Offroad MK3 Camper

[axxez]

Hi funkyfallk,

I replied to you via PM, but will explain in short for everyone else.

The locker is a modified 100% locker that was mostly built for Jeep Wrangler and adapted to my axle. It uses vacuum from the generator which switches a membran, which pushs or pulls a locking bolt into the axle. It is necessary to stop the car, trigger the switch, do a few meters with a turn or wheelspin on one side and then the diff is locked / or open again. Quiet gruff, but works fine (as long as it works). Right now my membran is broken and I do have problems to get spare parts. Will let a friend reprint it on a 3D-printer and see how it works.
I would suggest to use a compressor rather than the vacuum from the generator, as it is used for the breaks as well.

Cheers

[MinorMatt]

More details publically would be good if that okay?

[axxez]

Sorry for answering late.Very late. Hope you are still driving a Transit? So the thing is this difflock really annoyed me so much that I totally avoided it. Why was it annoying? It costed serious money. Worked like twice and when doing a 27000km drive through the world it just failed. Could be brought back to life in Russia and worked again - maybe twice. On the ruffest offroad part we where driving, crossing a bigger river, I was activating it by hand, meaning lift up the car, open up the Locker, activating it, letting sb turn the week until it locked. Then we drove through the water and afterwards vice versa. Beeing back home I asked a guy with a 3D-printer, send him the original worn-out piece of rubber and then.. He just found excuses not to do his job. This took like a year, then we both gave up on each other and agreed on him sending back the rubber part. And I never recieved it back, excuse was that it was the fault of DHL. So.. I lost the original part, nice! After that and some years I gave it another try when getting to know sb else with a 3D-printer. I had hope again, but he had some technical issues with his printer and no time for me in the end. Again time passed. As 3D-printers are getting more common I learned to know another person willing to help me out. You already guess what happened.. Then I finally got myself a 3D-printer and after learning the software, measuring correctly, doing some material research on different rubbers I gave it a try myself.
First I wanted to print the rubber part directly, but that is too difficult due to materials available. So I ended up designing the negativ, the positive aspect of now having a negativ I can use lots of times. Like when the rubber breaks during travel every workstore will have some cheap silicon for me. Might not las long, bit still good enough as temporary fix. Now after successfully printing and doing the rubber part again I needed some time, emotionally to now get to a point where I felt the time was right for an overhaul and assembly. Everything in place and works as designed.

[axxez]

Design via Autodesk Fusion, private use is for free and limited

[axxez]

Slice the 3D files

[axxez]

Printing

[axxez]

The finished negative, which is a small box that can be transported.

[axxez]

The silicone

[axxez]

The finished rubber

[axxez]

Alu plates

[axxez]

The membrane box

[axxez]

Plates glued with double sided tape

[axxez]

Assembly 1

[axxez]

Assembly 2

[axxez]

Final assembly