Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 421013 times)

Armalite · « **Reply #600 on:** January 02, 2015, 10:50:19 AM »

Sorry about the Air Dog Don. I haven't heard any complaints on this end from anyone, yet. I installed the FASS on my lml, and ran it for about 90k miles. Highway roads to lots of off road and mud. Never did anything but change the filters every 10k miles...

Wise choice on replacing the HID lights. Was having a lot of issues out of mine after 50k miles, so I pulled them all out and went back with factory bulbs...

I know the LED headlights on my new dodge do not get very hot, at all. Doubt they would melt any snow or ice away if I ever ran in to the white stuff...

Flyin6 · « **Reply #601 on:** January 02, 2015, 04:22:17 PM »

Quote from: Armalite on January 02, 2015, 10:50:19 AM

Sorry about the Air Dog Don. I haven't heard any complaints on this end from anyone, yet. I installed the FASS on my lml, and ran it for about 90k miles. Highway roads to lots of off road and mud. Never did anything but change the filters every 10k miles...

Wise choice on replacing the HID lights. Was having a lot of issues out of mine after 50k miles, so I pulled them all out and went back with factory bulbs...

I know the LED headlights on my new dodge do not get very hot, at all. Doubt they would melt any snow or ice away if I ever ran in to the white stuff...

Aid Dog on LML is still leaking...Too cold and wet to mess with it just yet

HID: Not what you'd think! If you factor in reliability for the aftermarket ones, I'd have to give them a poor score. I even purchased a set for Square D probably a year ago, so those will likely never get used. I'll plug in some LED's, back them up with some incandescent bumper mounted lights as a reserve and call it a day.

Sammconn · « **Reply #602 on:** January 02, 2015, 09:43:48 PM »

I gambled back in 2007 or 2008 and bought offshore (yeah I know) HID's. They were cheap enough to try the gamble and throw away if they were junk so I said what the heck. Last fall I changed my first bulbs. Maybe I just got lucky, who knows, but having said that they continue to serve me well.
I am however interested in how the LED ones turn out. Deep in the bush lots of light is important to me.

Flyin6 · « **Reply #603 on:** January 03, 2015, 09:06:50 AM »

Quote from: Sammconn on January 02, 2015, 09:43:48 PM

I gambled back in 2007 or 2008 and bought offshore (yeah I know) HID's. They were cheap enough to try the gamble and throw away if they were junk so I said what the heck. Last fall I changed my first bulbs. Maybe I just got lucky, who knows, but having said that they continue to serve me well.
I am however interested in how the LED ones turn out. Deep in the bush lots of light is important to me.

I have a set of 3200 Lumen LED bulbs for the Silverado which should be going in this week. But they too have some sort of ballast/ignition unit and are not simply bulb units. With the HID's the bulbs weren't what failed, it is always the ballast units going bad. I hope these new LED units are not the same.

Rescue Man · « **Reply #604 on:** January 03, 2015, 07:00:58 PM »

Quote from: Flyin6 on January 03, 2015, 09:06:50 AM

I have a set of 3200 Lumen LED bulbs for the Silverado which should be going in this week. But they too have some sort of ballast/ignition unit and are not simply bulb units. With the HID's the bulbs weren't what failed, it is always the ballast units going bad. I hope these new LED units are not the same.

I may have missed it somewhere between C-Max's build thread or D2's, but where did you find the LED bulb/ballast set up that you plan to put in C-Max?

BobbyB · « **Reply #605 on:** January 03, 2015, 09:00:16 PM »

Quote from: Armalite on January 02, 2015, 10:50:19 AM

my new dodge

Speaking of, how are you liking it now that you've had it for awhile?

Flyin6 · « **Reply #606 on:** January 04, 2015, 08:19:37 AM »

Quote from: Rescue Man on January 03, 2015, 07:00:58 PM

Quote from: Flyin6 on January 03, 2015, 09:06:50 AM

I have a set of 3200 Lumen LED bulbs for the Silverado which should be going in this week. But they too have some sort of ballast/ignition unit and are not simply bulb units. With the HID's the bulbs weren't what failed, it is always the ballast units going bad. I hope these new LED units are not the same.

I may have missed it somewhere between C-Max's build thread or D2's, but where did you find the LED bulb/ballast set up that you plan to put in C-Max?

They are JDM bulbs, check them out...

Flyin6 · « **Reply #607 on:** January 04, 2015, 05:25:55 PM »

Looking down the road, this was just purchased to be towed behind SquareD as part of a survival system. This thing will someday house a camper system, possibly a commercially procured unit like this Four Wheel Camper

I'll post more pics of it over in the trailer section

BobbyB · « **Reply #608 on:** January 04, 2015, 07:03:23 PM »

Quote from: Flyin6 on January 04, 2015, 05:25:55 PM

Looking down the road, this was just purchased to be towed behind SquareD as part of a survival system.

I told you to grab one of those awhile ago! But I await the results that follow.

