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C5 LDS Struts. (Liquide Suspension Direction)The struts are a sealed tube with the Hydraulic ram fitted inside a tube. The ram leaks a small volume of fluid, it has been designed that way, I "think" it is so that both sides of the seal are always lubricated. Somewhere it’s documented, on the “InterWeb” they have a design life of 100k miles/160k Km. See Citroen systems - www.citrina.lt/failai/tech/_xm/Hydractive2.PDFNow just using C5 struts at the rear. No Anti-Roll bar, no height sensors, no CPU in the pump. The basic strut, over engineered for a 2cv, would be good for a project on Suzuki Jimny, or Landrover.  Strut top with sphere before modification (butchering).
 Strut Top mount cut down with Spring cup fitted.  The sphere, the valve arrangement, similar effect as a shock-absorber, the fluid flow restricted to provide damping. Strut showing top mount/pivot point. Fabricated clamp from aluminium, for fluid return, more robust and to survive off-road usage. Fabricated Strut lower mounting leg. LDS pump. LDS pump in situ with Spaghetti pipe work.
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REAR DIFFERENTIALCitroen 2CV gearboxes can be broken, with extreme off-road usage (Red_Mist_Moments  mostly the differential (Planet Gears).
When this occurs the broken bits go around the box and spoil everything. Occasions there has been a hole in the casing or the whole casing cracked and thus useless.
Quaife produce an ATB diff, no benefit for off-road traction, BUT they don’t break… A solution at £750.
Many years ago, I was given a couple of Citroen GS gearboxes, bigger and stronger than 2cv and most times same diff ratio.
They were stored (Hoarded) in Shed 3.
So I thought what about modifying the GS gearbox to make a robust differential for the rear diff.
Have been lent a Harrison 140 metric lathe and acquired a Myford metric milling machine.
Now using Google/Youtube they can be your friend if your persevere and ignore the curse word to select the good stuff, it is possible to “Teach An Old Dog New Tricks”Standard Citroen 4 Speed box.
 Cut The Back End Off.
Pinion Shaft way too long.
 Mill The Back End Flat.
The alloy cuts very nicely with carbide tools. Hold All Together Using Pinion Shaft and A Fabricated Shaft.
 Welded Up (Thanks to Ian at Alisport)
 Turndown and make new thread on the Pinion Shaft in the Lathe.
Shaft is case hardened, but modern carbide with inserts make things easier. Shortened Shaft.
Broke about 3 inserts making the thread, hence thread not so precise, but it’s still holding.
 Used the mill again to make the bolt-on bearing support and lip seal holder. Finished Gearbox (the dipstick fouls the body:( )
 Rear End With Differential In Situ.
The rear discs have had their diameter reduced, to reduce the braking disc area.
Hopefully not over-braked at the backend?
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Last Edit: Nov 12, 2020 17:09:33 GMT by subarupete
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Nov 12, 2020 17:06:16 GMT
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Last Edit: Nov 12, 2020 17:10:28 GMT by subarupete
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mat88
Yorkshire and The Humber
Posts: 1,542
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Nov 12, 2020 17:22:07 GMT
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Can't say that I've ever particularly been interested in 2cv's but the engineering alone in this is worthy of a bookmark! The fact it's madder than a box of frogs is just a bonus!
Bookmarked!.
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Nov 12, 2020 21:14:38 GMT
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Wow. Wonderful!
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1968 Mini MkII, 1968 VW T1, 1967 VW T1, 1974 VW T1, 1974 VW T1 1303, 1975 Mini 1000 auto, 1979 Chevette, 1981 Cortina, 1978 Mini 1000 1981 Mini City, 1981 Mini van, 1974 Mini Clubman, 1982 Metro City, 1987 Escort, 1989 Lancia Y10, 1989 Cavalier, 1990 Sierra, 1990 Renault 19, 1993 Nova, 1990 Citroen BX, 1994 Ford Scorpio, 1990 Renault Clio, 2004 Citroen C3, 2006 Citroen C2, 2004 Citroen C4, 2013 Citroen DS5. 2017 DS3 130 Plenty of other scrappers!
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Nov 12, 2020 22:06:37 GMT
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Great thread, more please!
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Nov 14, 2020 15:12:13 GMT
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Remote Gearbox. Using A Citroen LN Gearbox Cost €50
This Has Lower Ratios Than A GS Gearbox, Better For Off-Road.
 Using the Pinion Shaft From a Citroen GS 5 Speed Gearbox
Allows a Drive Flange to be fixed on the Bit That Sticks Out.
 Showing Gearbox Internals Drive Flange Turned Up On The Lathe.
Hardy Splicer 1140 Series   Splined Up.
Front Prop Shaft Tight Fit.
Gearbox Back Together
Bellhousing Cutdown.
Room For Seats.
Overview Long Ways.
In The Chassis.
The Jimny Gearknob Somewhere In The Storeroom (Hoard) Has Been Replaced 
Jimny Transfer Box Attempt To Reuse The Floors. Jimny Transfer Box. £55
 Attempt 1 Of An Oil Sealer Mount (Hole Too Big!)
Various Versions of the Transfer Box Selector Other Version Of Oil Seal Mount Gearknob For Main Box.Positions Are Inverted Because The GS Normally Has An Inverted Remote Gear Shift Fabricated Gearbox Mounts.
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Some top engineering going on here!
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Can't say that I've ever particularly been interested in 2cv's but the engineering alone in this is worthy of a bookmark! The fact it's madder than a box of frogs is just a bonus! Bookmarked!. I see what you did there. Just noticed this thread. will have to follow it now. Always admire someone who can reengineer a thing like this and make it work. |
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Nov 16, 2020 14:55:55 GMT
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Crazy brilliance! |
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Nov 16, 2020 20:00:13 GMT
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Some pretty epic home engineering going on here. How many people have told you it will not work and go buy a Landrover.
Annoying that the front steering/ suspension thing cuts right through the middle of it all. Cant think of a better or lighter way to achieve what you have done. Keep it up !
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Nov 16, 2020 20:16:39 GMT
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The story of this beast.
Have a 2cv 4x4, down various Green Lanes in two wheel drive to embarrass the LR’s when we get stuck a push or 4x4 mode also very difficult to tip it over.
The limitation of a 2cv is no low ratio, so steep bits can be achieved with speed and momentum if room!
The beast has low ratio and when it gets bogged down raise it up, drive on and get even more stuck!
Weight currently 800+ kg
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Nov 16, 2020 20:53:26 GMT
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Only possible improvement I can think of would be a rear locking diff. Older Audi have them, ally case so light but not sure if ratio would match. Actually thinking about it, they turn opposite way to most. Sure you could overcome that though.
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Nov 17, 2020 10:13:02 GMT
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procrastinatorDiff Locks are on the list or even LSD type of diff. Audi boxes have been used in 2CV racers, but need to add Inboard Brakes, Cheers Peter
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Nov 20, 2020 15:09:24 GMT
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test
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Nov 20, 2020 15:09:37 GMT
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test
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Nov 20, 2020 15:09:48 GMT
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testing
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Really appreciate you taking the time to document this. I know so little about 2cvs and your concise pictures and descriptions are helping me to see the vehicle you are building. Thank you and please continue
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mostly the differential (Planet Gears).
