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Just acquired a burnt up bombi (i think)

labradorshooter

New member
figured I'd clear up some stuff on the Br100+ , you were saying the 100+'s have a drop dive axle similar to a unimog axle. they don't have have that unfortunately, the use a planetary gear set that is inside the diff housing. a short side axle runs from the Bombi/Br100 diff ( which there is 2 versions of as well, the newer carriers like mine have 45 tooth side axle gears and 13 tooth pinions which are hard to find, older models use a 30 tooth side axle gear and 9 tooth pinions which seem to be easy to get) to the planetary gear set then another side axle runs to the sprocket.

here is that setup,


I would rather a bombi diff honestly, the gears in the steering part of the diff are cheaper and easier to find and I changed out my stock 5.89 ring and pinion set to a 4.27 set to gain some speed. the 4.27 gears with the planetarys of the br100 gives me an overall ratio pretty close to a bombi with its stock 5.89 gears but now I have a bunch more parts that can fail and they are all expensive and getting harder to find.

if my planetary sets give any more trouble I am going to remove them and get 2 axle shafts made to go right from the diff to the sprockets and put my 5.89 gears back in.
 

GlacierSean

Member
SUPER Site Supporter
I have a 1987 br100 that was mentioned earlier on this forum. I had custom long axles made that eliminate the planetary. They were made by Mark Williams enterprises out of 300m. They have worked great so far. I had 3 made in case one breaks but since they are 300m something else will likely break first. My planetary was working good but the gearing was to much. I have the LS v8 br100. So yeah long shafts that eliminate the planetary work just fine. Also to owners of bombi,br100 and br100+ new cogs are awesome and a great purchase. And finally the v8 is a fun upgrade for the woefully under powered br100.
 

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forum8fox

Member
Figured I'd provide an update. Failed to get pictures of the mid stage of the build with my real camera but I think we have a few cell phone pictures. Anyway I shot these about a week ago and they are of our current build stage.

We basically stripped everything.

Then trailered it to the car wash.

Re geared and rebuilt the differential (4.27's which barely clear, had to shave a little to give it some clearance, new bearings and seals)

Had the brake (steering) bands refurbished with new kevlar pads, addressed a couple cracks.

Then chopped it in half, had a couple pieces of 14 gauge sheet bent to match the original lower half (we call it the tub) so we could lengthen the whole thing to match (close at least) a br100.

We added another set of axles and bogey wheel, and did tons of welding.

Next we got the Jeep cherokee drivetrain in place, we could not find a 2wd tranny that would mate so we decided to just run the 4wd with transfer case (now we have low range). we had to do a little bump out on the side of the tub to accommodate the T-case. had to custom build the exhaust to route it out where we wanted.

We also got the dash from the Jeep Cherokee mounted up (including it's heat system).

Next we decided we wanted seating for 6 in cab and we didn't want to sit on the floor. So we fabricated up frames for custom bench seating. We designed the seating to be transformed into a bed for overnight trips. After that we framed out a firewall to isolate the cab from the drivetrain and we have new floor panels to cover it all.

Got pedals and shifters mounted, also got the cooling system installed, had to fabricate a frame to hold it off the back to improve airflow.

added a caliper and proportioning valve to the driveline break,

Soon we will be starting the process of framing out the cab.
 

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forum8fox

Member
Here are the cell phone shots of the previous stages.
 

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nikos

Active member
orum8fox

Here are the cell phone shots of the previous stages
 

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forum8fox

Member
Pushed pretty hard this last week. Finished some bracketry, out plywood on seat frames, layed the seats out to test how the bed will work. Then stripped everything out of it in a few hours and began the paint prep process which included lots of sanding, some wire wheeling, grinding and a little welding. We finished painting the base shortly before dark taking advantage of minimum painting temps in December, then finishing making pannels and riveting them to the frame for the firewall then painting it not long before it started snowing. Did a quick clean up and wheeled it into the garage with the wood stove going.
 

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DAVENET

Bronze Member
GOLD Site Supporter
Looks like you could use a bigger shop! :horns::thumbup: (I feel your pain!)

Making good progress
 

Pontoon Princess

Cattitute
GOLD Site Supporter
good looking build, lots and lots of work,

thank you for posting all those pictures and details of the work done,

all very inspiring and can't wait to see the finished machine
 

forum8fox

Member
I'm glad you all are enjoying the build so far! We have been plugging away at this thing still despite me spending the last few weekends skydiving and cat skiing (with glacier sean). The drive train is all back in minus a bunch of tinkering with wiring and hoses, the firewall is siliconed down, dash is back in, so we started framing the cab. The 3 main hoops are complete, and tied together. Picking up more steel today to finish the front of the cab and to start framing in the front and rear windshield and frame the doors in! It's not going to be aesthetically fancy, more like a boxy van, but should get the job done. There will be lots of headroom (5.5' from the floor) I can barely touch the roof arms fully extended when sitting on the bench seat. Hopefully we don't have issues with towing and low bridges, or low branches in the trail (that's easier to deal with though, just need a saw).

