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Fabbing own T-case Adapter



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Old 09-15-2009, 03:48 PM   #1
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Fabbing own T-case Adapter

OK so I'm probably gonna come off as completely nuts for this idea but... I bought the wrong case for my setup, thinking the adapter would fit but it had a different size and bolt pattern, plus I couldn't find the 6 bolt 205. Anyway I'm thinking of fabbing up my own adapter to mount it to my tranny.

T-case 8 bolt 205-Tranny NV4500

First idea is to cut out a piece of 1/2 plate with the 8 bolt pattern shape that goes into the 6 bolt pattern and bolt it to the t-case and then into the tranny. That way if it doesn't work I don't lose the case.

Second idea is only if the 8 bolts into the case get in the way. Cut a donut shaped piece and weld (wahoo I love welding cast) it to the 205 case then drill and tap the 6 bolt pattern and be done with it.

I want it to be just a plate between the two with no extensions or anything I think it will be a lot stronger that way.

Either way I will need to cut out the chunk of the tranny where the 205 shift rail will need to go.

Haven't taken exact measurements yet but I'll definetly give it a shot before I buy the whole adapter kit from Advance Adapters. Let me know what you guys think.
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Old 09-15-2009, 04:51 PM   #2
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Better check your shaft length. If you push the t-case back 1/2" there may not be enough spline contact to hold up.
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Old 09-15-2009, 08:31 PM   #3
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you'll prolly have room to move the case back a half inch, I had to put a short 32 spline( smae input you have) into my 6 bolt case. I had to grind about 3/8 of an inch off the 4500 output to get my t-case to mount up. I think you will still have way overkill spline contact if you can get this setup to work. In my mind though, you will have to use tapered bolts into one side of the adapter to mate it to the t-case, and then drill and tap for studs to be able to mount it to the tranny.It will be alot of precise drilling and tapping to get it right, but, I suppose if its worth the money savings to you, go for it!. If you were to find the 6 bolt 205, it still costs @ $135 to get the short gear put in it to be able to mate the two without any adapters.
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Old 09-15-2009, 09:06 PM   #4
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Yeah I am a little worried about the amount of spline contact but I'll at least give it a try. If it all bolts up right I'll probably get some bolts that will go through the plate and into the front of the case flush the inside so I have some threads in the case as well as the adapter. As you can tell I really don't like spending money with advanced I bought the bell housing setup from them and am still wondering how much of a clutch I'll have, doesn't seem like it's gonna work right, and the boot for the clutch fork didn't even fit! If I'm paying that much it better be strait bolt in no adjustments! Thanks for the feedback guys.
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Old 09-16-2009, 08:33 PM   #5
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Got the Plate cut out today I'll post some pics up as soon as I can. Need to clean up the edges and bore out the hole for the input shaft to clear the snap ring. Then Drilling, Tapping, and Test fit. Anybody know of a place for a good cheap 205 rebuild kit?
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Old 09-22-2009, 08:32 PM   #6
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So almost done with my little fab project. This is what I've got, the three bolts directly around the input shaft need to be ground down on the outer edges to clear the tranny, or shave off a little bit on the tranny.

The next two bolts will require grinding on the tranny then it fits!

Just gotta tap my bolt holes! Then linkage and that crap. My favorite part is I clocked the 205 up a crap load for more ground clearance, might have to shorten one of my headers though. Man

I'm so glad I didn't pay 517 bucks for that kit! Still gotta post pics
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Old 01-09-2010, 07:45 PM   #7
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Well it's on the project. It all looks good but we'll wait and see when I put the body on the frame and drive it!
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Old 01-09-2010, 08:07 PM   #8
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Old 01-10-2010, 11:41 AM   #9
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I know I know, need to put pics on this computer then upload and post them.
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Old 01-10-2010, 12:04 PM   #10
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If I read this right, you are trying to match up a NP205 to a NV4500. If so the adapter on the NV4500 4wd version is already the 6 bolt pattern. You just need to notch it. Or, you can get the Advance Adapters unit which will allow you to hook up the shifters instead of having to booty fab.

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Old 01-10-2010, 12:40 PM   #11
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He's adapting a figure 8 np205 to the back of a nv4500. In reality all he needed to do was find a round pattern np205 and bolt it up. I think he likes a challenge though. We need pics for sure.
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Old 01-10-2010, 12:49 PM   #12
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He's adapting a figure 8 np205 to the back of a nv4500. In reality all he needed to do was find a round pattern np205 and bolt it up. I think he likes a challenge though. We need pics for sure.
Thanks for clarifying. Nothing like reinventing the wheel. I know a square peg can fit a round hole!
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Old 01-10-2010, 02:06 PM   #13
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LOL yeah challenge isn't bad, but also those round patterns 205 are pricey, and I couldn't find one and the AA kit is pricey too. So about the pics... They were deleted off of my zune so it's gonna be a few days. I've got them on my girlfriends laptop so I'll put them up soon.
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Old 01-10-2010, 02:38 PM   #14
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LOL yeah challenge isn't bad, but also those round patterns 205 are pricey, and I couldn't find one
That sucks that you went to all the trouble. I have a round 205 that I would have traded you.
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Old 01-10-2010, 03:11 PM   #15
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LOL yeah challenge isn't bad, but also those round patterns 205 are pricey, and I couldn't find one and the AA kit is pricey too. So about the pics... They were deleted off of my zune so it's gonna be a few days. I've got them on my girlfriends laptop so I'll put them up soon.
Contact Obijuan on here. I swear he round pattern 205's like it was normal.
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Old 01-10-2010, 05:11 PM   #16
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Ha ha oh well we'll see how it goes seeing as I already rebuilt the case and everything.
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Old 01-19-2010, 06:08 PM   #17
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