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Author Topic: SquareD Part 4: Paint, topper, Roof rack, and continued change!  (Read 197288 times)

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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #150 on: October 13, 2014, 12:03:36 PM »
Seems to be working...

I will add a second, taller bar tomorrow and tie them both together. I think I'll make this part removable since if anything gets smashed up, this is very likely to be the chosen part!
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #151 on: October 13, 2014, 12:04:00 PM »
And that's it for Build Day 126
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #152 on: October 13, 2014, 12:17:32 PM »
Quote:
Originally Posted by BobbyB View Post
Merely an observation.... But wouldn't it be a better idea to make the light box a bit more streamlined so branches slip off instead of grabbing hard on the 90s or the flat surface in front? Something like a teardrop shape? It'd also be a bit more aerodynamic (granted D2 is become aerodynamic as a brick with a parachute strapped to plywood) and cut down on wind noise, as well as cut your silhouette?

Just something I thought of while reading before racking out.

P.S. since you are building a new roof rack couldn't you include them into the structural design of the rack, so its a one piece unit instead of adding height and weight to the roof?

Streamlining for the sake of aerodynamics is lost with the factory silhouette, really.
However you are right with respect to the snagging on stuff comment.
OK, Bobby, I think I'll modify the box
Why not, everything else is modified
I talked about whacking off the top outside corner, so what I think I'll do is cut a generous angle into that corner and weld in a new plate all pretty like. That should make both you and some cedars down on the farm happier

Cool?

As for incorporating it into the rack. I thought about it and I agree, but as with the prebreather brush guard, I think I'll just make it a bolt in affair si if it gets torn up, or later on I want to replace it with something different it will be simplier. Never the less it will be sticking up some, but like a searchlight on top of that 105mm cannon on my old M60A1 MBT, although it might get catch a few branches from time to time, it sure was effective when you needed it.
That thing, BTW was 7.5 million candle power!
Here's something you didn't know...

Funny really

Did you know those searchlights work in the IR spectrum as well?

Know what that is good for?

Well when you infantry guyz are ah' sneakin up on us during some field exercise, we would flip the light to IR then focus the beam on you folks. That would expose you to like 2 hours of sunbathing in Miami every 10 minutes!

Ever get a sunburn during those exercises???
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #153 on: October 13, 2014, 12:18:20 PM »
I was thinking about, thinking just now, and this came to mind:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #154 on: October 13, 2014, 12:18:48 PM »
Makes one want to pray for rapid growth, doesn't it!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #155 on: October 13, 2014, 12:19:22 PM »
Well, messing around with the truck today, for a couple hours this late afternoon, I got the tailgate to close.
THis is a step forward, as when I purchased the truck, it would not stay closed and would only flop around in the open position

I finally remembered to get some linkage clips, which I ended up not using. I found some better all steel barrel clips that actually pinch the linkage rod in place making it as fool proof as one can I suppose
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #156 on: October 13, 2014, 12:20:17 PM »
Anyway all that went together and it worked...end of story
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #157 on: October 13, 2014, 12:21:03 PM »
it closes!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #158 on: October 13, 2014, 12:21:52 PM »
With Boby convicting me and with me already pondering the "Squareness" of the light box, I decided to apply some sparks to the semi-finished box
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #159 on: October 13, 2014, 12:22:53 PM »
Then through the pure magic that is fabrication all this happened:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #160 on: October 13, 2014, 12:23:37 PM »
That steel was much mo-better so things were well with the local universe for a time...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #161 on: October 13, 2014, 12:24:04 PM »
Ah, the steel nose thing

Got the idea from helicopters I have flown over the years. We have WSPS (Wire or something Protection System) Basically it's a hard edge that is the first thing that power lines that you, the pilot who just really screwed up badly, are in the process of bisecting. A real WSPS has saw teeth embedded in some hard rubber that literally saw the power lines in half thus saving you and the aircraft. My steel nose thing is not like that...It's just a piece of steel that stiffens up the front of Uni-light so it will kill branches and still sparkle like your brides diamond ring.
BTW, those WSPS things on Armee helicopters only get the problem of saving you for another day about 50% right
Ask me, I know
So, I'm the passenger in a Jet Ranger in Korea
Yea, the broken back story
ZThe first time I see the wires they are about 5 feet from my windshield
Before my heart stopped one millionth of a nano second later, that windshield was in my lap.
So I did the natural thing and threw out this really big hole in front of me.
The wire got cut all right while it was stretching, now being powered by Bell Helicopters in stead of Kung-Fool electric company, it couldn't take the argument it was having with several cowlings and those saw teeth and just like that it snapped.
And just like all good wires under a lot of helicopter inspired tension. it recoiled violently.
I guess the rotor blades didn't have wire strike protection because that recoiling wire ripped a chunk right out of one!
Yea, not cool. Blades keep your butt out of rice paddies, or in this case a frozen river right beside a rice paddy. So yea, we crashed, like right now spreading bell helicopter parts all over the place. The biggest parts of the helicopter still contained me and this lieutenant who just did all that, and that is an important fact because I am the guy writing all this and creating steel noses on things.
So, yea, what the heck was I talking about anyway...?
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #162 on: October 13, 2014, 12:25:15 PM »
Ah, the nose thing

