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Author Topic: SquareD Build Thread, Part 1: The beginning  (Read 140730 times)

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Offline Flyin6

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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #450 on: October 05, 2014, 09:07:28 AM »
The red pure bred German Shepherd ate up a can of Blitz spray paint today along with a roll of paper towels and a cross tip screwdriver!

Anyway, once those parts dried I started in with various primers. The copper colored stuff, is, copper primer! I thought on possible highly corrosive areas like inside the brake drums it might serve well
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Offline Flyin6

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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #451 on: October 05, 2014, 09:08:13 AM »
The backing plates dried all nice and black, so I covered all that up with a layer of zinc based primer
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #452 on: October 05, 2014, 09:09:17 AM »
Next came the rear axle itself. After forever and two hours worth of grinding it started to look like metal and not a signal buoy in the Indian ocean
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #453 on: October 05, 2014, 09:10:20 AM »
To keep everything sequenced in the painting/ drying, repainting production line, I sanded down Shawn's axle cover and painted it with the copper rich stuff
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #454 on: October 05, 2014, 09:10:59 AM »
I am never short of amazement over the quality of these axle covers he makes!

So, back to the axle, I cleaned the inside out pretty well then the housing itself with cans of brake cleaner. I like the stuff because it dries leaving no residue
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #455 on: October 05, 2014, 09:11:48 AM »
With the housing and inside cleaned up, I coated the thing with the rust converter

Here it is in sequence doing it's thing
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #456 on: October 05, 2014, 09:12:28 AM »
Does a pretty good job doesn't it!

With that drying and a cross country invitational fast approaching. I scuffed down a bunch of parts and plussed up the hanging jungle
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #457 on: October 05, 2014, 09:13:16 AM »
Then with a fresh batch of Lycoming gray Dupont Nason mixed up, I sprayed the jungle yet again
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #458 on: October 05, 2014, 09:14:03 AM »
Hard to even remember just how rusty those parts were just a day ago, now they look new.

I left the emergency brake pawl copper since it got several coats and that should give it all the protection it needs without getting some paint hardening in between parts that used to move freely
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #459 on: October 05, 2014, 09:14:41 AM »
Here is two fresh gallons of Gillespie WW2 OD Green paint just waiting to get all atomized and collect on some of Square D's ruggedly handsome shoulders!
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #460 on: October 05, 2014, 09:16:47 AM »
Well, it's morning...

Time to make good my promise

Here's a pic of that diff after the rust converter stuff fully cured
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #461 on: October 05, 2014, 09:17:25 AM »
Everywhere there was rust that I mostly removed the metal turned dark black, whereas the mostly rust free areas show a translucent color varying from black to brownish.

I beat on it with a hammer some, it's durable!

The radiator top mounts did not turn out well yesterday, so I stripped them all the way to bare metal. I found that the factory had galvanized or zinc washed them and I wanted to keep that appearance, but some of the metal was surface pitted from corrosion so I just sprayed them with that copper primer
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #462 on: October 05, 2014, 09:19:17 AM »
Next on to installing the spring pads onto the Ford axle
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #463 on: October 05, 2014, 09:20:29 AM »
Those beauties are another product of Shawn's at GLO. He makes good stuff (Obviously!) Look at the fit on the radius cut to the axle tube.

This is one of those things you measure again, and again, and a third time.

I was pretty nervous setting this all up, but in the end, it came out to within 1/16" of where I wanted it to be.
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #464 on: October 05, 2014, 09:22:15 AM »
With that out of the way, it was on to installing the locker
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #465 on: October 05, 2014, 09:24:07 AM »
Since the spider gear cross pin could slide out without removing the ring gear, I was hoping to get this done without removing the carrier.

First you pull the cross pin bolt and shaft
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #466 on: October 05, 2014, 09:25:14 AM »
Then the spider gears almost fall out
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #467 on: October 05, 2014, 09:26:12 AM »
You have to reach way inside, but the last side gear pulls straight out
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #468 on: October 05, 2014, 09:27:46 AM »
So far so good, so I slipped in the new side gears
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #469 on: October 05, 2014, 09:29:19 AM »
But...
I forgot something
The thrust washers that go behind those side gears
Those washers take up some space...

Yea

So without knowing at that moment, what I later discovered and know so painfully well now, I continued...

The center, locking part of the lock rite goes together with some simple pins, then slides in.

This sequence is a test
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #470 on: October 05, 2014, 09:34:32 AM »
I continued loading the parts

not knowing about the thrust washers and forgetting all about the steel pins

Yup

SO for some goofy reason. I think...

Did I just finish this thing?
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #471 on: October 05, 2014, 09:35:15 AM »
Continuing in my ignorant bliss, I said to me self

"Well, self, heck you're done! Let's glue on the gasket and button this sucker up!"

