Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 421115 times)

Flyin6 · « **Reply #1150 on:** March 09, 2015, 07:04:17 PM »

Quote from: EL TATE on March 09, 2015, 07:00:39 PM

So to help the ignorant, all of this will need to go into a faraday box of some sort or no?

Nope Tater, no faraday
Cause
It's not electronic
Just switches and wires and relays and fuse panels. Old school all.
Anything electronic which you will see in the form of a GPS and a laptop will be disposable
A laptop and drive will live in a ammo can which has the known universe stored inside!

Flyin6 · « **Reply #1151 on:** March 09, 2015, 07:06:09 PM »

First up today was to get the snorkel threaded Nutserts pulled into the chinaman fender from Dr Yeng fender works and catfish house. So I did

Flyin6 · « **Reply #1152 on:** March 09, 2015, 07:07:25 PM »

I pulled them with a large fender washer on the inside to make a mo-better grip

Flyin6 · « **Reply #1153 on:** March 09, 2015, 07:09:12 PM »

The two you see with the thin stainless washers on the outside were where due to underlying fender structure I feared a NSGGS (Not so good grip situation)

Flyin6 · « **Reply #1154 on:** March 09, 2015, 07:10:43 PM »

I test fitted the stainless button-head screws which will secure franken Snorkel once and for all

JR · « **Reply #1155 on:** March 09, 2015, 07:11:24 PM »

What are you drilling those holes with? Looks all pushed in. Is that how Don drills holes?

Ah, that looks all better with the inserts in.

Flyin6 · « **Reply #1156 on:** March 09, 2015, 07:36:50 PM »

Next onto fixing Dr Yeng's fender fo-pa. I had to beat on it just like it was some Chinaman's head which you were trying to explain the concept of quality to...I.E. you need to hit it both hard and many times!

Flyin6 · « **Reply #1157 on:** March 09, 2015, 07:37:57 PM »

Quote from: JR on March 09, 2015, 07:11:24 PM

What are you drilling those holes with? Looks all pushed in. Is that how Don drills holes?

Ah, that looks all better with the inserts in.

Dr Yeng fenderworks product...Steel is .00000000023" thick
Nuff said

Flyin6 · « **Reply #1158 on:** March 09, 2015, 07:39:42 PM »

I scored some 6061 aluminum .125" thick to make the overhead panel

Here it is before the "Operation"

Flyin6 · « **Reply #1159 on:** March 09, 2015, 07:40:42 PM »

It is going in up here:

Flyin6 · « **Reply #1160 on:** March 09, 2015, 07:41:55 PM »

I'll use a bunch of screws to fool me into thinking I'm in an aircraft again

Flyin6 · « **Reply #1161 on:** March 09, 2015, 07:43:32 PM »

The panel first gets the battery solenoid switch hole along with the indicator lights

Flyin6 · « **Reply #1162 on:** March 09, 2015, 07:44:45 PM »

Then I punched the holes for the tach and the voltmeter

The voltmeter gets a switch to allow me to check the voltage on either battery from the same gage

Flyin6 · « **Reply #1163 on:** March 09, 2015, 07:46:14 PM »

Next comes some more switch holes then the first of two fuse panels

Flyin6 · « **Reply #1164 on:** March 09, 2015, 07:49:49 PM »

Then I cut in a bunch more switch holes being careful to vary things up so that items can be identified by feel in the dark as well as position. The big chrome pull switch is the "Scene illumination" switch which turns on the world to throw light everywhere jest en kase them's bad boys come ah-sneekin' Ya see they would have all that bright lighe renderin' their eye-pieces more or less useless. Heck, they probably wouldn't even notice the 12 gage barrel right behind one of the floods!

Flyin6 · « **Reply #1165 on:** March 09, 2015, 07:51:38 PM »

I did some other things as well like build some wiring harnesses up which I will show later, but basically, that was another 7 hours of work on Square D and the completion of build day 225

N8MFH · « **Reply #1166 on:** March 09, 2015, 08:13:53 PM »

For your mystery connector back at the transfer case, it goes on a switch mounted at the outboard (2wd-4wd) shift rail where the poppet ball bearing and spring are. I'd have to look back through to when you did your rebuild to see, but maybe you just have two retainer bolts installed now? Hope that's helpful.
keep up the good work!

Flyin6 · « **Reply #1167 on:** March 09, 2015, 11:20:57 PM »

Quote from: N8MFH on March 09, 2015, 08:13:53 PM

For your mystery connector back at the transfer case, it goes on a switch mounted at the outboard (2wd-4wd) shift rail where the poppet ball bearing and spring are. I'd have to look back through to when you did your rebuild to see, but maybe you just have two retainer bolts installed now? Hope that's helpful.
keep up the good work!

Hmmm, I don't remember that switch, but it obviously must have been there
I installed an aftermarket spring/ball/screw setup that gives a more positive engagement in to the various positions. That explains why I didn't have something to replace!