Here's some more pics of the manly creation!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #163 on: October 13, 2014, 12:25:53 PM »
Call that in the bank for right now

On to the developing roof rack system

I needed a second hoop so konstruktion started on that
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #164 on: October 13, 2014, 12:27:07 PM »
It needs to look a lot like this by golly!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #165 on: October 13, 2014, 12:28:10 PM »
We'll call it a reverse question mark for the time being until I can come up with some kool Armee soundin' acronym.

SO more bendin' and looky what happened:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #166 on: October 13, 2014, 12:28:45 PM »
I think that's a keeper!

So using my not so famous Cleco thing-ah-ma-bob, I fastened the lower bar and started to mentally cipher out how the rest of it is going to fit.
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #167 on: October 13, 2014, 12:29:26 PM »
The upper run will fit somewhere near here:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #168 on: October 13, 2014, 12:29:58 PM »
Back to "Uni-Light w/nose device

It is going to go in somewhere around here
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #169 on: October 13, 2014, 12:30:44 PM »
As I started to look at it, I saw an opportunity to cut it right into the rack system.

If I cut the lower hoop right at the edge of the box, plus an eighth of an inch for some tabs, I could slide it down a few inches and tuck it in nicely and lower the profile.
That should keep bobby happy, and well, the rest of everybody's opinion doesn't matter anyway

Studying the position one could see how doing that would trick up this build even more
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #170 on: October 13, 2014, 12:31:18 PM »
That's all folks, another day, #127 now clearly in the bag...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #171 on: October 13, 2014, 12:32:35 PM »
From Dmaximus:
Quote:
Originally Posted by flyin6 View Post
Ah, the steel nose thing

Got the idea from helicopters I have flown over the years. We have WSPS (Wire or something Protection System) Basically it's a hard edge that is the first thing that power lines that you, the pilot who just really screwed up badly, are in the process of bisecting. A real WSPS has saw teeth embedded in some hard rubber that literally saw the power lines in half thus saving you and the aircraft. My steel nose thing is not like that...It's just a piece of steel that stiffens up the front of Uni-light so it will kill branches and still sparkle like your brides diamond ring.
BTW, those WSPS things on Armee helicopters only get the problem of saving you for another day about 50% right
Ask me, I know
So, I'm the passenger in a Jet Ranger in Korea
Yea, the broken back story
ZThe first time I see the wires they are about 5 feet from my windshield
Before my heart stopped one millionth of a nano second later, that windshield was in my lap.
So I did the natural thing and threw out this really big hole in front of me.
The wire got cut all right while it was stretching, now being powered by Bell Helicopters in stead of Kung-Fool electric company, it couldn't take the argument it was having with several cowlings and those saw teeth and just like that it snapped.
And just like all good wires under a lot of helicopter inspired tension. it recoiled violently.
I guess the rotor blades didn't have wire strike protection because that recoiling wire ripped a chunk right out of one!
Yea, not cool. Blades keep your butt out of rice paddies, or in this case a frozen river right beside a rice paddy. So yea, we crashed, like right now spreading bell helicopter parts all over the place. The biggest parts of the helicopter still contained me and this lieutenant who just did all that, and that is an important fact because I am the guy writing all this and creating steel noses on things.
So, yea, what the heck was I talking about anyway...?

I also have seen the WSPS (wire strike protection system) in action. The one on the Astar's as on the OH-58's are the same. I can't see it would cut anything larger than about 3/8". Any thing larger and your in a world of hurt. How about the tension on those wires. I was told it looked like 4th of July when the thing snapped. I was really surprise of the aftermath. Of course the wire took off the pitot tube and ran up the windshield. When it struck the WSPS it left some marks in the paint and that was it. The cabin is made of fiberglass and not a crack one surrounding the mount.

