Swamp fox files

[Tomo]

Hi ,
To the current owners Don ,Nightowl and Noel and other owners also

Reference to the ""swamp fox rebuild "" pictures in the gallery under "Tomo""

As i have had a few requests for info rather than reply individual some of the general info i will explain

Outside
fibre glass swamp fox body was painted with house paint . This had to be removed . Original colour was the typical brown . After 4 days of sanding the body was ready for paint .

Inside tub
was painted with many different paints
The decision was made to sand blast the inside of the tub to remove old paint and as a bonus get a good look at the f/ glass matt [exposed from blasting].
Do get an experienced blast operator as the threat of blasting to aggresively is high and u can wreck the body. I had the blasting done at a ship yard .

inside tub repairs
The body goes semi transparent and the light shows all the cracks etc when viewed from the inside . This is also a good time to fill the axle holes as well
Reapplied f/glass to inside 3 layers to the chain area // 2 layers to the general floor // 1 layer up the sides

Paint and coatings
The out side top and tub were done with
epoxy 2 part under water primer
urethane 2 part top coat
Inside the tub
MARINE Flow coat in whisper grey [brush on thick paste sort off ] sets hard and way more durable than any paint

tomo
chassis manufacture and mechanics next time see ya

[micmac]

Tomo Gallery - Amphibious ATV Pictures

[nightowl]

Great job Tomo. When you gonna Have her up and Dancin?
Or should I say Mud Rastlin. HEHE.

[jpswift1]

I LOVE that orange color.......that's going to be a really nice machine. Looking forward to seeing it go!

[AussieMax]

When we were on our holiday round most of Australia we called in and met Tomo, and saw this machine close up. The orange paint job is practically flawless, and the amount of manhours in building the new chassis is unbelievable! Tomo, you are a perfectionist, and it will be probably the best example of a Super Swamp Fox around. Look forward to when you get it on its feet!

[Noel Woods]

Tomo: Great job so far on the build. Orange is a bold color and I think its beautiful. It reminds me of the 1977 International Scout SS2 which I had when I was a teenager. It looks like the rest of the build is professional & delingently done. I can't wait to see the finished product.

[Tomo]

hi, to every one

Swamp fox build continuing slow steady but getting there .
Fitted trans ,engine, drive line
Rewired fitted with ""truck lite""" parts
sealed stop tail lights oval style grommet mounted
headlights 4 1/2 inch sealed beam units ****** 4 inch round mounting grommets****
Led courtsey lights f/r
12v plug and tacho optional

Shifter t20 as per original
forward reverse shifter converted from between legs operation to a stick type as per t20
shifter [comes up from floor and far easier to operate ]

Floor plates 3/4 ply wood rebated [recessed cut to clear all the protrusions from the chassis ]
timber floor sealed with a few coats of fibre glass resin then sanded
marine grade carpet used

engine covers 90 % finished

Engine
bandolero cam
new lifters ,pushrods ,valve springs ,retainers ,hduty rockers ,PVT conrods
heads machined down
timing key
28 mm kohler accelerator pump carb [kehin ] rejet [factory 26mm ]
use kohler air filter/ housing setup with cold air inlet out side of engine cover etc
general recondition honed cylinders , new bearings on crank etc
wired in rev limiter

tested for 20 mins goes real well
but ,disc brake spockets rubbed on secondary clutch slightly melting the slippers
Will space out clutches and fit new slippers

still waiting on new t20 discs

photos soon

tomo

[Noel Woods]

I can't wait to see the completed project, its going to have all the right stuff.

[jpswift1]

This sounds like it turned out really well! This is some really good motivation to help me get my 'Fox finished, I can't wait to see the pics!

[Tomo]

hi,
The Fox is alive ............
Road testing and getting a few of the bugs sorted out .

Prior to this as follows





new t20 stainless brake discs finally turned up [yes they are flat ]
Things u discover is how do u lube the transmission chains without covering the discs with lube ????????? Your suggestions would be appreciated ..
[A lube i have found that is super sticky is ROCOIL but open to anything better ]

With hydraulic calipers on the disc u may think that having the smallest amount of movement in the disc mount onto sprocket may be acceptable eg to allow for disc heating etc
BUT any movement at all no matter how small will give u increased pedal travel and this is bad .
Solution is to mount the discs as solid as u can under the original type circlips [use shim steel]

Finally setup the clutch alignment primary to secondary
measure with string line on the trans side of secondary and the engine side of the drive
comet salisbury 780 drive 770 driven
With belt installed the surfaces have to be inline .

More to come later
tomo

[Bazooo guy]

Dont you need to offset the clutches?

I did mine like this.

[Tomo]

hi bazoo guy ,
The mystery of clutch alignment hmmm hmmmm
Before i go on with the limited info i have if u have further info such as specific offsets for any model please post picture of the page[s] u may have .

I have found little info on offsets and this subject to be the biggest mystery
Why would u run offset is dependant on how the clutch system works together in unison so as i am no engineer this info is valuable .

My info lists 1/4 offset 780 drive 770 driven [belt installed or not unknown ]
So every body is aware the 780 drive with 780 driven lists inline [belt installed ??]

IN the end i rang max dealer
780 drive 780 driven belt installed ,as mentioned previously, inline measured by string

My belt setup seems to be happiest there ,as before with offset i was getting belt wear bad ..

My advice to anyone setting up a belt system on drive and driven clutches is to know the centre to centre distance [trans to engine ]the belt lenght is determined by this .
I have found some catalouges will supply cen to cen distance and the clutch spec and the correct belt to do the job very helpfull info ..

tomo

[Bazooo guy]

On a cvt clutch when the primary closes and the secondary opens (high gear) the centre to centre of the pulleys and belt changes. If the 2 pulleys are not offset the belt will be on an angle in high gear.
I have read about your method with them inline but to me it makes more sense to have the clutches inline at high speed.
Heres a video that shows how much the belt moves sideways.
Polaris Sportsman CVT clutch - YouTube

Heres more info

http://www.gates.com/brochure.cfm?brochure=1033&location_id=542

[Bazooo guy]

Heres a quote from a snowmobile website regarding the cvt clutch and belt.

Clutch offset and center to center distance is very important for proper clutch and belt function. If the offset is off it will cause more pressure to one side of the belt than another which results in excess temperature, wear, slippage and performance loss. If belt free play is excessive it will cause the belt to pull up into a higher ratio at engagement causing sluggish performance off the line as well as excess temperature, wear, slippage and performance loss. One rule that is beneficial for belt free play is to run the belt as tight as possible without creeping at an idle

[Tomo]

Bazoo guy,
Hi ,yes i do agree with u on all of the points of note u have raised in regards to pulley offset [primary to secondary ] .
********From the tech manual u posted does it list the offsets by model etc ?????************

As far as i am aware there are 2-3 reasons as to why u have different offset between the mounting of clutches

1/ align the belt so it is as close as possible to being inline at the rpm u desire eg this attains maximum efficent operation and therfore best transmission of torque and or hp

1a/ different clutch requirements 2 stroke or 4 stroke engine

2/ how much or little drag do u want on the secondary clutch at idle rpm eg belt inline will give little drag and most likely better engagement of gears .

tomo