Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 422478 times)

Flyin6 · « **Reply #1200 on:** March 11, 2015, 07:16:02 PM »

And the finished product:

Flyin6 · « **Reply #1201 on:** March 11, 2015, 07:18:40 PM »

The other panel was fitted to an area on the right fender under the snorkel.

Concept of the operation is to vent the heat the turbo and down pipe is making, so that side of the hood will also get perforated

Note the large opening through which you can actually see the turbo exhaust side

Flyin6 · « **Reply #1202 on:** March 11, 2015, 07:19:53 PM »

And here it is fitted and ready for finishing

Flyin6 · « **Reply #1203 on:** March 11, 2015, 07:21:43 PM »

Enough playing around...back to the salt mine!

Here I have wired in the rear flood light

Flyin6 · « **Reply #1204 on:** March 11, 2015, 07:23:24 PM »

And started to run more wires under the floor pan

The wire tie loops are temporary. Once the harness is all pulled, I will tape it, then cover with the convoluted tubing, then fasten it to the holes you see here

Flyin6 · « **Reply #1205 on:** March 11, 2015, 07:25:13 PM »

Next I drilled a 1" hole in the corner of the dash and set a wire clamp near the top of the A-pillar. Wires will run up through this hole to the overhead shelf

Flyin6 · « **Reply #1206 on:** March 11, 2015, 07:39:21 PM »

Here is the front ARB air pump harness which will power the Yukon Grizzly someday

Flyin6 · « **Reply #1207 on:** March 11, 2015, 07:40:16 PM »

The lower wiring harness is shaping up as well

Flyin6 · « **Reply #1208 on:** March 11, 2015, 07:42:41 PM »

I decided to add a brace to the water/alcohol pump and add some adel clamps down there as well. This area will get a skid plate

Flyin6 · « **Reply #1209 on:** March 11, 2015, 07:46:04 PM »

Late in the day, the harness is shaping up and now the fuel pumps are connected, the transfer pump circuit is run, half of the overhead
Scene Illumination" lights are wired in and the Air locker system wires have been run to the overhead

Flyin6 · « **Reply #1210 on:** March 11, 2015, 07:47:17 PM »

It was a pretty almost-spring day and that ends build day 227 in the SquareD saga

OldKooT · « **Reply #1211 on:** March 11, 2015, 08:13:46 PM »

Looking good Don....Your motivating me to make sure our crew cab has like maybe 30 wires tops LoL
At least your working on your truck. I was informed yesterday I have until early June to get our on the road. Yet another deadline missed most likely......

Flyin6 · « **Reply #1212 on:** March 11, 2015, 08:21:24 PM »

Quote from: OldKooT on March 11, 2015, 08:13:46 PM

Looking good Don....Your motivating me to make sure our crew cab has like maybe 30 wires tops LoL
At least your working on your truck. I was informed yesterday I have until early June to get our on the road. Yet another deadline missed most likely......

Early June!!!!!!!!!!

No way!

OldKooT · « **Reply #1213 on:** March 11, 2015, 08:26:01 PM »

I don't think I am ambitious enough to get it running by June. Then again, if I stopped sitting in the lawn chair so much and thinking it would most likely speed things up. I tend to work slow....proof in fact, I haven't got the frame out of the ice yet.... upside: The ice melted so no hurry now LoL

Flyin6 · « **Reply #1214 on:** March 11, 2015, 08:32:31 PM »

I'm sort of the same. I start slow then taper off from there

Like my wife says, Well you're slow, but at least you do poor work!

Flyin6 · « **Reply #1215 on:** March 12, 2015, 06:23:48 PM »

Another pretty long day of chorsey stuff.

