Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 455728 times)

Flyin6 · « **Reply #1450 on:** July 27, 2015, 10:44:12 PM »

Using some standard hinges, and more nut-serts those were screwed into place

Flyin6 · « **Reply #1451 on:** July 27, 2015, 10:46:14 PM »

More of the thread inserts were fitted to the actual hinges so that I could run a screw through the board and into the hinge

Flyin6 · « **Reply #1452 on:** July 27, 2015, 10:48:14 PM »

Then the two end pieces were made up

BTW, I am using 1/4" plywood reinforced with aluminum flat bar and angle and later will be covered with fiberglass cloth and polyester resin

Flyin6 · « **Reply #1453 on:** July 27, 2015, 10:50:08 PM »

Then the hole for the wash basin was cut out and the bakelite plastic bowl fit in there like it should

Flyin6 · « **Reply #1454 on:** July 27, 2015, 10:52:46 PM »

And now the strengthening begins. The top will get all manner of layers and reinforcements to make sure when one of the rangers decided to use this thing as a diving board, I'll still be able to shave and brush my tooth (I'm Kentuckian, so I expect to be down to a single tooth at some point...and I'll want to keep that sucker sparklin'!

Flyin6 · « **Reply #1455 on:** July 27, 2015, 10:54:28 PM »

The 1.5" aluminum straps are set in a heavy layer of resin, then top screwed into place. Then that operation was covered over with a fine weave fiberglass cloth which makes things stronger and berry, berry water proof.

husker77c · « **Reply #1456 on:** July 27, 2015, 11:05:16 PM »

Very nice. I hate working with fiberglass but in some situations it's just what the dr ordered.

Flyin6 · « **Reply #1457 on:** July 27, 2015, 11:09:26 PM »

Quote from: husker77c on July 27, 2015, 11:05:16 PM

Very nice. I hate working with fiberglass but in some situations it's just what the dr ordered.

I always get the sticky resin all over myself. Got it on my leg...Had a sweat bee digging in and I swatted him with the hand full of sticky stuff. Later I pulled the rugger gloves off and one of them managed to first hit my other hand, right before falling onto my foot. Got it on my ear (How did that happen?) and my sniper shirt/ Had one...sniper afghan shirt I purchased in Bagram, but since I'm no snapper, I guess I can lose the shirt!

Flyin6 · « **Reply #1458 on:** July 27, 2015, 11:10:36 PM »

Oh, forgot, also got some on the black dog of deaf...on his nose! That was funny

JR · « **Reply #1459 on:** July 28, 2015, 12:49:01 AM »

Should have glassed the red dog.

husker77c · « **Reply #1460 on:** July 28, 2015, 06:29:41 AM »

Quote from: Flyin6 on July 27, 2015, 11:09:26 PM

Quote from: husker77c on July 27, 2015, 11:05:16 PM
Very nice. I hate working with fiberglass but in some situations it's just what the dr ordered.

I always get the sticky resin all over myself. Got it on my leg...Had a sweat bee digging in and I swatted him with the hand full of sticky stuff. Later I pulled the rugger gloves off and one of them managed to first hit my other hand, right before falling onto my foot. Got it on my ear (How did that happen?) and my sniper shirt/ Had one...sniper afghan shirt I purchased in Bagram, but since I'm no snapper, I guess I can lose the shirt!

Exactly. Resin spreads like wild fire if I'm lucky I limit it to my clothes and the hair on my wrists. Which then has to be shaved or ripped out. I see you're using cloth which is soooo much better than the mat. That stuffs like house insulation. Itchy as all get out. But you can do some really cool stuff with it.

Flyin6 · « **Reply #1461 on:** July 28, 2015, 10:35:02 AM »

That was cloth layer numba hanna. Next I'll come back with a very heavy cloth, I want to say 40 oz. stuff! but just glass in patches here and there on the underside, well, you'll see...

TexasRedNeck · « **Reply #1462 on:** July 28, 2015, 11:08:00 AM »

Quote from: Flyin6 on July 27, 2015, 10:39:17 PM

I am using aluminum for this project to save weight

Bwahhhh, weight savings !?