So I did...

Yep
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #472 on: October 05, 2014, 09:36:11 AM »
So that's what I started to do

You might recall seeing the parts that came out of the diff sitting in the diff cover...?

Well, my plan is to paint and install the axle with the old diff cover in place, then bolt on Shawn's pretty piece so all that shiney paint doesn't get to looking like Normandy on D-Day.

Well, inside that cover, I immediately noticed tow really big washers

Hmmm

Then I sat down as I realized what I almost did. That momentary pause caused me to take inventory of things, and that's when I noticed the steel pins still in the lock-Rite box.

OK, no biggie, I'll just pull the thing out and stick it back in with ALL OF ITS PARTS

So I did that, and guess what...

It no longer fits

Those two silly washers caused the rest of the story...

So this is what happened next:
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #473 on: October 05, 2014, 09:36:51 AM »
Then this:
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #474 on: October 05, 2014, 09:37:36 AM »
And finally this:

Or so I thought at the moment
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #475 on: October 05, 2014, 09:38:10 AM »
The grease just holds everything together while you're slipping it all together again.

I reinstalled the diff, tightened the caps down then started to remove all the 5/16" bolts that helped align the gasket.

Then one bolt slipped out of my hand

As I reached in to it, I bumped it down into the inner recesses of the case

I could no longer see it

Hmmm

Out comes the magnet and for the next 30 minutes I fish around and can't find anything

Did this really just happen?

Did I imagine that just happened?

Nope, I didn't

So after tapping on the case, rotating it upside down and tapping, blessing it, and everything else I could thing about, no bolt

So I had no choice but to pull the diff back out once again, so I did

Guess what, no bolt in sight

But

There is a passage leading up to the pinion bearing

Could it have gone all the way up there?
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #476 on: October 05, 2014, 09:39:07 AM »
Well, I searched, prodded, tapped some more

Now the axle housing finish is starting to look like a roadside bomb went off nearby, but I continue

How in the name of all that's good and right is this happening to me?

With no place else to go, I got a really big socket and removed the pinion nut, and the pinion gear

It fell right out of the case, along with a little 5/16" bolt!

Can you believe that?

You just don't bolt a set of gears back together...Oh NO!

A little too much of this or not enough of that and the thing is all wacked out

SO I tightened, and loosened and tightened, put the carrier in, took it out, put it back in and so forth into the far reaches of the night, until at one magical moment, the preload, turning force, and runout all fell into place.

I quickly bolted on the cover and left the area.

That is why there were no pictures last night. I was set to finish around 1800, but I finally drug my defeated butt into the shower around 2130.

I took this picture from a distance, hoping not to offend anything!
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #477 on: October 05, 2014, 09:40:16 AM »
Quote:
Originally Posted by KensAuto View Post
I hate to question the Grand Master of suspension geometry and canine training, but do you think you should have waited on welding up the spring perches until you got the new springs in and diff located, so you could adjust the pinion angle?

Special K

I am certainly no grand master of anything, except maybe my chilli!

(I once won a contest where four other folks and I were judged...Impressive don't you think?)

Here's my thoughts:
The old Dana 70 axle had the perches welded at zero degrees (Level) relative to the pinion angle.
The new springs have a wedge attached to the bottom of the lower leaf that will rotate the pinion up what looks like 4 degrees.

You don't really want the pinion to be aligned exactly with the drive shaft center with a suspended axle subject to any wrap.
Why you ask?
Another good question BK (Brother Ken)
When torque is applied, the pinion climbs upward, so if it was slightly below perfect alignment, it would then climb to the point where it is nearly aligned.

I plan to add a torque bar to the design here, but even that will allow (the way I build em') to rotate just a little, maybe 1/2 of a degree.

Anyway, since super lift designed those springs, I assume (Big dangerous word there) that they know their business and have positioned that pinion angle where it needs to be.

That and I want to paint up the axle and install it and not have to keep putting it in and taking it out
__________________
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #478 on: October 05, 2014, 09:42:48 AM »
didn't get everything I wanted to get done, with running around getting things...
I did get the rear drums turned, Finally!

They came out fine with a minimum of a cut

I got a set of Bosch front powder coated rotors on the line (Headed this way). These things are 12.87" in diameter so I feel that is a pretty good place to start from.

The final plan is to install GM hydro brakes onto this truck and make the vacuum stuff go bye-bye.

I got the wood collected for the unique rear jack stand system I am about to invent. I figure I need to suspend the truck and support it from some place other than the rear axle, since it is about to come out.

Jack stands that I have located will not get 30+ inches tall so I'm going to do something else.

