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Author Topic: SquareD Part 4: Paint, topper, Roof rack, and continued change!  (Read 197251 times)

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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #200 on: October 13, 2014, 01:22:36 PM »
With the tube bent and another upright added, the fit is working out
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #201 on: October 13, 2014, 01:23:05 PM »
Now that upper hoop gets another bend
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #202 on: October 13, 2014, 01:24:46 PM »
Then that bar gets a fish-mouth cut in to mount to the next upright.

This upright will be taller to raise the upper hoop about 2" to cover that precleaner better since it's also taller
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #203 on: October 13, 2014, 01:31:17 PM »
I cut a similar mouth into the hoop to fit that upright like a glove
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #204 on: October 13, 2014, 01:32:08 PM »
Then the two, taller uprights were tacked in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #205 on: October 13, 2014, 01:32:45 PM »
The pre-bent basketball hoop will be the last thing to go in, so back to the front. Another upright goes in here. Each time I make one of these things, it gets measured, cut on a drill press using a hole saw, then dressed up with a grinding wheel
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #206 on: October 13, 2014, 01:33:20 PM »
Then the right one
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #207 on: October 13, 2014, 01:34:09 PM »
Then the section connecting the owl's eye box to the pre-cleaner cage was bent up, then tacked in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #208 on: October 13, 2014, 01:34:59 PM »
It will get some triangulation a little later

Now on to the protective cage

Here two more uprights go in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #209 on: October 13, 2014, 01:36:01 PM »
placing them at the apex of the bend to catch that pesky tree limb or disintegrating wall structure
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #210 on: October 13, 2014, 01:37:04 PM »
Then the previously bent top hoop is tacked on
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #211 on: October 13, 2014, 01:37:39 PM »
Far from done, the structure is definitely getting in there
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #212 on: October 13, 2014, 01:38:16 PM »
The owl's eye mount is PDS (Pretty darned strong)
I don't think that metal box will be moving around all that much
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #213 on: October 13, 2014, 01:39:12 PM »
The particle separator device will rest inside this:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #214 on: October 13, 2014, 01:39:48 PM »
That was a good point to call it a day so I did.

Here's the DGS (Don's Garage Situation) at the end of Build Day 129
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #215 on: October 13, 2014, 01:40:57 PM »
Quote:
Originally Posted by Cudakidd53 View Post
Looking good- nice to see sparks a flying again!

Great googly-moolgy you weren't joking about green-up in Tucky; let it go a few more weeks and you can bale it and sell it for Hay- fill up the trailer and cart it out to near Nate. Texas is always hurting for hay it would seem!

I was only down for a single day, Saturday, Man... the impatience around here!

I surprised myself with the amount of fab I was able to turn out yestertag, with it being Sunday and all. Spousal unit had to cipher all her expenses so's eye could finish summin the tax disinformation.

Anyone with me on this convoluted tax system?

I try my darnest to do it correctly. I oftentimes run it on turbo-tax, then get professional help. Yet every year the IRS sends me a bill for owed taxes!. THis year I get a bill from them for 2010 taxes for $1,800, then another for last year's for fifty something. Does it ever end?

They just have you over a barrel. At any time they come back and say, you know Mr. Harward, we noted that you claimed jelly beans as a business expense for your 1974 taxes. We just can't see that and are disallowing that deduction. You owe $3.21 for the jelly beans, $100 (per year) fine for filing that, and accrued interest, then when the fine amount exceeds your annual income you are subject to alternative minimum taxes which have also been unpaid, according to our calculations for a number of decades, so it is our determination that in addition to the $643,871 you owe in back taxes and fines, you have also been tried and sentenced in tax court and are to report to your local sheriff to be arrested to begin serving your 63 year sentence!

And what's the alternative minimum tax anyway. It's as if someone is saying, hey, this tax code thing is beyond comprehension, it's to the point where no one can figure it out and smart people actually use it to get out of paying any taxes at all, so let's just start again and throw out a couple rules. We can make it anything we'd like so let's fix it up to where after a week of sorting through all these rules we don't understand they will find this rule which simply says to surrender 75% of all your money! Yea, let's do that!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #216 on: October 13, 2014, 01:41:34 PM »
OK, time for everyone's evening fix

I know this silly thread is an addiction for a lot of people out there!