Sent from my iPad using Tapatalk

Flyin6 · « **Reply #1463 on:** July 28, 2015, 11:16:48 AM »

Quote from: TexasRedNeck on July 28, 2015, 11:08:00 AM

Quote from: Flyin6 on July 27, 2015, 10:39:17 PM
I am using aluminum for this project to save weight

Bwahhhh, weight savings !?

Sent from my iPad using Tapatalk

It's important! ;)

Nate · « **Reply #1464 on:** July 28, 2015, 11:18:36 AM »

Quote from: TexasRedNeck on July 28, 2015, 11:08:00 AM

Quote from: Flyin6 on July 27, 2015, 10:39:17 PM
I am using aluminum for this project to save weight

Bwahhhh, weight savings !?

Sent from my iPad using Tapatalk

didnt we hear that with the tac topper?!

Wilbur · « **Reply #1465 on:** July 28, 2015, 11:44:02 AM »

Quote from: Flyin6 on July 27, 2015, 10:52:46 PM

I'll still be able to shave and brush my tooth (I'm Kentuckian, so I expect to be down to a single tooth at some point...and I'll want to keep that sucker sparklin'!

a-HA!! So the toothbrush was invented in Kentucky!....Cause anywhere's else a-course it would've been called a teethbrush...

ba-dum-dum. ;D

OldKooT · « **Reply #1466 on:** July 28, 2015, 01:11:25 PM »

On the subject of weight.... any idea Don where Square D is going to scale in? I got to looking, seems my 91.5 CTD pickup is about 5700lbs.

rpar86 · « **Reply #1467 on:** July 28, 2015, 01:21:49 PM »

Don, you may want to think about making that support leg adjustable so if you are parked on uneven terrain you can adjust it accordingly. Might even want to make the aircraft cables somewhat adjustable so you can let out, or take up, some slack to get the table semi-level so your water stays in the wash basin for when you're bwushin' yo' toof.

EL TATE · « **Reply #1468 on:** July 28, 2015, 01:48:36 PM »

Agreed. Made me think of the legs on an ez up with the little holes along the length and the spring loaded silver ball scenario.

rpar86 · « **Reply #1469 on:** July 28, 2015, 02:23:06 PM »

Precisely! A simple clevis pin would do the trick, and I bet Don has a bunch of those.

Flyin6 · « **Reply #1470 on:** July 28, 2015, 02:45:14 PM »

Quote from: OldKooT on July 28, 2015, 01:11:25 PM

On the subject of weight.... any idea Don where Square D is going to scale in? I got to looking, seems my 91.5 CTD pickup is about 5700lbs.

Normis,

It was in around 5850 stock
Front bumper/winch +350
Rear bumper spare and junk +550
Extra fuel +360
Roof rack business +150
Topper +300
Wheels and tires +300
Add'l crossmembers, traction bar, wires/cables/dust: +300
Extra battery and business + 100
Travelling tool kit and junk +200
Extra fuses + 2 ounces

Total = 8460 and 2 ounces

Flyin6 · « **Reply #1471 on:** July 28, 2015, 02:46:54 PM »

Quote from: rpar86 on July 28, 2015, 01:21:49 PM

Don, you may want to think about making that support leg adjustable so if you are parked on uneven terrain you can adjust it accordingly. Might even want to make the aircraft cables somewhat adjustable so you can let out, or take up, some slack to get the table semi-level so your water stays in the wash basin for when you're bwushin' yo' toof.

Got cha covered kimo-sabee

KensAuto · « **Reply #1472 on:** July 28, 2015, 04:33:53 PM »

Where's the pink generator fit in to this project. :)

akraven · « **Reply #1473 on:** July 28, 2015, 05:09:18 PM »

Does the door of the hatch clear the tire or are you going to have to drop the tire/open the rack to get into the rear of the truck? Just thinking of moving quick and wanting to throw something in the back quickly. I had a similar rack on my old Land cruiser and found it a pain having to always open the rack to get inside. I ended up moving the tire onto the roof. Heavy but do-able by hand for the rare times you needed to do it. Heck at home I just lifted it up on top with the tractor. Just a thought.

