction i want to head in for the rear drive now.
Still having the K frame work done, but am thinking of a simpler way....
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Frequent flyer Gold
Posts: 421
Location: Brisbane,qld | Check this site out, if your thinking about an electric rear drive, the motors connect to your drive shaft http://www.go-ev.com/
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Thanks for that wsbtt, yes have looked at that site. Some mean looking setups for sure.... |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Administrator - 10/2/2012 18:42
Sayer....
Of course you were correct.
The Endeavour fuel tank is hopeless to fit in this application.
This is because the Endeavour is higher and the back seat in the Galant is lower, it is impossible to make work.
I have decided to do everything else and will do the fuel tank re-design to fit in with the tailshaft and exhaust.
I meant to ask you, how do you intend to keep the ABS wiorking with your Evo rear axle?
I think the driveshaft to hub sensors are totally different to the Galant, yes? You go on the trail. However, do not repeat our mistakes. I don't want you to mislead or deceive. The idea with the design of the tank is a bad idea. We abandoned it. The tank from Evo 9 the perfect option. Hub is different from the Galant. There is a solution, hub Delica - bingo. I wrote to you, that this is not my project. But I know each step. I start in the spring of my project AWD.Rear axle of our Endeavour. He just painted and installed new silent blocks
Edited by stayer 12/2/2012 05:31
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Thanks stayer, I already worked out the hubs and knuckles to fix the different camber.
Car is ready for driveshaft now.
How are you going to control your transmission ECU? |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | They say In Russia " Will be the day - will be food". Up to this point have not yet come. But we have a strong team of engineers and programmers. We can solve this problem. |
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Our problem now in the other. Namely, on how to install a steering? Shaft transfer case rests on the steering. The steering need to raise above or down below, how do you solved this problem? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | stayer - 13/2/2012 00:45
Our problem now in the other. Namely, on how to install a steering? Shaft transfer case rests on the steering. The steering need to raise above or down below, how do you solved this problem?
That is the biggest headache.
I have engineer cutting K-frame and raising steering rack 115mm and machining steering ends upside down and longer bushes.
Here is how they did the all wheel drive Magna
notice K frame goes above tailshaft and steering rack bolted to firewall.
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AWD front K-frame.JPG (179KB - 541 downloads)
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Frequent flyer Gold
Posts: 286
Location: Russia, Perm | Obviously, your stretcher is different from ours. The issue is not settled to the end and discusses the various options. For example lower steering.
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Our steering is on the other side of the frame.
Much easier for us because the back transmission mount is clear, in yours the steering is where the mount goes.
Maybe you should try and mount steering rack on wall like Mitsubishi did it? |
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Posts: 8
| Just a tip.. The bolt pattern of the transfer case on an outlander looks very similar to that of the magna/evo transfer case. The only difference is the output shaft to the rear diff sits alot higher than that on the evo. Might help you clear the k frame, but may hit your firewall.
Rear diff on the outlander as the electric clutch... selectable 2wd/4wd.
The picture is upside down. But this is the mating side to the gear box.
Edited by savage3 5/12/2012 19:01
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chicken.jpg (13KB - 495 downloads)
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | Found another pic to make it all a bit easier...
It's only the steering thats the problem
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380 complete drivetrain.JPG (214KB - 538 downloads)
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Posts: 8
| What I was thinking if you used the outlander transfer case, you could ditch the spacers and have the tail shaft pass over the steering rack. |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | savage3 - 9/12/2012 21:41
What I was thinking if you used the outlander transfer case, you could ditch the spacers and have the tail shaft pass over the steering rack.
You're probably right...the things to consider are the length of the rack and the turns ratio as well as the pump connections and the column connection...as well as drive ratio?
(that's a mouthful... )
Don't suppose you've got one laying around that you can spare for a few minutes?
With my raised setup the posts are only an adjustable jig for fabricating triangular plates to weld to the K-frame, then a hoop over to firm it up.