Work continues on the roof rack build. It is nearing completion of the fab stage. After that it will get painted or coated, then the accessories will be installed, the wiring harness installed and the whole kit and ka-boodle will get bolted down for keeps

The 20" light bar showed up. I know this part is not EMP proof, but it is not a primary lighting system, but part of the "Scene illumination" feature I'm building into this truck. I want big light and low amp pull, so LED was the way to go. Primary lighting on this truck will remain old school incandescence

Here's that cool light bar:
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #217 on: October 13, 2014, 01:42:10 PM »
It will go into the front of the rack just to the right (Vehicle right) of the owl's eye
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #218 on: October 13, 2014, 01:43:04 PM »
The mount is a simple 1 X 1 section of square tubing set on two stations with 2ea 1/4" bolt/studs that the light fixture slides down over
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #219 on: October 13, 2014, 01:43:49 PM »
It welded on in three places and is pretty strong and secure
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #220 on: October 13, 2014, 01:44:28 PM »
The light bar simply slides onto the studs
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #221 on: October 13, 2014, 01:45:27 PM »
While I was working up front, I finished installing the triangulating brace onto the light box mount
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #222 on: October 13, 2014, 01:46:01 PM »
So far, so good
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #223 on: October 13, 2014, 01:46:51 PM »
Here, the final 1.25" square tube brace is welded in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #224 on: October 13, 2014, 01:47:41 PM »
Then the rear uprights were installed, completing the hoop assembly in the back
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #225 on: October 13, 2014, 01:48:15 PM »
Then I added one more upright onto the left side
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #226 on: October 13, 2014, 01:48:57 PM »
I think that pretty much finishes out the structure
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #227 on: October 13, 2014, 01:49:25 PM »
Now for the oil cooler. It will occupy this space:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #228 on: October 13, 2014, 01:49:56 PM »
About here:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #229 on: October 13, 2014, 01:50:45 PM »
The rear mount is a simple piece of angle with 2 ea 1/4" bolt studs welded in
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #230 on: October 13, 2014, 01:51:32 PM »
The cooler is so lightweight, that just the two tack welds supports the cooler for now
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #231 on: October 13, 2014, 01:52:56 PM »
The front mount is a bit more robust. 3" plate .125" thick with two more studs welded in place
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #232 on: October 13, 2014, 01:53:53 PM »
That piece is bolted to the cooler and then was welded to two legs made of 1/2" square steel tubing
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #233 on: October 13, 2014, 01:54:53 PM »
Air flow is going to be from the bottom, then up through the cooler, then exit out the top. That is why it is tilted and why I will make a cowling to direct the air flow where it needs to go.

The cowling is first made from cardboard, then the adjusted cardboard is traced onto metal, then cut out. I am thinking this needs to be made from sheet aircraft aluminum, say .025 or .032...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #234 on: October 13, 2014, 01:55:38 PM »
Quote:
Originally Posted by flyin6 View Post
Air flow is going to be from the bottom, then up through the cooler, then exit out the top. That is why it is tilted and why I will make a cowling to direct the air flow where it needs to go.

The cowling is first made from cardboard, then the adjusted cardboard is traced onto metal, then cut out. I am thinking this needs to be made from sheet aircraft aluminum, say .025 or .032...


Hey Big D-

Are you considering any louvres in front to deflect debree from striking the cooler? We used a homemade grill of them running horizontally to block dirt and rocks racing dirt track- air bent the corners, hard stuff did not. Easy to spray mud off of flat surfaces, not radiators! Side view of them had a high horizontal plane, ramp up 45 degrees, down 45 degrees but past first plane down to a second horizontal plane. All of these viewed from the front prevented seeing all but a thin line of radiator, with each louvre about 1-2" apart.