Flyin6 · « **Reply #1474 on:** July 28, 2015, 09:09:01 PM »

Quote from: KensAuto on July 28, 2015, 04:33:53 PM

Where's the pink generator fit in to this project. :)

It's about to fit in the trash can
Cheap Chinaman junk!

Flyin6 · « **Reply #1475 on:** July 28, 2015, 09:10:24 PM »

Quote from: akraven on July 28, 2015, 05:09:18 PM

Does the door of the hatch clear the tire or are you going to have to drop the tire/open the rack to get into the rear of the truck? Just thinking of moving quick and wanting to throw something in the back quickly. I had a similar rack on my old Land cruiser and found it a pain having to always open the rack to get inside. I ended up moving the tire onto the roof. Heavy but do-able by hand for the rare times you needed to do it. Heck at home I just lifted it up on top with the tractor. Just a thought.

Perhaps you missed it in the past when I talked about it, but the truck is going to lose the top hatch and the tailgate. I plan to build my own rear closure with a door and some other features.

Flyin6 · « **Reply #1476 on:** July 28, 2015, 09:12:12 PM »

Well, I did a lot of work today, but really didn't get much accomplished.

First up I scratched down the table piece in preparation for the heavier glass reinforcement.

Flyin6 · « **Reply #1477 on:** July 28, 2015, 09:20:40 PM »

The heat today was appalling. The dogs were trying to find a cool spot and the sled dog was having nothing to do with it. She was in a perpetual crash mode. She hardly opened her eyes. I heard the breed can slow their metabolism to cool them down...Must have been what she was doing.
The red dog growled at the older pre-ranger so I was about to stop her metabolism all together!

Flyin6 · « **Reply #1478 on:** July 28, 2015, 09:22:56 PM »

so I got the glass laid up on the folding top and set that off to the side to cure.

Flyin6 · « **Reply #1479 on:** July 28, 2015, 09:25:31 PM »

I took a drive over to the steel supplier and scored the materials to finish the skirt for the bottom of the bumper, build the steps, and build the tire rack parking stand

First up, I made up a washer affair that slides into some "C" channel material I found

Flyin6 · « **Reply #1480 on:** July 28, 2015, 09:30:30 PM »

The step stringers are 2" X 2" X .083 which is plenty strong but fairly light as well.

Here are the two step stringers fitted to the sliding storage rails.

The idea is to create a step that folds up into the truck so I simply would need to pull it out and drop it to use.

I am encountering a problem, however. There is not much room between the rear battery mount and the spring. I would be left with a step barely 9" wide which seems way too small. If I go any wider, then the steps will stow below the lowest point of the trailer hitch. I feel that is unacceptable. Therefore I built the steps up to this point and have that on hold while I decide the best way to tackle that issue.

Flyin6 · « **Reply #1481 on:** July 28, 2015, 09:32:34 PM »

Needing a small victory here, I started on the tire gate support for long term parking in a static location

I thought I'm make up a simple stand that plugged into this hole and stored somewhere on the tailgate

Flyin6 · « **Reply #1482 on:** July 28, 2015, 09:34:05 PM »

I flattened one side of some 1" round bar so that it created a "D" which could slide into the opening

Flyin6 · « **Reply #1483 on:** July 28, 2015, 09:35:14 PM »

I'll be using a couple pieces of 1" square stock to create the legs

Flyin6 · « **Reply #1484 on:** July 28, 2015, 09:37:11 PM »

To make that work I had to create a pivoting axle. I made it out of a 1/2" nut and 2ea 5/16" bolts

Flyin6 · « **Reply #1485 on:** July 28, 2015, 09:38:54 PM »

With a couple of homemade tabs, that was attached to the piece of 1" round bar

Flyin6 · « **Reply #1486 on:** July 28, 2015, 09:41:10 PM »

The legs were prepared by drilling some 1/2" holes, installing a pivot bolt, and welding on some feet. Each foot is drilled to allow me to hammer a spike through it into the ground. I guess I can nail the truck down if I need to now!