First up I still needed to make the connections between the filler ports/necks for the fuel tank and the water methanol tanks so I selected some radiator hoses to do the trick

Flyin6 · « **Reply #1216 on:** March 12, 2015, 06:24:44 PM »

The H2o/alchy tank was easy, just slip the 30" convoluted hose on and clamp it

Flyin6 · « **Reply #1217 on:** March 12, 2015, 06:26:17 PM »

Next I placed a filter in the supply line to the alcohol tank

Flyin6 · « **Reply #1218 on:** March 12, 2015, 06:27:57 PM »

Next I tried to add 4 gallons of 50/50 mixture to the tank, but I quickly discovered I forgot to add a vent when the funnel burped a bunch of the fluid all over me

Flyin6 · « **Reply #1219 on:** March 12, 2015, 06:28:53 PM »

So I added a vent and fixed it right up

Flyin6 · « **Reply #1220 on:** March 12, 2015, 06:30:25 PM »

That tank swallowed the 4 gallons of boost juice and a gallon of window washer fluid like it was nothing. So I know the capacity probably exceeds 5 gallons

Flyin6 · « **Reply #1221 on:** March 12, 2015, 06:32:00 PM »

Next I cut up that Gates radiator hose and fitted it to the fuel tank filler neck, completing that task. I am now ready to add fuel!

JR · « **Reply #1222 on:** March 12, 2015, 06:33:16 PM »

Forgot to add a vent to mine too.

Flyin6 · « **Reply #1223 on:** March 12, 2015, 06:34:51 PM »

Just about then, believe it or not the brown truck showed up with the battery cables I needed to connect the new overhead switch panel

Flyin6 · « **Reply #1224 on:** March 12, 2015, 06:37:12 PM »

Two 50" cables one 2 gage, one-4 gage. You'll see why in a moment.

By ordering battery cables it is cheaper than just buying welding cable. These two were around $30

I cut off the terminal end and soldered a ring eye to it

Flyin6 · « **Reply #1225 on:** March 12, 2015, 06:38:25 PM »

I'll be using two mega-fuses in line. One will host a 250 amp fuse, the other a 175 amp

Flyin6 · « **Reply #1226 on:** March 12, 2015, 06:40:52 PM »

First I soldered a ring eye to the switch bank power supply cable. Then routed that to the second mega fuse in line the 175 amp one which is mounted to the right fender here:

Flyin6 · « **Reply #1227 on:** March 12, 2015, 06:44:37 PM »

I ran the 4 gage cable forward to what is the first mega fuse, the 250 amp unit

That mega fuse, the 250 amp unit is hard mounted to the jungle Jim supplied front spring mount and frame tie and is sitting just inches away from where the winch will reside. This is the power supply for that winch. I am prepositioning circuits for what I know is coming up

Flyin6 · « **Reply #1228 on:** March 12, 2015, 06:46:33 PM »

Then the 2 gage cable attaches to the far end of the fuse and runs back to the primary battery

Flyin6 · « **Reply #1229 on:** March 12, 2015, 06:49:36 PM »

Again I needed a bit of a break from the monotony of wiring so I addressed the CB antenna keeper, which was a joke at best

I cut a thick flap of silicon ply, about 1/4" thick, bolted it to the inverted hook, and screwed it into place, then cut a slot which now securely holds that antenna

Flyin6 · « **Reply #1230 on:** March 12, 2015, 06:50:49 PM »

Back to the real work...The other box on the brown truck contained the new Cobra CB radio

Flyin6 · « **Reply #1231 on:** March 12, 2015, 06:53:11 PM »

I discovered there was no way it was ever going to fit in the overhead shelf, so after hunting around I found the only place I thought it would fit, on the dash. I didn't want to use this area as I had planned to add in a sliding shelf/desk thing with a computer on it, but so goes those plans!

Flyin6 · « **Reply #1232 on:** March 12, 2015, 06:53:48 PM »

And that, boys and girls is the end of build day 228

ce_tx · « **Reply #1233 on:** March 13, 2015, 08:24:16 PM »

WOW you have been busy, looking good Don!!!

Flyin6 · « **Reply #1234 on:** March 13, 2015, 08:44:41 PM »

Quote from: ce_tx on March 13, 2015, 08:24:16 PM

WOW you have been busy, looking good Don!!!