Flyin6 · « **Reply #1168 on:** March 10, 2015, 08:47:01 AM »

RedNeck, you will enjoy this part...

I just ordered my CB radio.

A Cobra 40 channel unit around $100 that has a color selectable screen. This one had a lot of features and with my being able to tune in a green or blue screen, it becomes NVG compatible

This will be part of the commo suite which will also include GMRS handhelds front and rear mounted with a docking port

EL TATE · « **Reply #1169 on:** March 10, 2015, 11:48:36 AM »

Quote from: Flyin6 on March 09, 2015, 07:36:50 PM

Next onto fixing Dr Yeng's fender fo-pa. I had to beat on it just like it was some Chinaman's head which you were trying to explain the concept of quality to...I.E. you need to hit it both hard and many times!

You and Nate ought to get together and do a body class!

Nate · « **Reply #1170 on:** March 10, 2015, 12:38:44 PM »

I know nothing about body work at all

Flyin6 · « **Reply #1171 on:** March 10, 2015, 01:58:38 PM »

I worked at a body shop about 400 years ago, but over the years I stayed on it. In the Army I was always painting something. One of my soldiers would get me to paint their car or trailer, or truck...Heck one Saturday I even helped one crew chief paint his Chinook Helicopter.
I know, I know...You heard that story before...

EL TATE · « **Reply #1172 on:** March 10, 2015, 05:27:27 PM »

Quote from: nmeyer414 on March 10, 2015, 12:38:44 PM

I know nothing about body work at all

after the work on daisy's hood you might be an expert.

Flyin6 · « **Reply #1173 on:** March 10, 2015, 08:09:57 PM »

Wiring is S L O W

Spent al day wiring things up, pulling wire, redoing harnesses and so many pesky little operations, well, I need a break

Before we get into that, the louver panels came in. These will be used to ventilate the power steering cooler fender area and the hood of hot engine temps

The white is a plastic peel-off cover

Flyin6 · « **Reply #1174 on:** March 10, 2015, 08:12:07 PM »

Just eyeballing it on the wrong fender, I could mount the louvers to act as scoops to draw in air, or mount them traditionally to allow air to escape.

I'm thinking keeping the opening facing aft will keep the fenders from scooping up mud and channeling it into the engine!

Flyin6 · « **Reply #1175 on:** March 10, 2015, 08:14:06 PM »

The #4 wire will supply power to all sorts of things inside the cab

The harness is definitely growing in size...I will have to create another way to get all those wires into the cab

Flyin6 · « **Reply #1176 on:** March 10, 2015, 08:15:10 PM »

The voltmeter showed up:

Flyin6 · « **Reply #1177 on:** March 10, 2015, 08:16:46 PM »

This manly switch is a on-off-on unit which I will use to select which battery voltage the voltmeter is reading

Flyin6 · « **Reply #1178 on:** March 10, 2015, 08:18:23 PM »

The ARC aotocontrols switch panel showed up today as well. This compact unit features 7 relays and 8 fuses which are remote mounted and ribbon cabled to the switch bank

Flyin6 · « **Reply #1179 on:** March 10, 2015, 08:19:29 PM »

Here is the business end, the 8 switches

Flyin6 · « **Reply #1180 on:** March 10, 2015, 08:21:35 PM »

The voltmeter selector switch

Flyin6 · « **Reply #1181 on:** March 10, 2015, 08:23:19 PM »

This thin and flexy ribbon cable connects the relay assembly to the switch assembly

This is some high quality stuff, and no teeny-weeny electronic circuits to get fried!

Flyin6 · « **Reply #1182 on:** March 10, 2015, 08:24:59 PM »

I needed some place to mount that relay assembly, so the glove box compartment got volunteered

Flyin6 · « **Reply #1183 on:** March 10, 2015, 08:26:22 PM »

4 #10 screws and some nylon lock nuts later and it is permanized

Flyin6 · « **Reply #1184 on:** March 10, 2015, 08:30:07 PM »

The heavy black cable gets attached to a hot battery post so that was routed out through the cowl to the right fender where I will mount a mega-fuse and use that to supply power to the winch as well

I needed another spot away from the way too busy left firewall to route all these new wires, so I created this hole and bulkhead seal in the passenger floor to accomodate

Flyin6 · « **Reply #1185 on:** March 10, 2015, 08:33:37 PM »

Once I run the wires, I'll place another piece of dynamat over the flattened wires and seal the holes with RTV

With that done, and the glove box door remounted I wired in both fuel pumps, the water/methanol pump and ran a wire for a future fuel transfer pump which will pump fuel from the aux tank into the main tank

Flyin6 · « **Reply #1186 on:** March 10, 2015, 08:37:04 PM »

So far, so good. I have 4 of those switches remaining and a half dozen more independent switches yet to task, so I'm in good shape to get everything wired in.

