Author Topic: SquareD Part 4: Paint, topper, Roof rack, and continued change! (Read 204120 times)

Flyin6 · « **Reply #300 on:** October 13, 2014, 04:48:55 PM »

Then Oil cooler gets installed

Flyin6 · « **Reply #301 on:** October 13, 2014, 04:50:01 PM »

Then it's cowling. I ordered some stainless screws which haven't showed just yet, so I'll revisit this step later on

Flyin6 · « **Reply #302 on:** October 13, 2014, 04:51:03 PM »

Then Duane's Owl's eye housing was installed with stainless, button head screws

Flyin6 · « **Reply #303 on:** October 13, 2014, 04:52:22 PM »

It will be important to make sure everything is grounded well, so I fashioned up this ground cable that goes from the common ground stud to one of the roof mounting bolts

Flyin6 · « **Reply #304 on:** October 13, 2014, 04:53:38 PM »

Then I mounted the spot lights and started on the wiring harness

Flyin6 · « **Reply #305 on:** October 13, 2014, 04:54:36 PM »

Those plug in connectors were then removed in favor of my weather protected harness ends

Flyin6 · « **Reply #306 on:** October 13, 2014, 04:55:35 PM »

They build up fairly easily

Flyin6 · « **Reply #307 on:** October 13, 2014, 04:56:15 PM »

Those steel pins are inserted into the plastic connector making the world, one with goodness

Next the front LED light was bolted in place

Flyin6 · « **Reply #308 on:** October 13, 2014, 04:57:23 PM »

Then one of those weather-pak ends installed onto the LED harness

The idea is to make everything so that it can be easily removed for service and plug into a central wiring harness that I am about to build.

Flyin6 · « **Reply #309 on:** October 13, 2014, 04:58:01 PM »

Then the side illumination LED lamps were bolted in place

Flyin6 · « **Reply #310 on:** October 13, 2014, 04:58:42 PM »

As soon as I bolted in the right lamp assembly I noticed a problem

Flyin6 · « **Reply #311 on:** October 13, 2014, 04:59:28 PM »

Yup, that oil cooler line wants to go straight into the lamp, so either the line has to change or the lamp needs to move.

I found a #8, 45 degree fitting that solved the problem

Flyin6 · « **Reply #312 on:** October 13, 2014, 05:00:03 PM »

Back to wiring

The spots got their connectors and that plugged into the growing wiring harness

Flyin6 · « **Reply #313 on:** October 13, 2014, 05:00:35 PM »

Wiring harness build out so far

Flyin6 · « **Reply #314 on:** October 13, 2014, 05:01:21 PM »

The ends that came on the LED's were cut off so that the weather-pak connectors could be attached

Flyin6 · « **Reply #315 on:** October 13, 2014, 05:02:48 PM »

Fast forwarding some, those ends were created, the harness connected, then convoluted tubing placed over the wires. That was zip-tied to the inside of the upper tube

Flyin6 · « **Reply #316 on:** October 13, 2014, 05:03:42 PM »

The harness ended in a 4 hole pigtail utilizing 2 holes for now that will allow for future growth. THe single line/plug is for the aft 20" LED lamp

Flyin6 · « **Reply #317 on:** October 13, 2014, 05:04:15 PM »

Still have a bunch left over!

Flyin6 · « **Reply #318 on:** October 13, 2014, 05:05:09 PM »

Some views of the build out so far

Flyin6 · « **Reply #319 on:** October 14, 2014, 12:03:13 PM »

Next, I'm going to find a place for these:

Flyin6 · « **Reply #320 on:** October 14, 2014, 12:06:01 PM »

This a typical load with a Rubbermaid action packer and a couple water cans.

In all actuality, I doubt the H20 cans will get up there because they tend to move the CG north a bit too far for my liking. But I wanted some sort of a pattern to use to place the tie down rings where they might be useful

Flyin6 · « **Reply #321 on:** October 14, 2014, 12:07:13 PM »

Those items resulted in the rings being positioned here:

Flyin6 · « **Reply #322 on:** October 14, 2014, 12:08:34 PM »

Drilled in and bolted in place, a couple bolts were left out because they penetrated the frame, and I will need to remove the floor to install the rack

Flyin6 · « **Reply #323 on:** October 14, 2014, 12:10:23 PM »

And here's the mess at the end of build day 136

Flyin6 · « **Reply #324 on:** October 14, 2014, 12:11:09 PM »

From streetrodchev:

Don, why not run the wire harness on the bottom side of the rack? It would be better protected there

Flyin6 · « **Reply #325 on:** October 14, 2014, 12:11:57 PM »

From FBJR:
Quote:
Originally Posted by streetrodchev View Post
Don, why not run the wire harness on the bottom side of the rack? It would be better protected there.