Danka!

Jungle · « **Reply #1235 on:** March 14, 2015, 08:20:27 AM »

Don
Awesome work!!!!!
Jim

Flyin6 · « **Reply #1236 on:** March 14, 2015, 09:57:51 PM »

Thank ya

BobbyB · « **Reply #1237 on:** March 14, 2015, 10:26:55 PM »

Ok, I'll make you a deal. You finish up D2, and send her up here, and I'll drive it around and show her off. Then you can take XJ and show the interwebz what you can do with her.. Or, yea just forget it..

Flyin6 · « **Reply #1238 on:** March 16, 2015, 05:56:33 PM »

Quote from: BobbyB on March 14, 2015, 10:26:55 PM

Ok, I'll make you a deal. You finish up D2, and send her up here, and I'll drive it around and show her off. Then you can take XJ and show the interwebz what you can do with her.. Or, yea just forget it..

Disapproved

Flyin6 · « **Reply #1239 on:** March 16, 2015, 05:59:14 PM »

The wiring continues
But I've reached a point where this panel needs to be fitted near or in the shelf so I can start hooking things up and testing circuits.
I managed to figure out the ARB wiring and got that harness trimmed down and hooked up. I got the motor to turn on so if it's on it will lock that front diff...Cool!

Flyin6 · « **Reply #1240 on:** March 16, 2015, 06:01:20 PM »

The panel was stripped down and the Nutserts installed. They (size 10 X 24) went right in and worked much better than the 1/4" ones

Flyin6 · « **Reply #1241 on:** March 16, 2015, 06:02:24 PM »

With that, the panel was cleaned, sanded and primed with the acid etch stuff

Flyin6 · « **Reply #1242 on:** March 16, 2015, 06:03:38 PM »

Then painted with three coats of the Nason acrylic enamel with hardener

Flyin6 · « **Reply #1243 on:** March 16, 2015, 06:09:35 PM »

That thing will look good installed up on the shelf all filled up with switchamolgistics

Since the nutsert tool was out, I decided to install #10 screws into the louver panels instead of the larger 1/4" hardware. I think it will look more finished that way

Flyin6 · « **Reply #1244 on:** March 16, 2015, 06:10:26 PM »

The heat extractor on the passenger side fender got the same treatment

Flyin6 · « **Reply #1245 on:** March 16, 2015, 06:12:35 PM »

Turns out I had to open up the aft electrical compartment to access the ARB Pump. That went easy enough, but I found I had not installed the pressure shutoff switch so I'll need to grab a Brass "T" to fit it in there

Flyin6 · « **Reply #1246 on:** March 16, 2015, 06:14:24 PM »

This seat is much better than those race looking seats in the cab, so it's going back in there. Cammo will brighten up things some and match the gray panels...Oh, I plan to redo the dash panel in Lycoming gray as well!

Flyin6 · « **Reply #1247 on:** March 16, 2015, 06:18:34 PM »

Then it was back to running wires and hooking things up. I found some sort of glitch in my super-duper ARC switch panel, as in it is not switching anything on!
So I went to installing a better ground(s). I also ran the wiring and antenna for the CB radio
That didn't turn on either...neither did the fuel pumps...or H2O pump...or the...
Spark chasing...I hate spark chasing

Well, that sufficiently frustrated me into throwing in the towel. At least I solved some problems while discovering new ones. The ball moved downfield, but was penalized 5 yards as well!

JR · « **Reply #1248 on:** March 16, 2015, 07:35:28 PM »

Sure like those louvers on there, nice work.

Funny about electrical. It is so simple, but tedious!! Then it doesn't work,,,,,,,,,,,

Flyin6 · « **Reply #1249 on:** March 16, 2015, 10:43:25 PM »

Quote from: JR on March 16, 2015, 07:35:28 PM

Sure like those louvers on there, nice work.

Funny about electrical. It is so simple, but tedious!! Then it doesn't work,,,,,,,,,,,

Exactly!