Author Topic: Ramcharger Rebuild (Read 7360 times)

wilsonphil · « **Reply #50 on:** June 24, 2019, 02:16:34 PM »

Tenactiv

wilsonphil · « **Reply #51 on:** July 02, 2019, 11:52:29 PM »

Ok small update, I finished removing the entire electrical system. More pressure washing and inspecting I removed one front spring so I can take it to Deaver for a measure up. One of the studs in the D60 galled on me when I was removing it, looks like the threads in the housing will clean up so no issues yet

Then I started adding parts to the "NEW" Cummins I added the IP, new vacuum pump for the hydro boost setup and a few odds and ends.

Its much simpler to work on these trucks this way, no struggling and having to lay on my back I can just use my engine hoist to lift everything out of the way.

Sorry for the lack of pictures was very busy today trying to get things done, I'm looking at Farms/land this weekend so I'm trying got make headway.

wyorunner · « **Reply #52 on:** July 03, 2019, 12:20:40 AM »

Shiny! Where did you get the IP from?

wilsonphil · « **Reply #53 on:** July 03, 2019, 12:49:44 AM »

they were out of Iowa, I'll find the info later for you.

wilsonphil · « **Reply #54 on:** July 03, 2019, 01:04:13 AM »

Sorry it was Kansas City Mo

Farrell Diesel Service

EL TATE · « **Reply #55 on:** July 03, 2019, 10:51:54 AM »

Quote from: wilsonphil on June 24, 2019, 02:16:34 PM

Tenactiv

They're "tough actin'

wyorunner · « **Reply #56 on:** July 03, 2019, 12:19:35 PM »

Quote from: wilsonphil on July 03, 2019, 01:04:13 AM

Sorry it was Kansas City Mo

Farrell Diesel Service

Thank you!

wilsonphil · « **Reply #57 on:** July 10, 2019, 09:49:37 PM »

So Phase 2 of the build will be starting soon and I need to start to buying new parts, I plan on adding a doubler to my setup so there are two choices Off Road Design and Advance Adapter

Offroad Design http://offroaddesign.com/catalog/Magnum%20Box.htm is a planetary bolted in front of a NP205, draw back to this setup is its 2.125 inches added to the overall length and I will have to make a custom mount from the planetary to my cross-member, they want you to ditch the factory mount that bolts to the tail shaft of the 46RH. This means I will have to do some driveshaft work Front and Back. I have not heard anything bad about the Doubler they sell.

Advance Adapter https://www.advanceadapters.com/products/atlas-4-speed-transfer-case-builder/ is a all new made AL case with the same concept as ORD I am waiting to heard back about specifics like Legnth and weight to see how much rework I will have to do, Im assuming this setup will be lighter than the NP 205 unit. I have not found anything negative about their units either.

So cost wise they are about the same and about the same lead time on the build, and a third lever/cable to engage the planetary I am going to dig into this as the low gear set would be nice to have long term.

stlaser · « **Reply #58 on:** July 10, 2019, 09:59:05 PM »

Northwest fab?

wilsonphil · « **Reply #59 on:** July 10, 2019, 11:36:02 PM »

Looked at those but I wanted a complete unit ready to install and once you add up all the "extras" its about the same price as a ORD unit, you can buy just the OFD doubler but I didnt want to mess with tearing apart a good NP205 to install.

Also the NWF units are longer than the ORD, remember I have a RC so the rear DS is short already.

wyorunner · « **Reply #60 on:** July 10, 2019, 11:58:11 PM »

Do you have a need for this?

JR · « **Reply #61 on:** July 11, 2019, 01:22:35 AM »

I have seen a few ready to go on pirate. Shipping might hurt but you never know. Might be a good option when I get to mine,,,,,yep when.

https://www.pirate4x4.com/forum/engines-trannys-t-cases-sale/2683908-new-nwf-eco-box-chevy-205-a.html

How much was the rebuilt pump, mine has been sitting for some time.

wilsonphil · « **Reply #62 on:** July 11, 2019, 10:17:25 AM »

Yes and this is why you GM guys have it so good, lots more parts out there. Unless its Dodge specific there is a lot more rework to do.

