Author Topic: SquareD Build Thread, Part 1: The beginning (Read 141623 times)

Flyin6 · « **Reply #400 on:** October 04, 2014, 11:48:39 PM »

You may have noticed that I moved from the front to the back and am now working forward.
That is because the muffler will be a custom fit requiring me to trim off sections of two different pipes. I am hanging it way up high and tucking it in the frame to be out of the way.

The muffler is pretty heavy and I planned to hang it as securely as I could

Since the threaded "L" or "J" was working I decided to just keep using it

Flyin6 · « **Reply #401 on:** October 04, 2014, 11:49:48 PM »

That is 1/2" solid steel rod.

I drilled two 1/2 inch holes in a cross member either side of the exhaust

Flyin6 · « **Reply #402 on:** October 04, 2014, 11:51:08 PM »

At this point the pipe is not trimmed, and held temporarily in place with another hangar. All that will be cut off before the muffler will fit though

Here' the approximate alignment and the other half of the hangar system I invented. A simple 4" clamp with two 1/2" studs welded to the flat side

Flyin6 · « **Reply #403 on:** October 04, 2014, 11:54:00 PM »

Here's the mount carrying the weight of that muffler and the pipe up stream

Flyin6 · « **Reply #404 on:** October 04, 2014, 11:54:49 PM »

I intentionally welded the studs on opposite sides of the clamp so that they would align facing slightly fore and aft

That should isolate and swing that develops, and the slight torque of the clamp makes it all more rigid

Here's another shot

Flyin6 · « **Reply #405 on:** October 04, 2014, 11:56:06 PM »

I added yet another hangar to the rear of the muffler.

That made for a total of 5 hangars and the turbo outlet carrying the weight.

I also wanted adjustability, and this system has it all over. I adjusted exactly where I wanted the pipes to hang, tucked up, but away from rattle points. A simple turn of a nut and the system moves either up or down

Flyin6 · « **Reply #406 on:** October 04, 2014, 11:57:00 PM »

Here it's adjusted into the final position

Flyin6 · « **Reply #407 on:** October 04, 2014, 11:58:59 PM »

Next I focused on the tailpipe sticking way too far out

Flyin6 · « **Reply #408 on:** October 05, 2014, 12:00:11 AM »

Bright aluminum color will never do, so I changed it up.

That duty fell to my always handy John Deere Blitz black paint

Flyin6 · « **Reply #409 on:** October 05, 2014, 12:01:16 AM »

Remember that everything rusty in the pics now is to be removed and replaced with upgraded parts.

I've meant to replace the fuel filter for some time now, so I finally did.

The old Mopar filter has been on there for some time!

Flyin6 · « **Reply #410 on:** October 05, 2014, 12:02:33 AM »

The new one is a lot prettier. I put it in filled with fuel and with new O rings

It's barely visible in the pic behind the IC pipe

Flyin6 · « **Reply #411 on:** October 05, 2014, 12:03:49 AM »

This injection pump is all stock.
By adjusting the star wheel under the dome cap, the fuel screw under the cap in the back, and bumping the timing a little this 160 horse motor will add 100 + horsepower and raise torque from 400 to around 600! All by adjusting a few things!
I'll do that pretty soon

Flyin6 · « **Reply #412 on:** October 05, 2014, 12:04:27 AM »

Here's a look at the paint
It's a Gissepie (Texas) Synthetic enamel. The color is late WW2 through the Korean war for the US Army.
I'm not crazy about it, but my dad was a pilot of B17's who flew (Barely surviving) all 35 missions bombing Nazi Germany. I guess I feel a kinship by selecting the color from his time at war

Flyin6 · « **Reply #413 on:** October 05, 2014, 12:05:05 AM »

Well, I had a new can of paint, an old fender surface...There was no danger, so I took the shot!

Here's just one wet coat

Flyin6 · « **Reply #414 on:** October 05, 2014, 12:05:53 AM »

And a second coat

Flyin6 · « **Reply #415 on:** October 05, 2014, 12:06:39 AM »

And after a plate of spaghetti

Flyin6 · « **Reply #416 on:** October 05, 2014, 12:07:16 AM »

Shawn and GLO supplied the new spring hangars for the Sterling axle that is next up.
The factory plates will be cut off and these welded on in place of them

Flyin6 · « **Reply #417 on:** October 05, 2014, 12:08:13 AM »

Shawn also supplied one of his great axle covers. The Dana 60 one he sent earlier is going back to him, hopefully so he can use it on his bronco! Be a shame to waste the paint job...!

His covers are just the best. These things just scream overkill and precision!

This one will get the same paint job as the others have

Flyin6 · « **Reply #418 on:** October 05, 2014, 12:09:53 AM »

From CuddaKidd53:

Don-

Wow, a week goes by and lots happened! Like the "Don's Garage" website idea, with build stuff public and CIEMR stuff subscription; but maybe not- here's the thought process:

Gods made you the "change a few fluids" guy who rebuilds most of the truck! It's what draws people here and makes them hang around. Because of us DOTs, the site crash and the continual state of National Disarray, other discussions happen......

