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Old 10-25-2017, 10:37 PM
Aussie Crawl's Avatar
Aussie Crawl Aussie Crawl is offline
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Join Date: May 2012
Posts: 9
Post Australian Ultra4 Build

This is going to be a slow build that has already taken longer than planned.

Where im at with my Current Specs,
Ls1 engine with a few add on goodies for more power.
Th400 with a fresh overhaul
Np205 transfer.
Dana 60 Ball joint front with 35 spline 4340 axles
Dana 60 converted to unit bearing in the rear and 35 spline 4340 axles
Chassis is all 2" 120 wall through the cab area and 1.75 120 wall everywhere else.

This project came about after the sale of my old hilux that i ended up selling to fund the purchase of my first house. This was sold in 2013, since then life has had a habit of getting in the way of doing anything more that buying parts as they popped up and selling parts as the plan changes. After spending 2 years buying land and building a new home we moved in and planned on getting started after the landscaping was completed. That turned into a much larger job than planned and we worked out we needed retaining walls that turned out being in rock, We ended up building 65sqm of core filled block walls and digging out 36 cubic meters of rock with a jack hammer and a 1.5 tonne excavator. So after 12 months of spending everyweekend building retaining walls i ended up getting started on this at the start of the year.

During this time i picked up a pair of Diffs from a 80 series land-cruiser as i was only planning on running a supercharger ecotec 3.8l V6 and lt230 landrover transfer case. But when a deal came up on a Ls1 with a th400 strapped behind it for the same money as the ecotec the planned build went out the window.

Last year i had a bare frame come up for sale that was a bargin that i had to jump on. Being all excited i raced out and grabbed it and threw it on the back of the truck and dropped it off to my work shed where im building it.


Once the Ls1 TH400 was here i quickly realised the 80 series diffs would not be any good and the search was on for something stronger.

I found a pair of dana 60 Diffs and as soon as i got them threw them under the frame for some motivation.


Then the rules for the racing series i am planning on running in changed the requirments for material thickness. when from 2.6mm(0.90") to 3mm(0.120"), After talking to the guy who built the frame he confirmed it was all 2.6mm i ended up selling the frame and decided to build my own.

So i grabbed a jd2 model 3 and a notcher and made up a mount on castors and fabbed up a Air Hydro Conversion for the bender


Then i built a table to build off, Again on heavy duty castors each rater to 1000kgs. the table has the axles at full bump at the right wheel base. i mocked up the location for the Motor and trans and mounted them and the axles to the table.


Then my transfer case turned up. Being in Australia finding a np205 is near impossible. but after a few months of searching a np205 out of an old ford truck was list but it was a divorced unit.

So i got in touch with Offroad Designs in the states and spoke with them about what i had and was planning on doing and all the gear was ordered and delivered to convert this to a 32 spline short input. I found a 4l80e to np205 adaptor with will work with a spacer im going to make up to mount the 2 together.

While this was all happening i downloaded fusion 360 and started working out a design.

After a massive learning curve i have come up with this.


Now im up to the fun part of actually building this thing.




Now im just waiting on my 2" die to turn up for my bender so while i wait i have starter working on my truss and getting the geometry all set up.


Then for some idea of proportions i threw one of the tires on the front.


that brings me up to where im at now. Sorry about having to click the link for the photos im having trouble embedding them.
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Old 10-26-2017, 03:18 PM
entropy's Avatar
entropy entropy is offline
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Join Date: Sep 2007
Location: 95-miles from the center of Oregon.
Posts: 8,374
Looks like a good start

When did empirical knowledge get replaced by a theoretical education?

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Old 11-05-2017, 05:10 PM
Captainfab's Avatar
Captainfab Captainfab is offline
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Join Date: Jan 2006
Location: Coeur d'Alene Idaho
Posts: 2,738
Welcome to the forum

Looks like this is going to be a nice build. Did you fabricate those knuckles? Are those for a unit bearing conversion?
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Old 11-05-2017, 11:57 PM
Aussie Crawl's Avatar
Aussie Crawl Aussie Crawl is offline
Junior Fabricator
Join Date: May 2012
Posts: 9
Originally Posted by Captainfab View Post
Welcome to the forum

Looks like this is going to be a nice build. Did you fabricate those knuckles? Are those for a unit bearing conversion?
No the knuckles are from Trail Gear, they are a direct fit to the 99-04 ball joint dana 60s, they also come standard with unit bearings. I am converting the rear to unit bearings. This is so i can keep a spare in the pits if i need to swap out while racing.
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build, racecar, ultra4, wheeler

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