I am going to talk to Advance Adapters today and see what they say.

stlaser · « **Reply #63 on:** July 11, 2019, 10:40:56 AM »

Quote from: wilsonphil on July 11, 2019, 10:17:25 AM

Yes and this is why you GM guys have it so good, lots more parts out there. Unless its Dodge specific there is a lot more rework to do.

I am going to talk to Advance Adapters today and see what they say.

Phil, they used to have issues with highway duty on those. May have just been an early issue? Seem to recall oil coming out breather or something. Maybe Tate recalls and will chime in?

Hard to beat an np205......

wilsonphil · « **Reply #64 on:** July 11, 2019, 11:10:06 AM »

Yes that was an earlier issue they had but it seems it has been corrected and I have not seen any other issues from anyone recently.

I couldnt agree more on the NP205, they are really bullet proof, the 2 to 1 low range is the issue. My RC has 3.54 gears which makes going down the freeway nice/manageable. My RC does really well offroad with the 33" tire but there were a couple times it would of been nice to have more gear. I could do a gear change but I will pay for that in many ways, the doubler solves that and is there only when needed.

As with any aftermarket product most do not get the design overview or tested properly in every possible condition possible, most of the time the OEMs do pretty good in that aspect, IE thermal, stress/load, longevity. I seem to always be the outlier person and find the "flaws" and then I start looking at the design and ask myself if they did any real development testing or analysis of any type.

All of the doubler setups out there are based/copied from the NP241 or so it seems.

stlaser · « **Reply #65 on:** July 11, 2019, 11:11:55 AM »

^^^^^^^ hard to argue any of that

wilsonphil · « **Reply #66 on:** July 11, 2019, 12:05:17 PM »

And this coming directly from Advance Adapters.

Thank you for contacting us regarding your project. The Atlas 4 speeds are not suitable for full size Truck and Cummins application. Atlas II speeds only.

So its looking more like ORD is the only game in town.

stlaser · « **Reply #67 on:** July 11, 2019, 12:26:13 PM »

Well, at least AA isn’t claiming they are unbreakable any longer......

205 for the win!

wilsonphil · « **Reply #68 on:** July 11, 2019, 03:09:49 PM »

Advanced Adapter give me the supposed reason why.

It’s the strength of the high speed side of the gear set when 2.72 is used combined with the weight and torque of the engine. Also planetary main shaft would be another issue in 2.72

wilsonphil · « **Reply #69 on:** July 14, 2019, 05:32:36 PM »

Big thumbs down on POR15!

will be painting everything with enamel going back together

Yes surface prep was done correctly the case was completely disassembled bead blasted and then painted.

wilsonphil · « **Reply #70 on:** July 14, 2019, 05:33:33 PM »

The only frame damage I have from the roll over, very very easy fix and I will install a doubler in the area.

stlaser · « **Reply #71 on:** July 14, 2019, 05:33:55 PM »

Ouch....

I’ve always had good luck using engine enamel

KensAuto · « **Reply #72 on:** July 14, 2019, 06:47:47 PM »

Yucko. I've been using farm implement paint. It's old school nasty stuff, but will stick to anything...just doesn't stay super shiny.

wilsonphil · « **Reply #73 on:** August 13, 2019, 12:27:17 PM »

As I tear the RC down I am finding more items that need attention of note as I was prepping the frame for paint I found these. The passenger side rear spring front bracket was trying very hard to separate itself from the frame.

I have never seen a Dodge truck or RC give problems in this area of the frame, the passenger side has cracks in three of the holes that hold the bracket to the frame and the drivers side has one.