Yeah our work space is as cramped as it gets, it's hard to walk around let alone build this. But we are getting it done. Its getting hard to get pictures now though. Also speaking of cramped space, we had to take the wheels off and set the axles on 2x4's to have enough clearance. After the cab is done minus the very front we are going to lift it and slide it off the back while dragging the lower half out of the garage (on the 2x4's) because it won't fit under the garage door...Here are a couple pictures I snapped last night with my cellphone.
 

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forum8fox

Member
Thanks. Its kind of funny, the thing is pretty much more Jeep Cherokee than bombi at this point. We call it the bombikee shred bus. Gonna have to get a custom decal made for it.
 

forum8fox

Member
It's coming together. Framed out the front end including the windshield area, above the doors and most of the back window.
 

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forum8fox

Member
Went from basic skeleton to almost completely framed out in the last week or so. French doors framed in with openings for 30 inch(ish) sliding windows (handles/latches and hinges on), 48x36 inch front windshield opening, 48x24 opening for rear window, spreaders for body panel backing/support. New rubber for the tracks should be ready by next week, double stick tape and aluminum body panels will be picked up in the same time frame. Glass has been quoted and will be in within a week of ordering (got the hook up @ cost as I worked at a glass shop for 4 years and my childhood friends family owns it). Sorry just more cramped for space cellphone shots for now. Gotta get this thing outside to really show it well.
 

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forum8fox

Member
More progress. The body is mostly paneled, aside from the front. This week consisted of a lot of long days and auto pilot/ zombie mode. Vastly underestimated the amount of effort just to cut them out and get them stuck. Lots of back and forth, test fitting, heating the frame up with a heat gun and keeping the fire stoked in the garage. We are a bit burnt out, but it's nice to see it coming together.
 

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GlacierSean

Member
SUPER Site Supporter
Looks like your dog is ready to go for a ride. Great progress, looking forward to seeing it on the snow this season.
 

forum8fox

Member
That was the first time they had ever been in it, and they didn't want to come out. They loved it, back and forth under the front seat, standing on the back seat even though it is covered in tools and parts. Fingers crossed we get to see it on the snow soon. It's a draining process, of both energy and funds. Have thrown about everything we can at it. We picked up rubber last week, didn't have the holes punched... Gonna be a ton of work there between the 2000 holes and bolts. It's getting to the point that we are going to need to enlist helpers for the tracks and to separate the top and bottom and get them outside for good. Mark is on his way to help wire switches for fans, pumps, and aux lighting. Headlights are here, interior led lights are here, light bars on the way. Probably going to get a secondary heatercore and box/fan to help keep the back warm, should also keep motor temps even more in check. Mostly only need to buy grousers at this point though probably some tires too (maybe some bearings, and a part for a tensioner also). Speaking of which we dropped 2 tires off to get filled last week. Ahh crap I forgot foam for seats, material to cover it, and possibly some heating pads for the seats.
 

forum8fox

Member
Today we wired in 12 switches and harnesses for front and rear light bar and 2 lights on each side plus diff cooler pump, a set of in cab lights, a secondary set of in cab lights (rgb led strip eventually), under cab rgb light strips (eventually), secondary heater(eventually), heated seats front and rear (eventually), and running siren light thing. Finished up lifting the cab off and sliding it back a bit in preparation of the separation. Unfortunately slightly mangled a couple panels that overhang the joint of the lower half (bottom corner of both back doors) frustrating and dumb but I guess rivets and door trim should fix and hide it (mostly straitened, but needs a little attention/ a few inches of new tape/ and or a couple rivets).
 

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forum8fox

Member
My brother and I separated the tub and cab a couple nights ago. That was a challenge, litteraly drug the bottom half out from under sliding on 2x4's. It is too tall to fit through the garage door together. Getting the bottom half out of the garage for good allowed us to reinstall the cooling systems and fill coolant, go through wiring to get rid of what wasn't needed anymore (my brother had left a bunch of the extra wiring and my friend insisted on gutting it) and get it to start and run. We tried to start it 2 weeks ago when my friend helped with interior lights and auxillary light wiring and nothing happened.

Having them separated also allows more room to finish some of the body work like door trim and windows plus we couldn't finish the front because we slid the whole cab off the back of the tub on to jack stands.

We got most of the wiring straitened out though we lost our dash panel lights so that will need fixed. It started and ran, sometimes decently but other times not. Need to figure out why now. This morning we picked up a fuel pressure tester and we also know we have a spot in the wiring harness that may have been compromised from some falling molten slag we that will be a good place to start.

Most of the interior has been insulated with 1" foam sheeting at this point. I siliconed all the body panels to the framing before foam to be extra sure of seal even with the tape which holds the panels on being weatherproof and trim on all the joints outside siliconed. Interior wiring harnesses are hidden under or beside the foam mostly except where it passes over framing which should cover ok with carpet. I welded in brackets for 2 of 4 speakers, and 4 tabs for a overhead cargo net, tried to plan ahead and do it before foam but failed a little and had to do a few with foam in already (melts pretty good around a hot weld).