Good old 6 X 6's and 2 X 6's

Again, going old school and hillbilly for at least a part of this adventure.
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #479 on: October 05, 2014, 09:43:33 AM »
I had planned to paint up the diff, axle hubs and since I'd be spraying the JD Blitz paint, the front radiator area as well.

Remember my radiator bone is connected to the rear axle bone theory?

Well with today's accomplishments, that theory lives once again!

I had previously used some acid etching primer on the new parts of the axle
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #480 on: October 05, 2014, 09:44:29 AM »
One backing plate had been previously installed while I mocked up something. When I reinstall a backing plate I layer on a bead of RTV to make it a tad more waterproof. That was the case here.

I then removed the lower grill valence panel to gain good access to that front sheet metal
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #481 on: October 05, 2014, 09:45:09 AM »
Then it all got sanded and scuffed up with a combination of papers, wire brushes and the abrasive pad
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #482 on: October 05, 2014, 09:46:16 AM »
The rear hubs were next. Getting degreased, wire brushed, then coated with that rust converter
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #483 on: October 05, 2014, 09:46:52 AM »
Next things got taped off and washed down with the prep-sol
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #484 on: October 05, 2014, 09:47:28 AM »
Then came paint time.

Here's a fresh quart of the Blitz stuff

I mix it with a little reducer and the Valspar hardener

Valspar is the company that makes paints for John Deere
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #485 on: October 05, 2014, 09:48:12 AM »
The front end with one, still wet, coat
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #486 on: October 05, 2014, 09:48:52 AM »
Then the Sterling axle
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #487 on: October 05, 2014, 09:49:51 AM »
Then the hubs.

Here is showing after two coats
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #488 on: October 05, 2014, 09:50:29 AM »
Then the third and final coat
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #489 on: October 05, 2014, 09:51:36 AM »
Pushed that ball downfield another foot or so today.

First I collected the 3" wide brake drums which cleaned up great and are now true and round. That only cost $30! What a deal!

Next I reassembled some stuff in the engine bay. Those radiator mounts went back in first. I just left them in primer since it is a pretty durable surface.
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #490 on: October 05, 2014, 09:52:13 AM »
Pics are a bit fuzzy...this camera is giving me fits!

Next the hood catch/release went back in
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #491 on: October 05, 2014, 09:52:59 AM »
All that stuff was removed so that I could repaint that radiator support before replacing the upper radiator rubber air seal

I chose some ag belt cut to size. I used this slick tool to punch the holes to line up with the factory design
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #492 on: October 05, 2014, 09:53:48 AM »
Then some of these plastic expand tabs that locked it all back in place
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #493 on: October 05, 2014, 09:54:30 AM »
That is done enough for now.
I have decided to pull the factory intercooler and put a late model power stroke intercooler in its place. The ford unit is approximately twice the size.

Why you ask?

Well, seems I am pushing the boundary of the fluid change project a bit more. I decided to just go through the motor all at once elevating it ftom it's 160HP/400TQ up to 400HP/800ish TQ.

With these motors it's not all that hard or expensive and you get a mile per gallon more to boot!

More than that I need to go through just about everything on this truck before I'll declare it ready and serviceable.

Here's the axle after the Blitz paint dried and hardened
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #494 on: October 05, 2014, 09:55:35 AM »
And some innocent bystanders
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #495 on: October 05, 2014, 09:56:42 AM »
The sled dog is wintering up again. That cat is skittish. Guess he never forgave me for knocking him out a year ago...Long story.

Well, today was H-hour for the rear axle removal.

Since it has supported the truck by way of two jack stands, and needs to go bye-bye, I had to come up with something else.

Here's what I did:
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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #496 on: October 05, 2014, 09:57:50 AM »
It's sturdy an about as immovable as a fat woman in a candy aisle!

Here's the axle losing the jack stands and some parts
Site owner    Isaiah 6:8, Psalm 91 
NSDQ      Author of the books: Distant Thunder and Thoren

Offline Flyin6

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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #497 on: October 05, 2014, 09:58:39 AM »
My buddy, Mr. Hypertherm helped make quick work of that rusty steel
Site owner    Isaiah 6:8, Psalm 91 
NSDQ      Author of the books: Distant Thunder and Thoren

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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #498 on: October 05, 2014, 09:59:45 AM »
The springs were not so easy

The bolts had rusted to the sleeves and the rubber dry rotted. It was a bear getting those bolts out but after pulling pounding, and cutting, they yielded
Site owner    Isaiah 6:8, Psalm 91 
NSDQ      Author of the books: Distant Thunder and Thoren

Offline Flyin6

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Re: SquareD Build Thread Part 3: The build gets more serious...
« Reply #499 on: October 05, 2014, 10:00:47 AM »
Springs...things that have been, and things to come
Site owner    Isaiah 6:8, Psalm 91 
NSDQ      Author of the books: Distant Thunder and Thoren

 

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