Author Topic: SquareD Part 4: Paint, topper, Roof rack, and continued change! (Read 206496 times)

Flyin6 · « **Reply #750 on:** October 16, 2014, 12:24:18 PM »

Here's all the parts to mount the 4" longer Chevy springs into a Dodge truck chassis

Flyin6 · « **Reply #751 on:** October 16, 2014, 12:25:14 PM »

Jim actually sent me all three sets of shackles. The ones on the new super beefy hangars are stock length
The long ones are for a 2" lift which should be correct to keep the geometry correct with a 2" lower spring location. Those shackles also move the axle about 2" forward

The strange dog leg looking units keep the axle near the stock location, perhaps 3/8" forward of stock. THat is where I plan to start with all this.

Take a look at the utter strength and build quality of Jims shackle mounts:

Flyin6 · « **Reply #752 on:** October 16, 2014, 12:25:57 PM »

Notice that the units are greasable and the larger sized 5/8" bushing bolts are even drilled for a means to grease the bushing from that end.

THe front mount replaces the wimpy factory stuff. This mount is obviously one piece which ties everything together and strengthens the front end a bunch

Between all the mounting holes and the various shackles, I'll have a wide range of axle positions and mount options available.

By moving the axle forward, I reduce approach angle, increase wheel base, and lessen the drive shaft angle, all positive attributes

Flyin6 · « **Reply #753 on:** October 16, 2014, 12:27:17 PM »

That's one good looking bolt/bushing setup!

And I can keep it lubed!

Flyin6 · « **Reply #754 on:** October 16, 2014, 12:28:13 PM »

Two of the optional shackles...

Flyin6 · « **Reply #755 on:** October 16, 2014, 12:30:05 PM »

The old and the new...Things are about to get a whole lot stronger!

Flyin6 · « **Reply #756 on:** October 16, 2014, 12:30:43 PM »

I picked up some new spring pack bolts as well to reassemble the "Donized" spring pack

Flyin6 · « **Reply #757 on:** October 16, 2014, 12:31:15 PM »

The hardware is top notch all the way

Flyin6 · « **Reply #758 on:** October 16, 2014, 12:31:54 PM »

This cool template will help me drill the correct sized hole in the exact spot called for

Flyin6 · « **Reply #759 on:** October 16, 2014, 12:32:51 PM »

Quote:
Originally Posted by ChrisLib View Post
Jungle does build some absolutely top notch gear for sure! And that front mount eliminates a weak link in the factory Dodge front end as the o.e. front spring mount rivets sometimes work loose and then the whole mess gets to shifting around which usually cracks the spring brackets and wallows out the frame holes, something every 1st genner needs to keep a watch for....well, not you now lol. Are the rear shackle mounts going to stay in the same location as stock, even with the longer springs or will you have to move them back on the frame?...OR is that what Jungle`s new design front spring mount is for? His earlier designs did not have the multiple mounting hole setup. I`m betting that SD is going to have a nice comfy/flexy front suspension with those longer springs as even a good set of 48"`ers makes a huge improvement.

Copy that

If you noticed the dog leg shackles, those allow for the 52" springs only moving the axle 3/8" forward I believe.
If one uses the straight shackle, then the axle is pushed about 2" forward
The multiple holes allow for the use of a stock 48" spring, or a 52" spring in several different positions to help you place the axle where you want it.

Flyin6 · « **Reply #760 on:** October 16, 2014, 12:33:24 PM »

Well, got a few hours in today, surprisingly!

I started with sanding the big front spring mount

Flyin6 · « **Reply #761 on:** October 16, 2014, 12:34:20 PM »

Then the new robust shackle mounts. They were treated to some quick wrist action and some #180 grit

Flyin6 · « **Reply #762 on:** October 16, 2014, 12:35:06 PM »

Then it was all treated to a fine dispersal of mist containing various chemicals and some cool gray pigment!

Flyin6 · « **Reply #763 on:** October 16, 2014, 12:35:52 PM »

OK, movin' on. Time to tear down the springs

Flyin6 · « **Reply #764 on:** October 16, 2014, 12:36:34 PM »

The prior Chevy's that were stolen by Mexicans and melted down to create these came apart easily. The leaves were well formed and required only hand pressure to squeeze together to pull out the bolt

Next off comes the bolt holding the military wrap together

Flyin6 · « **Reply #765 on:** October 16, 2014, 12:37:09 PM »

Then the thing falls apart

Flyin6 · « **Reply #766 on:** October 16, 2014, 12:38:08 PM »

Initially I pulled out the two leaves pointed at in the pics. I thought a 5 leaf spring would approximate the Skyjacker springs already in the front

I was wrong...