BTW: Liking the roof rack very much.
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #172 on: October 13, 2014, 12:33:14 PM »
:
Originally Posted by Dmaximus View Post
I also have seen the WSPS (wire strike protection system) in action. The one on the Astar's as on the OH-58's are the same. I can't see it would cut anything larger than about 3/8". Any thing larger and your in a world of hurt. How about the tension on those wires. I was told it looked like 4th of July when the thing snapped. I was really surprise of the aftermath. Of course the wire took off the pitot tube and ran up the windshield. When it struck the WSPS it left some marks in the paint and that was it. The cabin is made of fiberglass and not a crack one surrounding the mount.

BTW: Liking the roof rack very much.

That OH-58 I was in was not so lucky. THe wire ripped off one of the trim tabs and about a hand sized piece of rotor blade

Big time instability and vibration
Know about "Pylon whirl" in the jet ranger? The transmission tore that stud off the bottom of the case and threw the cowling all over the place, some of it through the tail rotor.

I didn't tell this part. but we were just outside of the DMZ in Korea which requires position reports every 15 minutes I think. well after we had missed several, they launched search and rescue. Toward the end of the day a South Korean MD-500 comes ripping up the valley looking for us, and that's when I saw another wire. THis guy hits that wire, looses control and spins in right next to us. Yup, two crashed up helicopters!
Then the UH-60 crew that heard the ROK pilot radio in that he had found us made an approach and believe it or not was making an approach into the single remaining wire!!!!!!
I ran over to the wreckage, turned on the battery, flipped the VHF over to guard and started yelling, Black Hawk on approach to the crash site, go around, go around.
He did, and later that CW4 who was the commanding general's personal pilot said if I hadn't made that call, he would have flown right into that wire.

What a day!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #173 on: October 13, 2014, 12:34:49 PM »
From Dustoff35:
:
Originally Posted by BobbyB View Post
...I realize you haven't finalized the mounting position yet, but if you force a thick wire, steel cable or wait a minute vine down towards the bottom of the lightbox it could snag and if strong enough remove your lightbox from the roof rack...

Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #174 on: October 13, 2014, 12:36:24 PM »
From cudakidd53
Quote:
Originally Posted by Dustoff 35 View Post
Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me.


In case Don misses the shot here..........Whooooo, Whooooo, whoo asked ya....
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #175 on: October 13, 2014, 12:36:53 PM »
Quote:
Originally Posted by Dustoff 35 View Post
Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me.

You named it, the owl's head it is!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #176 on: October 13, 2014, 12:39:51 PM »
Quote:
Originally Posted by FBJR View Post
Have you guys ever seen a WWII submarine? It had a wire from the bow up over the coning tower. With all the stuff on the truck, why not a simple wire up each side to the rack/future topper to do the same thing?
Run form the corner up on each side will keep your engine access clear as well as the air cleaner??

You're talking about limp risers, and yes the truck is getting them, but at some more distant point in the future. After I build the front end, and a part of the exo-skeleton, then I will add the 3/16" steel cable on a aircraft turnbuckle and a spring. That will attach to the highest point of all that business that is getting built in at the moment
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #177 on: October 13, 2014, 12:40:39 PM »
Here's a bit more done on the truck.

First I remounted the lights in Duane's aptly named Owl's head
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #178 on: October 13, 2014, 12:41:12 PM »
All the interference is right here
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #179 on: October 13, 2014, 12:41:41 PM »
So I notched it

This simple clearance allowed the box to sit 2" lower into the protective frame
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #180 on: October 13, 2014, 12:42:36 PM »
Instead of cutting up that pretty lower bar, trough notching the "Nose" the box sat much lower. All that was required to get the Owl's Head to rest there was to build a shelf for it to sit onto.

Here is that simple but effective piece:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #181 on: October 13, 2014, 12:43:17 PM »
The 3" wide shelf piece has the 5/16" nuts welded to it, therefore mounting the box to it will be simpler.

That lip welds to the underside of the main support beam
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #182 on: October 13, 2014, 12:43:52 PM »
And here is the light box nestled lower in the roof rack
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #183 on: October 13, 2014, 12:44:54 PM »
With that in about the right place, time to form up the two forward mounts I envisioned

The right mount was made from a curved and angled short section of steel tube and a home made flange that bolts to the Owl's Head
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #184 on: October 13, 2014, 12:46:33 PM »
Then with a couple of uprights tacked or really, semi-welded into place, I started to form the left/outside upper bar and owl's head mount
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #185 on: October 13, 2014, 12:47:12 PM »
It fits pretty well. The upper bar maintains the swept back angle to aid in shedding 2X4's, Kia parts and branches
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #186 on: October 13, 2014, 12:47:59 PM »
I've been learning a lot about that bender, which will help me do a better job with the exo skeleton. Instead of cutting that bar and welding another 90 to it, I carefully measured, marked, then set up the machine and bent this upper hoop. What do YOU think???
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #187 on: October 13, 2014, 12:48:49 PM »
The OH right side mount was short, strong, simple, and gets the job done with no fuss
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #188 on: October 13, 2014, 12:49:35 PM »
Remember those 6-element lights?