I am also suggesting to reverse the tie rod ends and custom fabricate additional length in them to even things up a bit.
BTW those special bolts were 20 dollars each..... |
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Posts: 8
| I wish I could help you out with the transfer case. I don't know how far you've gotten with your AWD project, just throwing it out there as a suggestion. Have to keep in mind ratios between the transfer case and the rear diff. I'd be worried about the output of the outlander transfer case hitting the firewall..
Just throwing it out there anyway. Might save you some effort - or create more headache for you. You see to have some connections, you might be able to borrow a case from a wreckers or something.
Nothing's cheap when it comes to doing one off things for cars. The mivec valve housing cost me $700 to have machined and sleved, just to slot the distributor onto. Interesting thing is your "friend" on the other forums apparently has a manual AWD up and going. That's the next avenue I intend to go up pending reliability and more importantly pictures.
Edited by savage3 10/12/2012 22:40
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | savage3 - 10/12/2012 22:38
I wish I could help you out with the transfer case. I don't know how far you've gotten with your AWD project, just throwing it out there as a suggestion. Have to keep in mind ratios between the transfer case and the rear diff. I'd be worried about the output of the outlander transfer case hitting the firewall..
Just throwing it out there anyway. Might save you some effort - or create more headache for you. You see to have some connections, you might be able to borrow a case from a wreckers or something.
Nothing's cheap when it comes to doing one off things for cars. The mivec valve housing cost me $700 to have machined and sleved, just to slot the distributor onto. Interesting thing is your "friend" on the other forums apparently has a manual AWD up and going. That's the next avenue I intend to go up pending reliability and more importantly pictures.
Yeah...anyone can get a manual AWD Magna put together.
I know all about one offs too...the LSD was a much bigger project than we all thought it would be.....4500 dollars inc the Quaife.
hey...I appreciate your suggestions mate. |
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Frequent flyer Bronze
Posts: 34
Location: South Australia | How is the AWD project progressing?
Is this the way to tame the turbo tyre shredding qualities? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | RM380 - 21/3/2013 20:32
How is the AWD project progressing?
Is this the way to tame the turbo tyre shredding qualities?
It's on the back burner sizzling away.....
Other projects need completion first... |
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Posts: 19
Location: Bendigo, VIC | This is awesome, keen to see progress. |
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Frequent flyer Bronze
Posts: 33
| Been a while since we've heard any update on this?
Have you managed to go any further with this build, or is it still waiting for another day? |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | I have dropped all projects for the time being cause I bought a private island off the coast of Tasmania and am busy building jetty, ramp,pontoon, houde, solar power, desalination unit etc etc etc
Also had to buy a boat big enough to take a car on to my island.
That's all, I'll be done soon...LOL |
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Frequent flyer Gold
Posts: 1092
Location: An island off southern Tasmania. | here is the underside of an AWD magna for reference
 (magna awd crooked-view looking down tailshaft from engine.JPG)
 (magna awd looking back from rear axle.JPG)
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magna awd crooked-view looking down tailshaft from engine.JPG (185KB - 721 downloads)
magna awd looking back from rear axle.JPG (213KB - 701 downloads)
magna awd view directly under rear of engine bay.JPG (188KB - 856 downloads)
magna awd tailshaft showing exhaust side by side in tunnel.JPG (215KB - 856 downloads)
magna tailshaft mounts.JPG (126KB - 669 downloads)
magna awd tailsaft-it's not straight.JPG (160KB - 765 downloads)
magna awd start of tailshaft view.JPG (155KB - 689 downloads)
magna awd under rear diff exhaust layout.jpg (199KB - 800 downloads)
magna awd rear axle view from petrol tank cutout.JPG (184KB - 810 downloads)
magna awd rear stabiliser layout.JPG (182KB - 1105 downloads)
magna awd rear axle view from petrol tank cutout.JPG (184KB - 804 downloads)
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