Flyin6 · « **Reply #767 on:** October 16, 2014, 12:38:58 PM »

That created this spring, which at the time I thought was what I was going to use

Flyin6 · « **Reply #768 on:** October 16, 2014, 12:39:41 PM »

Here's a stocker and a modified spring

Flyin6 · « **Reply #769 on:** October 16, 2014, 12:41:01 PM »

Moving right along, next up is removal of the spring eye bushings. I'll use mo-better Poly bushings with mo-bigger 5/8" bolts

The work is crude, but you have to beat the lip up and away from the eye so that you can cut it off, then hammer the bushing out

Flyin6 · « **Reply #770 on:** October 16, 2014, 12:44:19 PM »

Mine came apart fairly easily

Flyin6 · « **Reply #771 on:** October 16, 2014, 12:45:47 PM »

Here's the new hardware that will be used:

Flyin6 · « **Reply #772 on:** October 16, 2014, 12:47:10 PM »

Afterward I reassembled the springs to take some measurements

5 Leaves each...the ones I built and the ones on the front of Square D

Should be the same, right?

But...What if the leaves are different thicknesses????

Hmmm, better take some measurements...

Flyin6 · « **Reply #773 on:** October 16, 2014, 12:47:49 PM »

Hmmm, seems my five leaves are a bit thinner than the Sky Jacker springs

Check out the measurements

By adding in the leaf I removed, I brought the spring pack back to almost the exact thickness as the Sky Jacker spring...Within .035"!

Flyin6 · « **Reply #774 on:** October 16, 2014, 12:48:40 PM »

OK, enough on the leaves for now. I am waiting on the friction pads to show up so I can drill the leaves and fit them, then paint and coat the leaves, install the bushings and finish them

After cleaning the blower motor and its housing, I reinstalled it

Flyin6 · « **Reply #775 on:** October 16, 2014, 12:49:28 PM »

Oops, forgot to show the compare shot showing the factory 9/16" hardware, and the greasable 5/8" bolts I will be using:

Flyin6 · « **Reply #776 on:** October 16, 2014, 12:50:21 PM »

I added some sound deadener to the firewall

Flyin6 · « **Reply #777 on:** October 16, 2014, 12:51:25 PM »

Then the cleaned and touched up factory cover was set back in place

Flyin6 · « **Reply #778 on:** October 16, 2014, 12:52:23 PM »

Then I transferred the fan belt...It is a bit too long...ERRRR!!!!

Flyin6 · « **Reply #779 on:** October 16, 2014, 12:52:58 PM »

And that is all she wrote...I hear a fat lady singing and some burgers getting ready to be cooked

(No the wife is not fat! Nor are the girly daughters...)

Flyin6 · « **Reply #780 on:** October 16, 2014, 12:55:02 PM »

The turbo is built and shipped
It ended up being a HX40 style twister with a 65mm wheel and a 12cm housing selected to spool quickly and to eliminate the smoke from the large injectors
The injectors remained the Cummins 370 horsepower marine units and I will be using a new HX-40 down pipe. This motor will produce approximately three times more power than the stock engine that resides in there at the moment. Torque should be well north of 1200 and with the super high gearing the truck has the potential for amazing fuel economy
The spring friction pads came in and I procured a couple cans of the graphite dry film lubricant to coat the springs with.
I think they will get a multiple stage process of cleaning to remove the poor quality paint from the edges. Yup edges...Only the sides of the inside leaves were painted, the rest of the leaves remained untreated raw steel. No wonder why these things rust so badly.
I think I'll pay attention here and get some good red oxide primer, then follow with a good epoxy primer, then John Deere blitz paint with hardener. I'll top coat all of that with the graphite and hope for the best after that!
__________________

Flyin6 · « **Reply #781 on:** October 16, 2014, 12:55:41 PM »

Quote:
Originally Posted by DuramaxExpress View Post
Curious as to why you would run marine injectors in your TRUCK?

On a more serious note, everything I have read on marine injectors says they have a different spray pattern and like to run hot and hazy. Which was something I thought you were trying to avoid with the build.

The tech at Gillette diesel and I had a load of conversation on that subject.
One thing about that injector is the pricing. Whereas most of the bosch and aftermarket injectors run $100 or (a lot) more each, these go out the door for $72. Economy of scale principle and all that. Since it is an injector built by the scads for all the Marine purposed engines, you get a high quality part that costs less because of the large production runs.

Next, yes, they are smoky injectors. Smoky that is if you don't do something about it. We did...Did you notice the tiny 12CM exhaust housing? That housing will run the turbo up quicker eliminating a lot of that smoke.
I stayed on that point...No snail trail, and they heard me loud and clear. They feel strongly this combo can easily meet the 550 HP requirement and probably produce 600HP or more with reduced smoke.
If it hazes, that is acceptable. I am going to spray in alcohol and water so I think I have a good means to get on top of the higher temps.
Now as for the spray pattern, I believe they spray somewhere from 155-159 degrees. That is a tad bit problematic with stick pistons, but not so much with the Marine pistons I have installed in this motor.
Ah, in the end, I hope this combo works out well, but if it doesn't, I'll sort it out then

Flyin6 · « **Reply #782 on:** October 16, 2014, 12:56:42 PM »

Quote:
Originally Posted by FBJR View Post
Which primer will bite and remain flexible?

