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December 21-27, 2008: Jakutsk - Magadan
How to build a rear axle differential on Christmas due to boredom
I was still in Aldan on the 24st to repair the expedition vehicle F1 and drive it together with the trailer MJ46 to Jakutsk - which finally was successful (arrival 25st 1.00 a.m.). The reparation as such was extremely difficult and together with my Russian companion Dima, I needed two days and nights for it, due to a wrong delivery of the rack & pinion set of the spare parts distributor. As in Russia everything is possible, we manage to build the differential out of 2 wrong differential sets together with the support of some helpers from Aldan.
How? Take a too thick ring gear, destroy it for testing purposes and turn it to fit with an axle turning machine of a gigantic size. Therefore one has to modify those machines, which means a lot of ours of work, after stopping the production of industry parts with the help of an understanding manager. To use those huge machines, one has to produce a suitable clamp tool out of a chain set of a crawler which is not in use any more (instructions on demand :-)). Same procedure for the bevel gear shaft, after determining the necessary measures in uncountable installations and demounting in advance without any measuring tools. Furthermore, ideally some old screws with special thread measured in inches are needed. These have to be modified to screw thread carving tools with the help of a rasp. This effort similar difficult as a puzzle is necessary to carve new screw threads in the ring gear.
Later on, let an exceptionally gifted, old Russian mechanic whet three 0,2mm space discs by hand and them with other discs of the wrong modification sets. From then on there are only some more hours of patient setting test, the manual construction of a gear clamp as well as a special lifting tool and self-made thick washers (on the above mentioned huge axle turning machine). There you are, a differential (otherwise only available in the USA for a lot of money) build out of nothing.
To make it perfect it is recommended, to accept the hospitality of helpers when the tiredness and the cold in the big halls are overpowering, to pay hundreds of telephone Euro, and not to feel annoyed with it - of course. Reaching Jaktusk on 24st December together with Dima who kept me somehow away to be able to drive, I flew to Magadan 3 hours later (at the crack of dawn) for discussion and other remaining topics. Evgeny also flew there via Habarowsk.
The remaining team which accompanied me to this point were already flown out on the 24st with the last plane and has sooner or later reached Germany.
At this point again many thanks to the excellent team which accompanied me and Evegeny since Moskau:
Astrid, Joachim, Marco, Hendrik you did a great job. I had much fun travelling with you. Thanks for all the support and the mutual, basically never-ending, laughter.
The new team will arrive in Jakutsk on January 15, 2009 to start the journey through Chukotka towards the Bering Strait.
Finally, thank you to all for the supported first part of the expedition with approximate 22,000km from Paris to Jakutsk and I wish you all Merry Christmas and a Happy New Year.
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