First Terra-Jet Project, for a Newbie

[Goach2]

More progress;

Got 2 layers of BoxLiner on the bottom, left out the grit for a smoother finish that hopefully lasts longer.
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Finally got the spar tranny split and pulled the axle through, I had to get at the clips to let it slide off the gears, as I would have broken the case trying to separate it totally. You can see what a PO did to try and get it out originally
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Since it was so chewed, I elected to cut the gear sleeve off of it and now I know why my other one won't budge. The key has welded itself to the sleeve:
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Here's hitting it with a cold chisel and small sledge:
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Guess I will be cutting the other one off too, since I've been pounding on it for weeks...

Oh, and here's a early axle next to a later one, as you can see, the early one is a little longer. FYI...
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[allwheeldrive]

Lots of good info and pics for anyone wanting to go this in depth in a restore later. Good idea keeping the grit out of the box liner underside. The goal is to have as smooth of a belly as possible to let these machines slide over stuff when they high center. My trick has been to hit the underside with WD-40 right before I take my Coot out into the mud, the difference is night and day, almost seems like it can't get hung up.

[Goach2]

Thanks for the tip AWD, I will lube the bottom before finally heading out.

Cut the sleeve off the good axle, cut along the key this time and it came loose and can be salvaged.
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My bearings came in for the rear axle, just waiting on the seals and a few parts from TJ, then assembly can start.

I also have an older clutch brake to put in, it's a little different than the newer models, not too clear what's missing to make it work. If anyone has any pics of this setup, that would be great.
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After the axle and tranny, I will be looking to fit the Vanguard in. Anyone have experience with this swap?

[Goach2]

Still waiting on seals, Louisiana is quite the distance away...

Dropped the motor in for a look:
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I'm assuming I have to cut the muffler off and somehow get it to 'Y' into the stock exhaust. Anyone have pics of their setup they want to share?

[ARGOJIM]

I'd hate to see you cut that muffler. Is that engine from a Max?

[Goach2]

No, this is a B&S Vanguard, came off a big pressure washer. Wish I could work with it, but it'll be in the way and I need the flanges....

[Goach2]

The dipstick is pointed in the wrong direction, I had to swing it 180 degrees, which means the original bracket is useless. Tried my best to fab a new one...

Original:20200229_001356.jpg

Forming some scrap: 20200229_000853.jpg

Welded: 20200229_002901.jpg

With paint: 20200229_154318.jpg

May not be pretty, but should do the trick. Left the original in place, if I ever need to go back to it. If it gets in the way, will cut it off.

[Goach2]

Finally got my bearing seals, time to start putting this basket-case together. Axle is going in through new transmission. First things first, loading up the anti-seize on the keys to avoid it seizing up again.
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[ARGOJIM]

Goach, where abouts are you located?

[Goach2]

Near Niagara Falls, Ontario.

[Goach2]

Finally got the transmission and axle in place, took some persuasion with a big hammer and a block of wood.
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Got the engine placed in it too. Need to make a few more modifications to it to make it work. Ordered a clutch, so while I'm waiting on that I can work on the engine and get the drive chain in place. I've heard that's a fun job...
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[allwheeldrive]

getting closer! going to be exciting to see this run.
I buy WD40 in a jug and pour into a spray bottle. Much cheaper than aerosol can, lasted me years of runs.

[Goach2]

Thanks allwheeldrive, I like saving money

Got the chain in and here's how:

If a chain was in it, I would have used the old one to pull the new one, but it didn't, so I fed a clothes hanger OVER the tensioner sprocket, under and around the front wheel sprocket and again over the tensioner sprocket. The chain was attached to the wire and I slowly pulled it through, while turning the front tire with my other hand to move it along. This took more than a few tries to get it to go, but it did. I actually put the chain under the tensioner first, before I figured out it was wrong and went back and did it again! The back sprocket is a piece of cake in comparison. Next make sure your tensioner bolt is fully released, so it sits as low as possible. Once I had the two ends close together in the middle of the track, I put the handles to a pair of pliers through the last two links and attached a big C-clamp to the ends of the pliers to pull the links together. I was probably less than an inch apart and couldn't get it to budge any closer, although it would have been perfect if it did go together. If I added a link, it would droop far too much, so I ended up getting one of these:
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And it went in fairly good, although it's slightly wider than the chain links, so getting the cotter pin back in was really tough and I had to grind the pin a bit to get it to fit, but it did.
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Next adjust the tensioner bolt as much as you can to get the chains tight. Mine is fully down and the chain still moves if I push it down. I may take one of the nuts out of the bolt to see if it will drop down any more. I guess I could always get a bolt that's slightly longer as well... There must be some limit though to how high you can raise the tensioner before the chain starts to hit the chain above it. Perhaps a little loose is better than too tight.
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Also, this came in, so now I have to figure out how to install it and which belt I need to make this all work. Getting close!
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[allwheeldrive]

That's quite the snake around with chain, I find chain no matter how tight I set it up finds a way to loosen after a few runs, so don't worry if its too tight feeling. On the other hand, if the sprockets are good and everything is in alignment loose chain still works fine without skipping. You'll know if it does from the loud POP POP POP sound that rattles off under load. While annoying, at least this isn't a 6x6/8x8 dealing with all those chains can be a pita. I'd suggest keeping whatever coat hanger tool you made in a tool box with you when you drive this, in case you ever broke a link you could potentially fix it on the trail.

[Goach2]

Good advice. I may try and see if it 'stretches' at all after some use and see if I can pull the cheater link out...