JR, you knucklehead...

I'm going to use that red Obamaoxide stuff

It's guaranteed to change the rust but doesn't. Somehow I feel, that, despite the overwhelming evidence to the contrary, that the stuff actually does work.

It's manufactured by the Golf adventures and paint company in Moscow, but also in China and North Korea I hear. No one actually knows for sure where it comes from though! Some people even think it's made in Hawaii! HA, I don't believe that either, the part about it coming from the commies...Nope, again I sorta know for reasons I can't explain that it must come from Hawaii. In fact I once goggled the founding documents from that company. And there it was in black and white: "Incorporated in Honolulu Hawaii, USA, 11 September 1775!

This paint remains flexible. Flexible enough to change at a moments notice into anything the manufacturer can think up...Actually had some of it change into environmentally stable bubble gum once! Had that stuff sprayed on the left fender of my Chevy back then...It Kept attracting deer...Weird? Don't worry, though, I treated them in an environmentally responsible manner along with some barbeque sauce and a bed of hot coals...

Yup Obamaoxide is some good stuff, even though it actually doesn't work. You see when I first started using it, I found out that it prequalified me to company dividends. Yes, it's true. All I had to do was to keep on using it and they sent me all sorts of things...free things mostly from my working neighbors. Naw, I don't quite get that part of the Obamaoxide experience, but as long as they keep sending me my neighbor's stuff, why, I'm gonna just keep on using the stuff.

One thing I don't like about it, is that it smells like bull crap! Really, and well, I just sorta got used to it. Heck most of the environmentally responsible people who also use Obamaoxide don't bathe very often (saving water for the plants and fish I guess) so the bull crap smell of the paint sorta gets lost amongst them if you know what I mean.

I just hope those deer don't come around licking my freshly coated springs though. Although I don't mind seeing my EPA buddies on a regular basis (We all hang out together when they aren't stickin' it to those capitalist and imperialist pigs down at the factory), and drink beer the ATF confisicated from one of those capitalists. Ah, what the heck, if the deer come, we'll just treat one of them in an environmentally responsible manner, build a barbeque pit, and have a party on the beach!

Yup Obamaoxide is the stuff. Get it on you, and even though it doesn't work, it is hard to get off...I mean you just can't get rid of it. Then if you do, someone puts your name on some list somewhere for some reason...market research I suppose, well, whatever. I'm mindless, brain-dead, in need of some freebees, and loving the change with obamaoxide paint, and it's time to get out and vote! Gotta go
See ya'll later!
__________________

Flyin6 · « **Reply #783 on:** October 16, 2014, 12:59:29 PM »

Quote:
Originally Posted by FBJR View Post
Which primer will bite and remain flexible?

That turbo sounds great!

JR, ya know I think as a responsible citizen and father I should point out something rather obvious about your avatar...Not that we've had avatar issues with you in the past...

How old is that child you have in your employ?
He appears from my viewing angle to be around 6 years, 2 months, 23 and a half days in age...Am I close?

I know that you being an officer of the law, you have intimate knowledge of the law with respect to the child labor laws. Now here in the tucky we consider you an adult (and married) at 13, but Kalifornia? I thought with all the video games, and surfin', and playin' around, your children finally hit puberty around 31?

Am I correct?

So why are you employing a mechanic who is only 6?
I'm sure you have the proper state county and town approvals and licenses, and have signed the release forms, gotten the environmental impact statements, site surveys, and town commune studies and approvals. You certainly are paying employment tax, labor tax, air purity access fees, land use and future reclamation fees, have him registered with the social security administration and enrolled with a proper OB kare policy.

But with all those things completed, did you consider the sensibilities of your Mexican, Palestinian and Hamas neighbors? I mean do you think they could have been emotionally scarred by such an early display of "an intent to work" attitude? How exactly does that play into the girly sensitive fabric of the local socialist society?

Me, I think someone is headed your way to have a very politically correct conversation with you about you truing to instill a work ethic into a member of the Kalifornia collective. That's very disruptive you know, and shows just how thoughtless you law enforcement types really are!

Flyin6 · « **Reply #784 on:** October 16, 2014, 01:01:29 PM »

I fixed it!

After all that business, and I was buttoning it up, I discovered the MCU (Motor control Unit) had vibrated out of its mount. Yup, that was it! With it moving about, it was tugging on this wire or that causing an intermittent connection which caused the brain of the thing to throw a miscommunication code. So with all connections pulled, wiggled, and reinserted, I got a load of towels through! I figure short of washing an Armee tent, towels would be the most abusive...Passing that test would prove it works...AND IT DOES!

