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Will a G35x transfer case fit on a Frontier 4x4 box?


Icehouse

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The G35/37 transfer case can be fully locked.  That's what so cool about it.  From open to lock, The GTR guys put a switch inline with the fuse so they can have fun in RWD then switch back to AWD.  I hope to do the same thing.  

So I've made some progress.  Here are some pics.


Getting a good scan inside holes to find the centers is the toughest part.  So I tried using tight fitting drill bits.  Maybe since I can take reference points from anywhere to use in any plan I choose it will work better.  Still trying to get better at all the software.  It's really tricky to use.  Makes SolidWorks seem so easy.  

sooxyMJ.jpg


Point cloud 

Jqnn7J1.jpg

Info from the point cloud used to sketch in the plane I made.  

Ck8nkaG.jpg


vSb0A8a.jpg


The two patterns I need to line up.  looks easy enough.  

uA122JU.jpg

Almost done modeling the part, needs a little cleanup. 

AjnzhQW.jpg

New part printed out 1:1 for a test fit.  Seems good.  

GEV1qef.jpg


eeKQY5u.jpg


Once the transfer case is on the trans I have to hook that to the SR.  So me and Sam made an adapter.  

B6kmVFn.jpg

Next, I need to get a chunk of aluminum and get to machining.  It's a really big piece and I've never machined anything of this size on my mill.  I'm trying to imagine how to do it in stages just in case my mill freezes or I have to call it for the day.  Wish me luck guys!  

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