Transfer case mounting/relocation question

[RamblerRob]

I was hoping to gather some opinions on the best path to take.
I'm getting ready to fit my drivetrain into my 109 station wagon mounted on a range Rover lwb chassis. To get the clearance I need at the front of the engine, I'll need to move everything back 4". I've got plenty of room to play with and will have to weld in new engine mounts regardless.
I'm batting around whether to drill and reinforce new mounting holes for the transmission brackets or get some brackets fabricated to shift everything back the required 4".
In terms of convenience it would be easier to go with brackets as I won't have to haul the truck anywhere to get the work done, just wondering if that 4" displacement from the fasteners is going to cause any undue strain or instability.
Thoughts?

[swamijake]

I would just drill new holes for the brackets. They aren't reinforced at all in the frame, or at least they aren't in my 110 frame. Just use some big washers on the bolts on the outside of the frame.

[RamblerRob]

Thats good to know.. Lain from designa chassis indicated that you needed to reinforce the holes if you drilled new ones in my conversations with him when I was looking at having a frame done up custom.
Just drilling new holes was my initial plan

[red90]

If the holes are not sleeved, then there is no way to tighten the bolts without crushing the chassis.

[swamijake]

I had mine off two weeks ago and when i tighten the bolts the chassis flexes in considerably. I also didn't see any sleeve.

Red90, are you sure the stock chassis is sleeved?

[RamblerRob]

Thanks Red, that was the info I was working with. I'm just trying to get as much done as possible in my own garage and unfortunately welding is not one of those things!
Do you think custom brackets to move the transfer case back 4" while maintaining the stock holes is a good idea or should I just bite the bullet and get the holes done properly in the new correct location relative to the engine etc?

[LandyAndy]

On the D90 frame there is an internal spacer where the bracket mounts, not exactly anti-crush tubes for the holes but it does stop the frame sides collapsing in. When I moved my t'case back for the LS and crawler box install I drilled new holes & sleeved them.

This is how I did it...

I drilled holes for the M8 bolts in required location and drilled a large washer with two small holes that aligned with the ends of 1/2" black pipe. Bolted washer in place and drilled 2 holes on each of the M8 holes, inside & outside.

http://i946.photobucket.com/albums/ad30 ... pzzi7o.jpg

Then I cut 3 short lengths of 1/2" black pipe and slipped into the frame through a larger central hole (is covered by the t'case mount when done) and plug welded through the smaller holes at both ends.

http://i946.photobucket.com/albums/ad30 ... q4qw5f.jpg

Quick coat of paint and done, this keeps things simple and puts less heat into the frame.

Here you can see how far back I mounted the t'case to accommodate the crawler box.

http://i946.photobucket.com/albums/ad30 ... zmtapl.jpg

Hope that helps !