First thing I thought of too. Not exposed=less likely to damage.

Run the cooler lines straight back under the deck too. looks like a natural.

Will your tractor lift that thing

Flyin6 · « **Reply #326 on:** October 14, 2014, 12:13:21 PM »

OK, here's today's progress

First acting on that great suggestion yesterday, I moved the wiring harness to the inside/underside of the rack

Flyin6 · « **Reply #327 on:** October 14, 2014, 12:14:07 PM »

That was a great idea. it's much neater looking and everything is now well protected

Flyin6 · « **Reply #328 on:** October 14, 2014, 12:15:15 PM »

Next was prep for the big lift.

I pushed some heavy weights in the gym today, so I decided to just lift the thing myself, and it worked

I prepped the area first. THe floor was placed to be in a good spot to catch me if I took another fall

Flyin6 · « **Reply #329 on:** October 14, 2014, 12:16:03 PM »

I prepped the cab with some heavy thick blankets, some plywood and a couple 2 X 4's

Flyin6 · « **Reply #330 on:** October 14, 2014, 12:16:44 PM »

Then with a single clean and jerk style lift it was sitting on the roof!

Flyin6 · « **Reply #331 on:** October 14, 2014, 12:17:15 PM »

Then little by little I screwed in the bolts and pulled away the blankets and plywood

Flyin6 · « **Reply #332 on:** October 14, 2014, 12:18:07 PM »

I used stainless steel washer head 3/8" bolts to secure the rack to the roof hard points

Flyin6 · « **Reply #333 on:** October 14, 2014, 12:19:05 PM »

All the welding had tweaked the rack a little, but after bolting down the fit is pretty good

Flyin6 · « **Reply #334 on:** October 14, 2014, 12:19:59 PM »

I still don't have the button head screws to hold the floor down, so I temporarily bolted it with three fasteners to keep everything honest

Flyin6 · « **Reply #335 on:** October 14, 2014, 12:20:56 PM »

It almost looks like it was custom built just for this truck!

Flyin6 · « **Reply #336 on:** October 14, 2014, 12:42:43 PM »

I think the proportions look about right. I thought it might get a bit too tall, but now that I see it up there, it's just fine

OK, next up, let's connect the oil cooler lines

Flyin6 · « **Reply #337 on:** October 14, 2014, 12:43:39 PM »

Following the same excellent advice as burying the harness, I followed suit and ran the oil cooler lines below the rack floor.

I have to admit it turned out much better than the way I had envisioned

I was working with a selection of AN#8 fittings

Flyin6 · « **Reply #338 on:** October 14, 2014, 12:44:24 PM »

The best way I have found to cut this hose is to first wrap it with electrical tape, then cut it with a chop saw

Flyin6 · « **Reply #339 on:** October 14, 2014, 12:45:02 PM »

Then after a short visit to the vise, hose #1 was assembled

Flyin6 · « **Reply #340 on:** October 14, 2014, 12:45:32 PM »

Then installed

Flyin6 · « **Reply #341 on:** October 14, 2014, 12:46:06 PM »

Then the second hose...

Flyin6 · « **Reply #342 on:** October 14, 2014, 12:47:02 PM »

I used those plastic T-Clamps to isolate the hoses and prevent chaffing

Flyin6 · « **Reply #343 on:** October 14, 2014, 12:47:42 PM »

I'm pleased with the sanitary installation. Techy looking but not over the top

Flyin6 · « **Reply #344 on:** October 14, 2014, 12:48:42 PM »

Quote:
Originally Posted by lutzjk913 View Post
coming along nicely.

whats next on the list?

Today, probably window seals, windshield wipers, rust proof spray and some chorsey stuff

Need to get the bed back on so I can free up some floor space.

After that, the engine comes out, since the new P-Pump 12 valve motor is nearly finished. I was lucky enough to find it being rebuilt, so I got to pick certain things and modifications to build it right the first time.

When the engine comes out, well so does the trans and transfer case. I'll overhaul the transfer and now, since I found someone within 100 miles that specializes in these old A518's I'm likely to drive the carcass up to him and allow that to be farmed out...Not sure though as I'd like to learn how to do that meself.