Speaker boxes and speakers are here, auxiliary light bars and pods are here, 4 bench seat heat pads are here. Should be able to finish paneling and foaming the front, and installing a bunch of the carpet in a day. Glass for windows is on order and once installed the body should be ready to go outside on the tub for good. We are hopeful we will get some paint (rattle can) on there before they go in.

Still have 2000 holes to drill in the new track belting, then 2000 bolts to undo swap grousers and track guides to new rubber and put 2000 bolts back together. Still need 32 grousers, and we got caught off guard by the 64 track guides we need being $1100 used. We picked up some flat bar to make them instead which only costed about $75. But that's more work we hadn't accounted for. Still need to add foam to the bench seats and some vinyl canvas to cover it (will probably order them today). Also need to add a roll cage / rake to have somewhere to put ski racks and a roof top cargo rack and need to bend some new steering rods.

Close but yet still far. Fingers crossed we get it done in time for the 2nd annual Colorado snowcat jamboree. Wish us luck!
 

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forum8fox

Member
Carpeted the ceiling and the sides above the doors, also below the rear window. Finished paneling the front end and trimming it out. Then laid down 2 coats of paint starting around midnight. Then installed the 2 fixed triangle windows, and the first of the sliding windows. The window isn't slidingn well on dry rubber setting blocks so we just picked up some Teflon strips to line the top and bottom tracks with.
 

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forum8fox

Member
Well, we were trying to to figure out why we had some electrical issues (had to bypas some relays to get it to start properly, alternator was not charging the battery) and why the motor wasn't quite running like it should have been (picked up a fuel pressure regulator as the fuel pump was not from the Jeep and outputting too much pressure) then somehow the motor became seized and dead in the water in an instant. So kinda back to square one, gotta swap it out. Its kind of a good thing it happened before the body went back on at least. We were supposed to have it on last weekend but the front and back windshield arrived Friday and was cut wrong so that pushed the timeline back. We may have found another used 97 Cherokee motor (same year so it's compatible with the rest of the drive train) for about what we payed for the totaled Cherokee we ripped everything out of ($550) need to verify it has compression and if it does that's a relief. Seems unlikely we will make our deadline of the Colorado jamboree but may still be able to get it out by the end of the season. Still slightly hopeful we might be able to make the deadline but the stress is a bit much at this point. Headed to McCall with glacier Sean this afternoon, should be a good reset for my head and perhaps another kick start for motivation.
 

PJL

Well-known member
Oh man that's bummer. But better now than on some trail miles from the road.
 

forum8fox

Member
Well we haven't quite given up on hitting the original deadline on this snowcat. We made 64 track guides and ordered 32 grousers, then stripped the wide side of rubber off one of the old tracks to use as a template to drill the holes for all of the new rubber. Proceeded to drill over 800 holes in the 4 new pieces of rubber. Realized we need 6 more grousers and 12 more track guides once we figured out the length of the new tracks so ordered more grousers last minute and arranged to make 12 more track guides (need to use a local welding shops break and punch). Took glass and templates down to have the front and back windshield re-made. Foam is on order for the seats. The new used motor has been swapped in. Currently hung up putting the old track hardware on the new rubber because we need new nylock nuts and some new carriage bolts but have plenty of work stripping the old hardware off the 3 other pieces of old rubber.
 

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forum8fox

Member
Yesterday we put the cab back on the tub only made possible with the help of glacier Sean and my friend Darwin. That was one sketchy process, but only bent up a couple body panels. Removing the grousers off the old track on the side of the gas tank has been a royal pain. The carriage bolts seem to have practically welded from the heat and just spin inside the grouser. We cut off about 25 or 30 with a sawsall and about the same amount with a grinder where possible. Picked up some expensive new sawsall blades and it's making a world of difference. 1000 new carriage bolts will be in tomorrow morning so we can start putting tracks back together. Grousers will be in by Friday and foam might also. Fingers crossed glass is on the way too.
 

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Aaron Tucker

Active member
Yesterday we put the cab back on the tub only made possible with the help of glacier Sean and my friend Darwin. That was one sketchy process, but only bent up a couple body panels. Removing the grousers off the old track on the side of the gas tank has been a royal pain. The carriage bolts seem to have practically welded from the heat and just spin inside the grouser. We cut off about 25 or 30 with a sawsall and about the same amount with a grinder where possible. Picked up some expensive new sawsall blades and it's making a world of difference. 1000 new carriage bolts will be in tomorrow morning so we can start putting tracks back together. Grousers will be in by Friday and foam might also. Fingers crossed glass is on the way too.

cant wait! praying that you get it done !
 

forum8fox

Member
Probably needless to say but our cat never made it to the Colorado jamboree. We we went with glacier Sean instead of stressing about what we couldn't change.

In the last week we installed front and rear windshields, rebuilt the tracks, and got the tracks on the machine. Ended up adding 19 grousers on each side (and 38 track guides). Tensioner them up today and it seems we might be a little long as the tensioner is about maxed out on throw. Wanted to start it up and give a test drive on the fresh snow in the driveway but had no success with that.
 

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