Here's where they go, one on each side
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #189 on: October 13, 2014, 12:50:07 PM »
At the conclusion of build day 128, here's what's going on:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #190 on: October 13, 2014, 12:51:05 PM »
Quote:
Originally Posted by KensAuto View Post
Nice bending! Now your thinking outside (of) the box! 

I finally had the sense to experiment and find the exact point on the die that the tube actually starts to bend. Then by marking and measuring from the starting point of the bend, I can get it pretty close.

I'll do the same for the 1.75" or 2" die I'll use for the exo-skeleton tubing.
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #191 on: October 13, 2014, 12:51:40 PM »
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Originally Posted by TexasRedNeck View Post
Keep going Don!

Me thinks that in the time I've wired in a few accessories in my build thread, you've built an entire truck.....twice


Nope...

Neither is done, and Square D is far from operating

But it needs to get there.

I feel a certain push to get an EMP proof back up (Primary??) truck in place.

And no sooner that I get that done I'm starting on the tactical habitat thing or on the square fender, Cummins powered burb.
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #192 on: October 13, 2014, 12:52:18 PM »
Quote:
Originally Posted by TexasRedNeck View Post
Keep going Don!

Me thinks that in the time I've wired in a few accessories in my build thread, you've built an entire truck.....twice


I am under strong pressure to open my own site...To possibly make the money to fund "Real Man"

I see a bunch of like minded people (You) doing builds on vehicles, homesteads, guns, cookin' planning finances, canning, I did mention building gunz, right? and a whole bunch of like minded subjects.

Cool thing is a lot of the "Guides" I think we'll have will be ex-military, special operations types, of the sort they have made movies about in recent times. We'll give it to you straight, not mix in all this civie "background noise" crap we are all subjected to. Nope those folks will simply serve as evening hunt training aids!

Sorry about the "Civie" term, but hey, I can't seem to stop using it. You guys can call me something as well...cool?
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #193 on: October 13, 2014, 12:53:25 PM »
Quote:
Originally Posted by FBJR View Post
Oh no, it's popcorn time

Is it "BED TIME" yet ?????


Well, grass is coming in and that "Cuts" into my build time

Last week I was over at the Sherriffs office. In rolls an undercover unit...4 menses.
So I sez, "Hey you people finished eating out, drivin around and generally wastin' my tax money? I get a response out of two of them, both good menses. I sez, I need some strong backs and weak minds, you boyz look perfectly suited for the task! Then I sez, get your butts over to my place tomorrow and lift that bed back onto the truck frame for me so I don't twist an ankle or something..."

Well, I was kidding around, messing with them, man style. So the next day rolls around and I am sitting having lunch with my pastor. Me phone, she rings, well, beeps. One of those knuckleheads is on the other line. Turns out he and his buddies are in my driveway looking for me. You see, brave as they are, I find this funny, but they won't get out and check out around my house for me...They all think I'll shoot them or sick a killer dog on them, or they will step on a mine or fall into a pit or get caught in some Chinese man trap! Some of that is true unfortunately, one of them who I love like a son comes in my house one day sort of unannounced and the shepherd I had then takes him out in about three fifths of a micro second. It was a pitiful scene. Mikey has both arms up and is looking away like he doesn't want to see what's happing to this poor deputy. The dog has him, but hasn't clamped on and just waiting my command to start snacking. But I am laughing at the scene, watching one of our finest acting like a scared little school girl, so in the fashion of men, I just let the story spread, and all the officers look over truck and know my past so I let it all be...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #194 on: October 13, 2014, 01:14:19 PM »
OK, let's get on with the build. Even though we did Church, and the Sunday dinner, I got that roof rack a long way down the track

Here it is removed from the truckster
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #195 on: October 13, 2014, 01:14:51 PM »
First I bent this little piece to plug into the existing bottom hoop. I needed to get that formed in to build the top from
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #196 on: October 13, 2014, 01:15:23 PM »
And lookie here, it all connects
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #197 on: October 13, 2014, 01:16:04 PM »
With the outside perimeter connected, I added another stiffner to the main frame
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #198 on: October 13, 2014, 01:18:28 PM »
Then this brace went in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #199 on: October 13, 2014, 01:21:14 PM »
Followed by this upright

The back upper hoop bar is in place and if you look, already marked for the bend. Once bent, it will fall into the fish mouth and fit all purdy like
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