Flyin6 · « **Reply #609 on:** January 04, 2015, 08:26:45 PM »

Quote from: BobbyB on January 04, 2015, 07:03:23 PM

Quote from: Flyin6 on January 04, 2015, 05:25:55 PM
Looking down the road, this was just purchased to be towed behind SquareD as part of a survival system.

I told you to grab one of those awhile ago! But I await the results that follow.

Roger that...

Just took awhile!

JR · « **Reply #610 on:** January 04, 2015, 09:03:41 PM »

Nice addition Don. Should be great all setup.

Dustoff35 · « **Reply #611 on:** January 04, 2015, 09:05:09 PM »

The things I find for you to buy...

BobbyB · « **Reply #612 on:** January 05, 2015, 08:57:39 AM »

Quote from: Flyin6 on January 04, 2015, 08:26:45 PM

Roger that...

Just took awhile!

Pilots... ;D

ce_tx · « **Reply #613 on:** January 05, 2015, 01:48:56 PM »

Lovin the trailer Don! I'm wanting one also to tow behind my crew for extended trips to carry gear and put a RMT on it.

KensAuto · « **Reply #614 on:** January 05, 2015, 09:17:18 PM »

EL TATE · « **Reply #615 on:** January 06, 2015, 12:10:58 PM »

The trailer looks glorious! My hub tech master left you a VM yesterday. make sure you get in touch with him when you can so we can button up the front axle.

ce_tx · « **Reply #616 on:** January 06, 2015, 05:45:59 PM »

Quote from: KensAuto on January 05, 2015, 09:17:18 PM

RMT?

Sorry about that, Roof Mounted Tent.

KensAuto · « **Reply #617 on:** January 06, 2015, 08:01:41 PM »

Gotcha. Just ask Don about roof mounted tents, if you want to see someone get riled up!

Flyin6 · « **Reply #618 on:** January 07, 2015, 09:17:43 AM »

Quote from: KensAuto on January 06, 2015, 08:01:41 PM

Gotcha. Just ask Don about roof mounted tents, if you want to see someone get riled up!

Well, I think Bruiser is talking about a purchased one not a home (not) made one!

JR · « **Reply #619 on:** January 07, 2015, 11:48:21 AM »

Who ever is near LV there is one on ebay right now for under 1k, Henderson to be exact!

Rescue Man · « **Reply #620 on:** January 07, 2015, 02:45:49 PM »

Quote from: Flyin6 on January 04, 2015, 08:19:37 AM

Quote from: Rescue Man on January 03, 2015, 07:00:58 PM
Quote from: Flyin6 on January 03, 2015, 09:06:50 AM

I have a set of 3200 Lumen LED bulbs for the Silverado which should be going in this week. But they too have some sort of ballast/ignition unit and are not simply bulb units. With the HID's the bulbs weren't what failed, it is always the ballast units going bad. I hope these new LED units are not the same.

I may have missed it somewhere between C-Max's build thread or D2's, but where did you find the LED bulb/ballast set up that you plan to put in C-Max?
They are JDM bulbs, check them out...

Do you have a link to where you found yours? I'm just not sure exactly what I am looking for!

Flyin6 · « **Reply #621 on:** January 07, 2015, 02:48:30 PM »

Maybe here:

http://store.ijdmtoy.com/

cudakidd53 · « **Reply #622 on:** January 08, 2015, 07:22:06 AM »

Hey Don-

When's the new scheduled date for the upgrade on the ole knee?

Flyin6 · « **Reply #623 on:** January 08, 2015, 08:10:13 AM »

Quote from: cudakidd53 on January 08, 2015, 07:22:06 AM

Hey Don-

When's the new scheduled date for the upgrade on the ole knee?

Not scheduled yet...testing...

Flyin6 · « **Reply #624 on:** January 16, 2015, 05:33:50 PM »

Here's a short update:

The motor is comfortably resting within the frame rails of Square D once again!

Did it all by my lonesome, man that is one heavy engine and trans. Sort of creeped me out when I had it jacked all the way up and hanging in the air. But after a lot of weight lifting like heaving it settled into it's reconditioned cross member and I bolted it down

There is something really weird going on though...When I went to bolt the transmission cross member back in, it no longer fits. It seems the frame rails have closed up about an inch!!!
Now how is that possible??? As far as I know I didn't get into any crashes with it since I had the motor out, all I did was to strip it, recondition, weld in all those plates and refinish it.
I'm betting welding all the frame boxing plates has tweaked the frame a bit. So I'll try to hydraulically spread the rails apart and if that doesn't work, I'll have to redrill the holes and bolt everything together is a slightly altered position...

More to come

BobbyB · « **Reply #625 on:** January 16, 2015, 06:52:18 PM »

Quote from: Flyin6 on January 16, 2015, 05:33:50 PM

The motor is comfortably resting within the frame rails of Square D once again!

You say this, yet I (we) have no photographic evidence... Much like the unicorn or a very humble Warrant Officer... this must be a myth! ;D

Congrats on getting to this checkpoint.

