The transfer box on my classic warrior had finally given up. Didnt help getting stuck the other day and trying to rock it back and forth to get it out. Milners had sold out when i was there so i had a look through the poly bushes they had behind the counter and bought one for a tenner that was roughly the right size.

old mount:


So decided id make up a heavy duty transfer box mount

started with some thickish walled tube, cut it to size and faced it up in the lathe:


machined the bush down to fit in the tube properly:




Bit of a snag. the holes in the transfer box plate were to big. had a few options really. either make a new plate, drill out the center sleeve of the bush to take a bigger bolt or machine up some little packing spacers to fit in the existing plate.

making the spacers





Fits spot on now:

bent up some flat 5mm bar, drilled it to take a 10mm bolt and welded it in:



finished item:

Cracking work there mate , I think Lez had a polybush in his ......... or may have been someone else .........

But can the transferbox move at all now? Seems very stiff?

Very nice work, looks very good.

Its not quite finished yet. the amount of vibration is mental! its because the bush is quite hard. I'll drill some holes through the bush to try and soften it up and fit some rubber strip under the mount tomorrow to try and kill some of it down. failing that i'll be buying a proper one from milners. If it was a racer/off road toy it would be great as it does put the power down a lot better now without a load of transmission movement. ideally one of those slotted type of poly bushes would be better but machining them isnt really possible so would have to find some tube to suit or bore out some solid bar.

I can tell you why you have loads of vibration..the first pic is how the bush is meant to look after a few miles...The centre bit just floats inside the outer bit and isnt really a bush but more a steady/movement bush which stops the transmission rolling to far over.. I fitted a new mount when I refitted my gearbox and it is designed to break the thin plastic which mine did in the drive round the block..

Really? In a way it does make sense as it passed its mot in october when I bought it from the mitsi dealership. It just seems wrong to have a mount that looks so knackered

I'll machine abit more off the poly bush then to give it some movement in the tube.

I think as long as there is some rubber left and its not metal to metal then it's still a goer ........... still impressed with your ability to fabricate something to suit your needs though

Thanks krutly I have to make bits up like this at work quite often. I want to get on with relocating the rear shockers and making up some longer shackles at some point as well.

Looks good mate, but as said this is not a mount or a solid bush, it's a floating bush, the inner is supposed to be separated from the outer as per your first pic, a few have done similar mods to yours but all have experienced bad vibration, there needs to be around 10mm of fresh air around the inner to alow the box to move freely

I'll pull the bush out tomorrow and sort it then. Thanks for the info on this I never knew it was supposed to move about that much. The vibration is so bad at idle its actually hard to see lol. Honest to god ann summers could only dream about selling this much vibration lol.

Alex do you have any rubber sheet or fiber washer mate think the vibration is from steel to steel but could be wrong

Quote: krutly wrote in post #4

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Cracking work there mate , I think Lez had a polybush in his ......... or may have been someone else .........

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see lez for longer shackles..

Took a bit more off the bush today and its working fine. No transmission shunting or clunking and the vibration is sorted. Jobs a gooden as they say. Be better for the other mounts as it cant move about as much as before.

All things considered I think the shackles will be the easiest mod ive yet to make. And the £25-30 id save by making them would go towards a k&n filter.

I got my K&N off ebay for a few quid secondhand makes the turbo a bit noisier which is good... straight through exhaust next on your list as well

Straight through done. Just got the small silencer still in the tail pipe. Egr blanked as well. No major difference so a k&n is on the list to try and help. Not bothering with the apollo thing though I think its a bit of a gimmic myself. If I wanted a fancy filter housing id knock one up out of stainless. Boost and oil pressure gauges are on the list though.