Shortly I will tear down the panel, paint and label it, then install it and get some things working at long last

Not many pics, but a lot of work took place. Tomorrow more of the same unless I decide to take a break and cut in one of those Louvre panels

Sammconn · « **Reply #1187 on:** March 10, 2015, 10:42:08 PM »

Ah come on now Big D. Wiring isn't slow, just keeping it orderly and neat and...well I guess you could get away with saying its slow. 8)

husker77c · « **Reply #1188 on:** March 10, 2015, 11:43:25 PM »

Quote from: Flyin6 on March 10, 2015, 08:12:07 PM

Just eyeballing it on the wrong fender, I could mount the louvers to act as scoops to draw in air, or mount them traditionally to allow air to escape.

I'm thinking keeping the opening facing aft will keep the fenders from scooping up mud and channeling it into the engine!

I've had this same idea to cover up the holes in my fender where I removed the badges. Mine would be more for looks than function which goes against most of what I believe in but for $30 for a pair I can live with it. And I don't have to use my sub par welding skills to fill holes.

JR · « **Reply #1189 on:** March 11, 2015, 01:33:52 AM »

Darn those switches are purdy, to bad they are so pricey!!

Not much room in the glove box for gloves with that.

I do slightly question the wiring through the passenger floor. Isn't that a fairly high wear area?

Flyin6 · « **Reply #1190 on:** March 11, 2015, 08:10:09 AM »

Quote from: JR on March 11, 2015, 01:33:52 AM

Darn those switches are purdy, to bad they are so pricey!!

Not much room in the glove box for gloves with that.

I do slightly question the wiring through the passenger floor. Isn't that a fairly high wear area?

When I pulled the carpet way back when I discovered factory wiring which was run under on the floor.
I think it will be a non issue, especially being covered with some dynamat

And yes, those switches are over the top, but at $327 the last set I will be buying for awhile!

OldKooT · « **Reply #1191 on:** March 11, 2015, 08:19:08 AM »

I don't think I'd worry abut the wiring and the floor. I'd be more worried in my world about the relays starting the 45 left over napkins from Taco Bell my wife always seems to stash in the glove box on fire.

But being a 1st gen Dodge owner, smoke erupting from a dash area isn't cause for panic. It's rather normal LoL

Flyin6 · « **Reply #1192 on:** March 11, 2015, 08:39:02 AM »

Quote from: OldKooT on March 11, 2015, 08:19:08 AM

I don't think I'd worry abut the wiring and the floor. I'd be more worried in my world about the relays starting the 45 left over napkins from Taco Bell my wife always seems to stash in the glove box on fire.

But being a 1st gen Dodge owner, smoke erupting from a dash area isn't cause for panic. It's rather normal LoL

Funny Norm!

Well, there will be more avionics going in the old glove box space. and on the drivers side, I thought I install a few magazine pouches/holders, maybe a battery holder/charger as well

Oh, and a mount for my new tactical double barrel battle light:

OldKooT · « **Reply #1193 on:** March 11, 2015, 08:52:46 AM »

I should acquire one of those "tactical" devices. I have a nice LED Ray O Vac ($4.38) flashlight in my truck, but whenever I go to use it it's missing. Maybe loving family members wouldn't swipe the oinker light.

Flyin6 · « **Reply #1194 on:** March 11, 2015, 09:01:13 AM »

Quote from: OldKooT on March 11, 2015, 08:52:46 AM

I should acquire one of those "tactical" devices. I have a nice LED Ray O Vac ($4.38) flashlight in my truck, but whenever I go to use it it's missing. Maybe loving family members wouldn't swipe the oinker light.

That's why I use it
No one would be caught dead with it so I know it will always be there

And I have it rail mounted (Duct taped) to my M4. Anyone seeing that will 1. pause for a moment, and 2. not take me as a serious threat...which combine to give me the tactical advantage and win the fight.

Note: Pig flashlights work like grenades when thrown at crowds of muslims!

Flyin6 · « **Reply #1195 on:** March 11, 2015, 07:08:49 PM »

Needed a bit of a breather from the non stop wiring

So I decided to mount the louver panel

This is the factory left fender (Way heavier than Dr Yeng's Chinese made fender). The panel will go in the front

Flyin6 · « **Reply #1196 on:** March 11, 2015, 07:10:54 PM »

While I was prying off the rear trim piece, I discovered the first rust perforation on this truck!

Darn...not liking this, but I am not going to Dr Yeng for another fender made from soybean extract, so I'll fis my 'merican made jem!

Flyin6 · « **Reply #1197 on:** March 11, 2015, 07:11:43 PM »

The access panel will fit about here

Flyin6 · « **Reply #1198 on:** March 11, 2015, 07:12:54 PM »

So, first the holes are drilled and the panel cleco'd into place

Flyin6 · « **Reply #1199 on:** March 11, 2015, 07:15:18 PM »

Then after marking, the cutout is made by drilling the corners and using a fine tooth blade in a sabre-saw.