People speak of their experiences with God following your lead, others join in.......

Those who've been away for a variety of causes/reasons find themselves going back to the house of The Lord and share that fact with you/those here!

Buying a Diesel Chevy becomes an in road to all that is taking place all over your builds....

It's all born of your "listening" to his voice and putting it out there on a PUBLIC site.....going out into the world yet being more "not of" the world.

Were this a pay-only site, would those here, actually be here? Don't know, but I do know that God truly works in mysterious ways for/in all of us.

So I'm not sure constraining the public side to the build/educational material without the message is a solid "yes", but I'm just the DOT of Ed!

AWESOME exhaust install, I really like those clamps- have never seen them before. Your heating, bending and threading of the solid rod reminds me of my father and grandfather's fabrication work- learned early in life not to grab shinny blue Curley Q's of metal! If you wear a tool belt, I'm betting a can of Blitz is standard too.

God Bless you and your decisions as you make them-

Mike

Flyin6 · « **Reply #419 on:** October 05, 2014, 08:30:59 AM »

Man, you people have been busy in my absence!
I ate so much chocolate yesterday I think I actually O'D'd. Not as in the paint, but as in my blood sugar level!
Had to do an extra long workout this morning, but by noon I was feeling pretty good. Looking pretty good if I don't mind saying myself...Which isn't true, of course, but it's my thread, I can say anything I want!

OK, boneheads, pay attention, we have assemblage to get to!

As we know the priority is the rear axle...Right?

That's exactly why we are starting under the hood with stripping some stuff in preparation to do some painting!

Making sense so for?

Yea, I don't get it either...I just do this stuff!

I really wanted to get right on that axle, but I really wanted the truck to start turning a bit more green before I started.

So I started by taking off stuff

Flyin6 · « **Reply #420 on:** October 05, 2014, 08:33:35 AM »

Earlier in the deconstruction/build I was wire brushing and caught a piece of that chrome grill, essentially, killing it. Well that is all solved now, that the grill will actually be getting the paint treatment.

Color you ask?

Who knows... Could be J.Deere black, flat silver, OD Green, or here's one...How's about the base color of the truck as it sits now??? You see that's a silver, and I just happened to own a quart of that color...???

Anyway, the front area of the truck is getting uglier

Flyin6 · « **Reply #421 on:** October 05, 2014, 08:36:14 AM »

How did this all start you ask?

Well, see that roll of rugger belt? Well, that was going into the front and top of the radiator to replace the factory piece that the red dog chewed up. So I sez to myself, "Self, we need to paint the stuff beneath that before we mount it, I sez."

So that's how it all started. First I was just going to paint one small area, but we know how the various bones are all connected to the other bones, so the work area spread like poison Ivy on a patch of sunburn! The grill was all up in the way, so with the removal of six thousand screws, it was out of there!

I never did put that rubber thing on there, but I did spray some of that ugly paint!

Flyin6 · « **Reply #422 on:** October 05, 2014, 08:39:52 AM »

Comment: At this point I believe I was a bit sloppy. Painting the top and not removing things to do a proper job.. .

Somehow around here I am no longer just making things serviceable, but actually phasing into a restoration.

As things got prettier, I always knew that way down inside the belly of the beast so to speak, that it was still a turd, and that bothered me.

You'll see upgrades happening shortly that are definitely above and beyond the restoration process, but it was a couple month long slide into that way of thinking.

Shortly we will stop with Part 3 and move into Part 4 which was the beginning of that change of mind.

Flyin6 · « **Reply #423 on:** October 05, 2014, 08:41:07 AM »

Here's some pictures of rust:

Flyin6 · « **Reply #424 on:** October 05, 2014, 08:42:02 AM »

Lookey here! The wheels fit!

Flyin6 · « **Reply #425 on:** October 05, 2014, 08:42:40 AM »

, first the axles get pulled...Same-same as our D-max's

Notice the cool O-Ring sealed axle flange. I don't think the chebby axle is made like that...Good idea Ford!

Flyin6 · « **Reply #426 on:** October 05, 2014, 08:43:31 AM »

A quick check of the lock-rite confirmed that it will fit!

Flyin6 · « **Reply #427 on:** October 05, 2014, 08:45:03 AM »

Next the hubs came off

The bearings were excellent and will not be replaced

Flyin6 · « **Reply #428 on:** October 05, 2014, 08:45:48 AM »

So, let's tear down drum brakes for you numb-skulls who are afraid of getting your pinkeys dirty...I'll learn you all proper like how to do it...Step, but painful step

First, pull the emergency brake cable. Just yank the living snot out of it until you figure that won't work, then go get a set of diagonal needle nose and fish the thing out of it's hole. Kind of like snake hunting in a rabbit borough, only different!