JR · « **Reply #74 on:** August 13, 2019, 02:31:54 PM »

Thought those were cracks around a GM steering box!

wilsonphil · « **Reply #75 on:** August 13, 2019, 03:10:52 PM »

Dodge has those also, i fixed that a long time ago. My frame crack at the front shock mounts also, but i repaired and boxed the whole front frame and have not had a problem since until this happened.

wilsonphil · « **Reply #76 on:** August 19, 2019, 12:11:58 PM »

I drilled all the rivets for the cross member that were local to the area I am repairing, as you can see from the picture there was not a lot of effort when assembled to make sure there were good holes notice the gap full of rust and how the rivet walked during install or very poor hole alignment. 90% of the rivets I drilled out looked this way but none of them were loose.

Of note the drop legs of the cross member the rivet to the lower lip of the frame had 4ea holes but only 2ea were used. Not sure what the tool dimple is from I'm assuming some kind of clamp

TexasRedNeck · « **Reply #77 on:** August 20, 2019, 05:35:54 AM »

Interesting Phil. What are you going to do to reassemble? Weld where the rivets were?

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wilsonphil · « **Reply #78 on:** August 20, 2019, 09:33:10 PM »

No I plan on using good quality Grade 8 flange bolts and nuts, I will drill/ream the holes to just 1/2 so I have a tighter fit and torque it up. I could go NAS bolts a and make like an almost press fit but its really overkill and not required IMO. Its a 30yr old Dodge and I will beef up the area, that area lasted that long if I get another 30yrs out of my repair Ill call it good!

I have drilled out frame rivets over the years and used bolts and nuts many times and have never had a problem.

TexasRedNeck · « **Reply #79 on:** August 20, 2019, 09:57:50 PM »

Just curious. Never had to undertake such a repair.

I wish I could have gotten a picture of the old square body dodge I saw this morning.

Old man (older than me) and it was the cleanest original single cab long bed square body Cummins Ive ever seen

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wilsonphil · « **Reply #80 on:** September 03, 2019, 04:08:49 PM »

OK so I got TRN's engine out of the frame and to answer anyone's question of how much dose a Cummins weight? The answer is 920lbs, this is still full of oil and the turbo is removed.

I also started mocking up the frame for the mid engine conversion.

TexasRedNeck · « **Reply #81 on:** September 03, 2019, 07:25:29 PM »

That’s a serious hunk of steel right there.

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Bigdave_185 · « **Reply #82 on:** September 03, 2019, 08:12:07 PM »

Mid engine conversion? Like motor In the cab?

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KensAuto · « **Reply #83 on:** September 03, 2019, 08:55:47 PM »

Quote from: TexasRedNeck on September 03, 2019, 07:25:29 PM

That’s a serious hunk of steel right there.

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Yeah you might wanna think about getting something more like an LS.
:wink

TexasRedNeck · « **Reply #84 on:** September 03, 2019, 09:15:18 PM »

I do like the scale. Who makes it/where did you get it? My Kubota L3800 may or may not lift that thing.....

wyorunner · « **Reply #85 on:** September 04, 2019, 12:29:48 AM »

Quote from: TexasRedNeck on September 03, 2019, 09:15:18 PM

I do like the scale. Who makes it/where did you get it? My Kubota L3800 may or may not lift that thing.....

Charles, I’ll have to confirm, but the tractor I used to pull and install ours, I believe is a 38horse. Some blue thing can’t think of the manufacturer. Not a Ford not a new holland.

Bear9350 · « **Reply #86 on:** September 04, 2019, 08:16:44 AM »

Quote from: TexasRedNeck on September 03, 2019, 09:15:18 PM

I do like the scale. Who makes it/where did you get it? My Kubota L3800 may or may not lift that thing.....

I've been running my uncles L3800 around the house to complete some projects. It seems like I can fork and move 1000 lbs off the trailer. 25 sheets of 7/16" osb at 47 lbs per sheet wasn't a go but after pulling a few off the stack it could do it. Assuming you will be lifting off a semi-trailer you may want to leave some type of rear implement attached to the 3-point for some rear weight. With the load that heavy the front wheels like to buckle in a turn.

wilsonphil · « **Reply #87 on:** September 04, 2019, 11:19:08 AM »

Quote from: Bigdave_185 on September 03, 2019, 08:12:07 PM

Mid engine conversion? Like motor In the cab?