Flyin6 · « **Reply #1487 on:** July 28, 2015, 09:43:14 PM »

And just like that, the tail gator support was in the bag

Flyin6 · « **Reply #1488 on:** July 28, 2015, 09:43:53 PM »

The dog woke up

Flyin6 · « **Reply #1489 on:** July 28, 2015, 09:44:54 PM »

And that's it for a V E R Y sweaty build day 285

akraven · « **Reply #1490 on:** July 29, 2015, 12:00:00 AM »

Quote from: Flyin6 on July 28, 2015, 09:10:24 PM

Quote from: akraven on July 28, 2015, 05:09:18 PM
Does the door of the hatch clear the tire or are you going to have to drop the tire/open the rack to get into the rear of the truck?
Perhaps you missed it in the past when I talked about it, but the truck is going to lose the top hatch and the tailgate. I plan to build my own rear closure with a door and some other features.

Oops sorry guess I missed that post. I will review and report back to the class. :D

JR · « **Reply #1491 on:** July 29, 2015, 02:10:39 AM »

I know what you mean Don, it was 107 here today. So nice to have pool!!!!!!!!!!!!

Flyin6 · « **Reply #1492 on:** July 29, 2015, 08:07:07 AM »

Quote from: JR on July 29, 2015, 02:10:39 AM

I know what you mean Don, it was 107 hear today. So nice to have pool!!!!!!!!!!!!

I don't think it's the heat so much, but the humidity. We were routinely above 110 in Kandahar, my outside theometer would display 128, of which I took a pic, so that is what I called "Felt heat" with the sun beating down on you, but we had no humidity. My flight suit at the end of the day when I took it off was like cardboard from all the body salts that came out of me and saturated it...but the sweat dried instantly (Providing some cooling)

But this humidity is nasty. You are soaked with sweat nearly all day long...that cold shower at night fall feels sooo nice!

JR · « **Reply #1493 on:** July 29, 2015, 02:48:20 PM »

Yup, know about the humidity from playing in the lower deserts here. Maybe not quite as bad as you over there!

I used to wear a sleeveless sweatshirt when I worked in the fields near Hemet, the sweat cooled you so much. But high humidity felt worse when at the Salton sea.

Flyin6 · « **Reply #1494 on:** July 30, 2015, 11:04:18 PM »

Quote from: JR on July 29, 2015, 02:48:20 PM

Yup, know about the humidity from playing in the lower deserts here. Maybe not quite as bad as you over there!

I used to wear a sleeveless sweatshirt when I worked in the fields near Hemet, the sweat cooled you so much. But high humidity felt worse when at the Salton sea.

Got a decent day, today but I had damage control from yet another big thunderstorm and had no time left for the SquareD
I did get the last water can in so that's complete, and with not much more to do, I'll be pulling the bumper off soon to finish weld and paint it

JR · « **Reply #1495 on:** July 31, 2015, 03:26:27 AM »

Went to the mountains with the kids kayaking, was just 96 up there. 108 at home!! They played, I fished, good day.

Our cat won't go outside in this heat, spoiled err, well you know,,,,,,,

I like the water cans, but $50 each for plastic!!!

BobbyB · « **Reply #1496 on:** July 31, 2015, 03:36:13 AM »

Well we've seen Sled dog, we've seen glimpses of Red Dog, so wheres Black dog?!?

Flyin6 · « **Reply #1497 on:** July 31, 2015, 09:03:25 AM »

Quote from: BobbyB on July 31, 2015, 03:36:13 AM

Well we've seen Sled dog, we've seen glimpses of Red Dog, so wheres Black dog?!?

The black dog is: The black face of deaf!

He's around...I capture him today with a shot or two.

He's about twice the size as he was the last time I posted him up. He's the skinny variety, not like Bear who seems more the traditional, classic lookin' GSD

rpar86 · « **Reply #1498 on:** July 31, 2015, 07:07:07 PM »

JR, your cat could be twins with ours. He lives outside PERMANENTLY now since he wouldn't stop peeing on things and is not much liking this 100* heat. Oh well, his own fault.

duramaxdarren · « **Reply #1499 on:** July 31, 2015, 08:58:41 PM »

lotta DOT chatter......back to the build please