Let me know if it interests you and I can draw a picture incase verbal description isn't making translation from Obummer Land to Bluegrass Ville.
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #235 on: October 13, 2014, 01:56:12 PM »
Quote:
Originally Posted by Cudakidd53 View Post
Hey Big D-

Are you considering any louvres in front to deflect debree from striking the cooler? We used a homemade grill of them running horizontally to block dirt and rocks racing dirt track- air bent the corners, hard stuff did not. Easy to spray mud off of flat surfaces, not radiators! Side view of them had a high horizontal plane, ramp up 45 degrees, down 45 degrees but past first plane down to a second horizontal plane. All of these viewed from the front prevented seeing all but a thin line of radiator, with each louvre about 1-2" apart.


Let me know if it interests you and I can draw a picture incase verbal description isn't making translation from Obummer Land to Bluegrass Ville.

Yea, Mike I did give it some thought, but decided not to do anything. First this is not a dedicated off road machine, just one that is hardened up a little. When I have gone off roading in the past, not all that much mud was blown onto the roof, let alone any that would get "Sucked" into the opening. This thing has no suction as it were.

Mud would more likely fall onto the top as in descending after being splashed. The cooler is between 4-5 times the size of the stocker, so a lot of it could be covered and still do at least the job of that stocker. Finally, the stock cooler sat in the path of mudville. Nothing but a grill opening to impede the entry of debris, and the W250 was designed to be an on/off road work truck. So, no, me thinks louvers would be overkill in this application.
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #236 on: October 13, 2014, 01:57:41 PM »
Quote:
Originally Posted by BobbyB View Post
How heavy it the rack? What do you think the finalized weight will be? Pre load out and post loadout? Just asking, since I don't want to see it go down the road of TacTopper. But I'm liking the design so far.


It's getting heavier. I'd guess from having to move it around, that it is currently in the 95-100 range. It only gets a laminate lightweight floor, a couple lights, some tabs, and paint to finish it, so it is more or less there in the current configuration.

As far as additional loading. Well, I always throw the lightest stuff up on top just because I don't want it falling on my knoggin when I finally need it, so maybe 50 pounds more and call it a day...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #237 on: October 13, 2014, 01:58:45 PM »
Speaking of cooler, that's all I had time to mess with today.

I had to spend hours on this, but now Mr. Cheetah is ready to destroy some serious vegetation.
This machine is serious. 34 HP and a top speed of 16MPH, but that's on level ground. GO down hill and I'll bet it can hit 25...It's a screamer. It will wheelie just by taking off too fast. I need (Want) to put some Harley shorty mufflers on it!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #238 on: October 13, 2014, 01:59:31 PM »
Then no sooner I get started on the rack, and Jake the psycho dog from down the street shows up. He eats, and drinks at my place, plays with my mutts, tears up something then leaves fast as he came...Weird dog
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #239 on: October 13, 2014, 02:00:06 PM »
So today, I picked up the floor material and wanted to build in the air ducting for the cooler.
Using aircraft .025 aluminum I marked out the pieces
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #240 on: October 13, 2014, 02:21:10 PM »
Then cut them out with the big shear
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #241 on: October 13, 2014, 02:54:00 PM »
That went pretty quickly
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #242 on: October 13, 2014, 02:57:04 PM »
Before the ducting is added:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #243 on: October 13, 2014, 02:57:38 PM »
The top piece goes in first
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #244 on: October 13, 2014, 02:58:37 PM »
Hole by hole the piece is drilled and cleco'd into place
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #247 on: October 13, 2014, 03:12:41 PM »
I may add an extension to the left side, should I decide to retask that 20" light bar to the rear of the truck and add in an eight light, 8" lamp to open up that space in front of the cooler intake.
I guess, I'm pretty much deciding on doing that...

But here is the thing prior to removing the plastic and riveting it together. I plan to build the duct as a one piece affair which screws to the structure with some 10-24 sheet metal screws. That way I can remove it for maintenance and cleaning of if it gets buggered up
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #248 on: October 13, 2014, 03:13:20 PM »
And this is how the whole thing sits tonight, the end of a very short build day 131
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Offline Flyin6

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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #249 on: October 13, 2014, 03:15:21 PM »
OK, let's finish up this oil cooler cowling.

Here is the progression of that thing through riveting and the acid etching primer
Site owner    Isaiah 6:8, Psalm 91 
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