Of course while the trans is out and being altered, I plan to detail out the motor and rebuild the alternator, add a generator, rebuild the starter, and paint the Cummins.

I'll also start the next big project, the front suspension and steering conversion. That is a biggie...

Tate and I are discussing changing the thing over to 4.10 gears, adding a front locker, 35 spline axles and those super duper hubs he sells.

Seems I am doing some (Most??) things twice. Should have said at day one, "Mission statement: Build the most rad, low tech militarized/survival/expedition square dodge truck in the world."

If I would have admitted that simple truth to myself, I wouldn't be reopening things already closed up

Flyin6 · « **Reply #345 on:** October 14, 2014, 12:51:24 PM »

Quote:
Originally Posted by FBJR View Post
You sure about that 518 Don? I am leaning towards the 618 (47rh) after doing a little more research.

My 91 setup is nice with the 205 and all. But the 7100 motor with a 618 lockup sounds so much better.

JR,
Doesn't that 47RH have some electronic circuitry for the lock-up part of the converter? I know the 47RE is an electronic transmission so it is definitely a NO-GO, but although I am not sure, somehow I'm thinking there is a transistor, resistor, diode or do-dad livin in side that 47 trans.

Secondly the torque converter for the lockup design is more complicated and anywhere from 2-3 times the cost of the A518 unit?

Finally, the A518 can be made as strong as the strongest 47RH, so all one is really sacrificing is a little gas mileage and having to deal with some more heat production from the older A518. I added that big trans cooler and will add a 55 gallon deep pan just to deal with the extra heat.

I own a 518. I would have to buy a 47RH. People think the latter trans is gold plated whereas they treat the 518 like scrap cardboard with respect to price. The 518 accepts many of the 48 transmission parts so it can be modernized easily and do all that without needing electricity...

So, that's my argument for staying simple. That and the concept works harmoniously with how my brain works

Flyin6 · « **Reply #346 on:** October 14, 2014, 12:53:15 PM »

Here's some pics of the 12 valve motor going together

It is a 1995 P-Pump 6BT
Overhauled to zero time
Modified with Marine pistons
Dowel pin corrected
60 pound valve springs
Comp valve job
Head shaved (A little)
ARP head studs
4000 RPM governor springs
Cut delivery valves
Modified fuel plate

Flyin6 · « **Reply #347 on:** October 14, 2014, 12:54:47 PM »

Pistons are nice!

Flyin6 · « **Reply #348 on:** October 14, 2014, 12:57:00 PM »

Can you believe I'm 60 today!!!!!

Should have bought the farm in Korea in 1987 when we flew through wires and crashed
Should have been killed in Just cause when a .50 gunner lined up on me and opened up
Should have been killed 45 minutes into the start of Desert Storm when three surface to air missiles all missed, but we crashed anyway getting away from the last one
Should have been killed in Baghdad when I was dumb enough to get into an IED explosion on the ground with my helicopter which was W A Y too close to the fun and games
Should have died maybe a thousand times in Afghanistan when the snaps of bullets passing by all missed their mark
Maybe I could have died on the operating table a few times when Armee surgeons fixed stuff that got broke
Or up at the Swangunks when I held the rope that was tied to my brother who took a big fall and pulled me over the edge as well (Glad that little pine tree I was tied to held!)
Could have died when I rolled over my Merc Cougar, or when my buddy rolled over his GTO with no seat belts, or when I parachuted into the bay near flordia during water survival training...Got tangled in the parachute chords and my life raft didn't inflate.
There were a couple gunfights, a couple bar fights, and of course my wife who could dispatch me in an instant for doing any of ten million things punishable by death...like not screwing the lid onto the toothpaste...stuff like that

But look at me, I made it
6 decades
Fully twice the age of more than half the readership here, bless your little star mag hearts!
I made it

Flyin6 · « **Reply #349 on:** October 14, 2014, 12:58:49 PM »

OK, let's get a bit more done on this truck

The engine assembly continues. I will be placing it on a Harbor Freight 2K engine stand and dressing it all purdy like, then reinstalling it.

I am continuing on the JMVI (Jap Maple viewing initiative) which is associated closely with the PDI (Parts reduction initiative)

Basically that all means bolting on parts that have been blocking my view and cluttering the benches

With the truck painted, time to bolt back on the door stuff

First up: Mirrors

But with them being all shiny, I first had to make them black