OK, now back to the Square truck project.

Parts continue to arrive, creating somewhat of a backlog of sorts

Here's the 4" down pipe for the HX-40 style turbo that will soon rest in SquareD's engine bay

Flyin6 · « **Reply #785 on:** October 16, 2014, 01:02:17 PM »

Quite the difference between this pipe and the old style 3" down pipe from the 1st gen engine!

Flyin6 · « **Reply #786 on:** October 16, 2014, 01:03:20 PM »

The new injectors showed up as well...Compliments of Gillette Diesel of Utah. They decided I needed these Bosch Marine injectors and they sure are purdy!

Flyin6 · « **Reply #787 on:** October 16, 2014, 01:04:01 PM »

The box also contained a pretty new looking Turbo Charger
Based on the HX-40 series units it will make all the power SquareD (and I) can handle

Flyin6 · « **Reply #788 on:** October 16, 2014, 01:04:31 PM »

65mm compressor

Flyin6 · « **Reply #789 on:** October 16, 2014, 01:05:04 PM »

I know Steve had said he was building it with a 12CM exhaust housing...but I can't tell from these casting numbers

Flyin6 · « **Reply #790 on:** October 16, 2014, 01:05:57 PM »

It's one clean looking unit...If it would only stay that way!

Flyin6 · « **Reply #791 on:** October 16, 2014, 01:07:44 PM »

OK, back to the front suspension

But first a note: Anyone with a third of a brain will have noticed how much I jump around here. Going from torqueing main bearings to installing headliners back to setting pinion angles and then over to LED lighting!
Crazy, yes?
Not so quick!
I could just stay on, say the suspension until it was completed, then go on to fabbing up the radiator core support. The reason I jump around so much is because I have to get parts. You see right in the middle of doing something on the core support, I'll need some special hardware, that gets ordered that night. But so that the day is not a wash, I jump over to the steering gearbox.
You see, by having three-five things going at the same time I can get SOMETHING done all the time. Now we are putting together the engine, building the core support, modifying the front suspension and dilly-dallying on the lighting, interior stuff and a host of udder stuffes.

Comprende?

Well, it doesn't matter if you don't, that's the way we roll here. I was just trying to lower the blood pressure in about twelve thousand of you out there in forum land!

OK in the spirit of anything is in play, lets look at the new shackles Jungle just sent me. According to him a simple math error, adding 3/4's of an inch in stead of subtracting it caused Mr. suspension geometry to have a headache.

These laser cut shackles fixes all that!

Flyin6 · « **Reply #792 on:** October 16, 2014, 01:09:00 PM »

The dogleg shackles push the axle 3/8" farther forward, whereas the straighter ones push the axle 1.75" forward

I assembled Jungles HD front shackle mounts that will be going in the frame soon

Flyin6 · « **Reply #793 on:** October 16, 2014, 01:09:47 PM »

That Dupont Nason paint with hardner sure makes parts sparkle!

Next up we have the spring friction pads. The el cheapo springs I purchased for $145 each (A deal!) were just cheapo springs, Hey I just said that!

Installing these anti friction pads, treating the springs to a process you are about to see, and adding in the poly bushings bring them up to a whole new level

Flyin6 · « **Reply #794 on:** October 16, 2014, 01:10:24 PM »

These require a 9/16 hole to be drilled into the really hard spring steel

I did that by using a cobalt drill bit, plenty of cutting oil and a slow drill speed on the drill press

Flyin6 · « **Reply #795 on:** October 16, 2014, 01:11:48 PM »

And they fit just fine

Flyin6 · « **Reply #796 on:** October 16, 2014, 01:12:43 PM »

And then for the next couple of hours 19 more holes got drilled in all these leaves little bit by little bit

Flyin6 · « **Reply #797 on:** October 16, 2014, 01:13:47 PM »

The next step in the spring pack prep was to give each leaf a through sanding to get it as flat as I could. There was a bunch of surface gunk and slag stuck all over the steel. After another 1.5 hours I had all the leaves sanded smooth

Flyin6 · « **Reply #798 on:** October 16, 2014, 01:14:41 PM »

Then the leaves got wire brushed and thoroughly cleaned with solvent to prepare them for painting.
During the sanding process, all sharp edges were rounded off and blended in so nothing sharp could dig into anything near it.

The first step in painting is with a red oxide primer, which we all know is a very good rust preventative primer, which was actually developed for ship hulls that cross stuff like oceans.

It took two full cans to give all 12 leaves a heavy coat

Flyin6 · « **Reply #799 on:** October 16, 2014, 01:15:21 PM »

And, no, I didn't forget the main leaf...