Flyin6 · « **Reply #626 on:** January 16, 2015, 10:25:43 PM »

It's true, the motor is bolted back in

But I didn't have enough pics to warrant a full blown write-up so I thought I'd wait until I get the cross member reattached at least before posting.

cudakidd53 · « **Reply #627 on:** January 16, 2015, 10:32:04 PM »

Most certainly the welding- no load on the frame, no bracing from trans mount etc. allows for shift. Learned that the hard way when I got all excited welding a door panel on race car. It warped and Dad made me grind it off and straighten it out and re-install tacking and spot welding it first then finish the long runs. Did I say I hate grinding?

KensAuto · « **Reply #628 on:** January 17, 2015, 01:00:32 AM »

Congrats Don, but I'm with Bobby. Anyone can claim to have done something, but pics pretty much prove it....unless you're really good at photoshopping, but that's another discussion.:)

Flyin6 · « **Reply #629 on:** January 17, 2015, 06:10:21 PM »

OK, OK..Pics..I get it!

So let's get this motor installed

As you can see that's a lot of weight...scary weight and you have to lift it up really high! EEK!!

Flyin6 · « **Reply #630 on:** January 17, 2015, 06:11:56 PM »

And it's finally in!

Flyin6 · « **Reply #631 on:** January 17, 2015, 06:14:39 PM »

With the 3/4" nuts tightened down on the motor mounts, it's time to get the transmission cross member in

First I installed the trans adapter (Iron) mount, then the plate where the rubber mounts attach to, then finally the cross member

Flyin6 · « **Reply #632 on:** January 17, 2015, 06:17:39 PM »

And this is the point where I discovered the frame had changed it's position from when all this was taken apart. The 6 ea outboard cross member bolt holes were about an inch out of alignment.

Knowing I wouldn't be able to bend the frame (Earlier I entertained that idea) I decided to simply re-drill the holes. I started with some 1/8" pilot holes

Flyin6 · « **Reply #633 on:** January 17, 2015, 06:19:00 PM »

In just minutes I had the cross member fitting like it belonged there. I used new 3/8" flanged frame bolts to secure it

Flyin6 · « **Reply #634 on:** January 17, 2015, 06:21:36 PM »

In the earlier pic, you may notice the upper legs of the cross member mount and the fuel filter mount I created were a good 3/4" or more from fitting. That suggests the bottom edge of the frame rolled in toward the vehicle center. Using C-Clamps, I jacked the parts together and secured them with new hardware including nylon lock nuts

Flyin6 · « **Reply #635 on:** January 17, 2015, 06:23:53 PM »

Next up, this being a day of heavy lifting, the transfer case gets installed. First I had to pull the studs, which came out when I unscrewed the nuts, remove the nuts, then Locktite them back into the transfer case mounting flange

Flyin6 · « **Reply #636 on:** January 17, 2015, 06:25:17 PM »

It got a new gasket and blue RTV prior to getting hoisted into place

And no, I didn't forget to install the all important splined coupling

Flyin6 · « **Reply #637 on:** January 17, 2015, 06:27:27 PM »

Using my abused motorcycle jack, I hoisted the thing into position, then started a wrastlin' match to slide it home

Note: This is not easy!

Flyin6 · « **Reply #638 on:** January 17, 2015, 06:28:29 PM »

It boggles my mind as to why this considerable chunk of iron doesn't have it's own mount to help support all that weight!

Flyin6 · « **Reply #639 on:** January 17, 2015, 06:29:56 PM »

Then I buttoned up the bottom of the trans/torque converter access

Flyin6 · « **Reply #640 on:** January 17, 2015, 06:31:32 PM »

Now it's time to build that transfer case cross member

It will fit around and capture this aluminum bearing housing

Flyin6 · « **Reply #641 on:** January 17, 2015, 06:32:30 PM »

Here's the first part of the mount

Flyin6 · « **Reply #642 on:** January 17, 2015, 06:33:37 PM »

I welded a poly bushing DOM sleeve to the extension piece

Flyin6 · « **Reply #643 on:** January 17, 2015, 06:35:26 PM »

The bushing is color matched to the body bushings, achieving a pleasing blending of color on the underside!

Anyone here think I give three hoots about color matching???

Not!

Flyin6 · « **Reply #644 on:** January 17, 2015, 06:36:05 PM »

And that fits like this:

Flyin6 · « **Reply #645 on:** January 17, 2015, 06:37:01 PM »

Time to grow it a bit more.

Here it gets two tabs and a 1/2" bolt

Flyin6 · « **Reply #646 on:** January 17, 2015, 06:38:03 PM »

I ground a radius into the tabs and welded them to some steel tube

Flyin6 · « **Reply #647 on:** January 17, 2015, 06:38:44 PM »

Putting the parts together, you can start to see how it will all fit

Flyin6 · « **Reply #648 on:** January 17, 2015, 06:39:39 PM »

Bolted loosely into place and hanging:

Flyin6 · « **Reply #649 on:** January 17, 2015, 06:40:57 PM »

But I'm not into reducing ground clearance, so it got tucked up nice and tight into the frame