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Im joking, The engines are noisy enough in the engine compartment let alone sitting right next to you.

wilsonphil · « **Reply #88 on:** September 04, 2019, 11:21:23 AM »

Quote from: TexasRedNeck on September 03, 2019, 09:15:18 PM

I do like the scale. Who makes it/where did you get it? My Kubota L3800 may or may not lift that thing.....

Its a sureline and I think i got it off mcmaster BUT you can find them cheaper on the interweb. Mcmaster is like Cabelas "you cant pay more" but they have it. I have owned it for a few years now, its pretty handy.

wilsonphil · « **Reply #89 on:** September 04, 2019, 11:23:10 AM »

Quote from: KensAuto on September 03, 2019, 08:55:47 PM

Quote from: TexasRedNeck on September 03, 2019, 07:25:29 PM
That’s a serious hunk of steel right there.

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Yeah you might wanna think about getting something more like an LS.
:wink

Now kids if you keep fighting over this engine Ill donate it to charity!!!

stlaser · « **Reply #90 on:** September 04, 2019, 11:36:49 AM »

Shawn’s charity slush fund is always a good option just sayin and I don’t mind screwing with the guys so if you want mo entertainment send it my way and I’ll make sure it’s interesting!

KensAuto · « **Reply #91 on:** September 04, 2019, 07:45:24 PM »

Just looking out for my Texan buddy Phil. Hehe

JR · « **Reply #92 on:** September 04, 2019, 08:04:08 PM »

Does it run? Don could use it,,,,,,,,,,,,,,,,,

dave945 · « **Reply #93 on:** September 04, 2019, 08:19:07 PM »

But if you sent it to Don, you know there is a very good possibility he would stick it in the Colorado(aka the running vehicle).

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stlaser · « **Reply #94 on:** September 04, 2019, 08:52:23 PM »

Quote from: dave945 on September 04, 2019, 08:19:07 PM

But if you sent it to Don, you know there is a very good possibility he would stick it in the Colorado(aka the running vehicle).

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Colorado oil change you say? Boy that escalated quickly.....

Oh wait, that comment came from a Dave. Sorry forgot about the Dave rule!

Bigdave_185 · « **Reply #95 on:** September 04, 2019, 11:08:40 PM »

Quote from: JR on September 04, 2019, 08:04:08 PM

Does it run? Don could use it,,,,,,,,,,,,,,,,,

It wouldn’t “run” for long after he got it

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Flyin6 · « **Reply #96 on:** September 07, 2019, 09:31:25 AM »

Quote from: JR on September 04, 2019, 08:04:08 PM

Does it run? Don could use it,,,,,,,,,,,,,,,,,

Tell me about it!!!!

wilsonphil · « **Reply #97 on:** September 08, 2019, 08:58:32 PM »

Ok back to Ramcharger fixing, I cut some cardboard patterns for the doublers that am installing and then I cut the steel using a shear. I got them pretty close and had to do minimal trimming. I beveled the edges so the plate would not interfere with the radius of the frame rails and sit nice and flush.

Then I clamped everything in place, I ground out the cracks all the way down to the doubler plate and welded away, also welded any holes that were not needed. Ground it smooth and it looks OK now. The three holes in front of the hanger are where the rock-sliders bolt too.

I have not finished drilled the holes yet they are undersize. I will also be adding a cover plate that ties the other three together, I know its overkill but I don't want to have to go back and fix this again.

I also made a plate for the rea of the frame where the rear spring hanger bolts to the frame I still have to do some trimming

JR · « **Reply #98 on:** September 08, 2019, 11:31:41 PM »

Any reason not to box it? Did that with my 77.

Flyin6 · « **Reply #99 on:** September 09, 2019, 09:14:36 AM »

Nice work Phil

And same question as JR

I boxed Square D