Flyin6 · « **Reply #429 on:** October 05, 2014, 08:46:47 AM »

Then the spring on the self adjusting star wheel, then that rusty Iceland looking thing

Flyin6 · « **Reply #430 on:** October 05, 2014, 08:47:45 AM »

The the cylinder screw thing ah-ma-jig

Flyin6 · « **Reply #431 on:** October 05, 2014, 08:48:38 AM »

Clean your wounds, tape them up, check up on the tetanus shot currency and continue

The least covered shoe is next. Remove the spring that keeps it in there one millimeter from total annihilation!

Flyin6 · « **Reply #432 on:** October 05, 2014, 08:49:11 AM »

Then fish the bent nail out the back side

Flyin6 · « **Reply #433 on:** October 05, 2014, 08:50:13 AM »

Now, using a 3 pound hammer and a 12" prybar pound the dog snot out of the shoe, or just look at it for a minute or so until it falls out on it's own accord!

Actually, there's still one spring that is holding it loosely from falling onto your foot

Flyin6 · « **Reply #434 on:** October 05, 2014, 08:51:15 AM »

Next go after the spring(s) holding the remaining shoe in place

Flyin6 · « **Reply #435 on:** October 05, 2014, 08:52:59 AM »

Now we pull that shoe off

No, bonehead, not your shoe, the brake shoe...kids!

Flyin6 · « **Reply #436 on:** October 05, 2014, 08:53:57 AM »

Next pull the Australian part off (the boom-a-rang) and throw it as hard as you can at the first jap car you see. If it all works out it will skip off the hood, totaling the piece of non American junk and keep on going!

You really didn't think it would come back did you?

If you have kids, select one and send them after it

Flyin6 · « **Reply #437 on:** October 05, 2014, 08:54:34 AM »

Then the wheel hydraulic cylinder comes off
Not too much to this thing

Flyin6 · « **Reply #438 on:** October 05, 2014, 08:55:08 AM »

Here's about what you'll have left unless you are dissembling a Korean kar. Then there will be some dried rice and fish scales stuck about here and there!

Flyin6 · « **Reply #439 on:** October 05, 2014, 08:55:56 AM »

The backing plates were laid out in the driveway where I soaked them down with degreaser and as bait. I kept the small ball peen hammer close by. I was waiting on the red dog to come ah-sheakin. I figure I'd hit her with the hammer, teaching her she needs to stop stealing all my stuff!

So here's the axle so far

Flyin6 · « **Reply #440 on:** October 05, 2014, 08:57:02 AM »

In the second shot, I had removed the lines and wiring harness

Now it's time to grind welds to remove the shock mounts, which I will not be using

Flyin6 · « **Reply #441 on:** October 05, 2014, 08:59:46 AM »

As we near the end of Part 3, I am removing the shock mounts, simply because they do not line up with the factory upper mounts, but this change is more aggressive that a simple "Fix" and starts to get into the "Fab" thing which is characteristic of what happens to the whole truck in the months and parts to come

Some foreshadowing perhaps???

Flyin6 · « **Reply #442 on:** October 05, 2014, 09:00:20 AM »

Then the spring pads get the same treatment

Flyin6 · « **Reply #443 on:** October 05, 2014, 09:01:12 AM »

These backing plates and Australian part got cleaned up. Tomorrow, they will get the rust grinding treatment and get all purdy

Flyin6 · « **Reply #444 on:** October 05, 2014, 09:01:43 AM »

And the axle is now torn down and ready for a super cleaning, wire cup grinding and rust control and paint

Flyin6 · « **Reply #445 on:** October 05, 2014, 09:02:47 AM »

Quote:
Originally Posted by dkami712 View Post
Those drums sure looked nasty before you took them apart. They're nasty on a good day, must have been fun with 15+ years of rust! Sounds like you'll have that sterling in new looking conditions 'morrow. Excited to see the converter do its magic again!

Yessir, I'm gettin' on em' right after the workout!

Have a problem with the grinder though...
Seems as though the red dog has been busy...

Flyin6 · « **Reply #446 on:** October 05, 2014, 09:03:41 AM »

So, let's get some more done with the square Dodge

Today was all about making rust go away and prepping parts to become a viable axle ready to go back in the truck.

But to work, one must first have to work, to be able to work.

Grinder had to be repaired first...

Flyin6 · « **Reply #447 on:** October 05, 2014, 09:04:44 AM »

Only cost me one old extension cord.

So with the grinder back in action I went to work on all that rust. Suffice it to say, I was in an orange cloud for hours!

Flyin6 · « **Reply #448 on:** October 05, 2014, 09:05:48 AM »

Then I coated those parts with the rust converter

Flyin6 · « **Reply #449 on:** October 05, 2014, 09:06:52 AM »

That's when I saw these two catching a cat nap...I had dark killing thoughts, but before I could carry through, they passed and I started getting hungry!