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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #500 on: October 10, 2014, 04:08:38 PM »
Next test, does it work with the booster and does that fit?
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #501 on: October 10, 2014, 04:09:28 PM »
So far, so good!

Now remember that 2nd gen standoff? That exists because the engine resides partially under the cowl, unlike the traditional 1st gen square truck. The old unit is 2 3/16" shorter than the new one
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #502 on: October 10, 2014, 04:10:16 PM »
The middle mark is approximately center of the rod, and the other two marks are the actual cut lines

Here's the rod after shortening
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #503 on: October 10, 2014, 04:11:03 PM »
While setting this up for the next procedure, I cleaned and primed the mount plate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #504 on: October 10, 2014, 04:13:07 PM »
The plan is to tap either end then screw them together with a coupling nut which is a long nut used to join all thread if necessary. This was 1/2" so I cut 1/2-13 threads into either piece
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #505 on: October 10, 2014, 04:14:39 PM »
For simulation only, I joined the two pieces with a standard nut.

I'll search out a coupler tomorrow
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #506 on: October 10, 2014, 04:27:35 PM »
So now everything is the proper length, time for the paint!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #507 on: October 10, 2014, 04:28:35 PM »
The painting finished this operation and me for the day!
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #508 on: October 10, 2014, 04:29:42 PM »
Quote:
Originally Posted by lutzjk913 View Post
Coming along nicely don.

When do you think you will be finished with this?


Finished is a relative term!

I hope to drive something this summer or fall, but I suspect I'll be doing things to it for years to come!

I have the SAS to do on the chebby

Then the tac-trailer project. The trailer/habitat is the only way all of this makes sense. Neither truck has sufficient room, so the trailer is a necessity.

I hope to drive the truck after the engine, twin turbos, coil spring suspension, front and rear bumpers and rock rails.

Then while I'm driving it and sorting it out, I'll start the exo-skeleton. With that complete, I'd have to call Square D effectively done with the occasional upgrade keeping it alive as a project for years...
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #509 on: October 10, 2014, 04:30:36 PM »
Quote:
Originally Posted by BobbyB View Post
I think you should leave it the camo paint job you have on page 484. It's definitely a "hide in plain sight, broken down truck" paint job... 

Bobby, ya know...that isn't so bad of an idea.

Make it look so junky, how could it be anything...

I think you have something there...

You know I was painting it with OD Green and the bumpers and so forth in semi flat black

But as I mentioned some time before here is a great little home-made camo paint scheme which also looks half way OK:
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #510 on: October 10, 2014, 04:32:21 PM »
Quote:
Originally Posted by duramaxdarren View Post
Yup she's my angel! Thanks guys. I'm afraid it's to late and I got axed. They weren't real men and I didn't drink the koolaide. Not to worry, god has his plan for my family and I will work as I was meant to ( in the field and running a crew) while I hunt for a new full time jig. Wife's not thrilled and she's right (as always) but I will provide for my family and god is with me


Sent from AutoGuide.com Free App


Darren, try this out...
You may have troubles, but Jesus told us we would have trouble in the world.
He also told us to rejoice in him and in times of trouble;

Faith in Christ is the foundation for joy and hope in life. Jesus' life on earth, his death and resurrection is the cornerstone of Christian faith. This faith is not based on the state of our emotion. That's why it is important to study the Scriptures to strengthen our faith and grow in our knowledge of the truth. The Bible teaches that Jesus came into the world, entered human suffering and conquered sin and death. Only through faith in Jesus Christ can we persevere and sustain our hope and joy. The Bible gives us reason to rejoice. We rejoice because God showed his love and grace to us. We have reason to celebrate because God is in control. We should rejoice because God is good and his love endures forever. We must learn to rejoice in the Lord always.
Feel free to use these verses for a Bible study or a short devotional. For more encouraging Bible verses check out the articles posted on the next page.

Philippians 4:4
Rejoice in the Lord always. I will say it again: Rejoice!

Psalm 13:5
But I trust in your unfailing love; my heart rejoices in your salvation.

1 Thessalonians 5:16-18
Be joyful always; pray continually; give thanks in all circumstances, for this is God's will for you in Christ Jesus.

Psalm 40:16
But may all who seek you rejoice and be glad in you; may those who love your salvation always say, "The LORD be exalted!"

James 1:2-4
Consider it pure joy, my brothers, whenever you face trials of many kinds, because you know that the testing of your faith develops perseverance. Perseverance must finish its work so that you may be mature and complete, not lacking anything.

Psalm 30:5
For his anger lasts only a moment, but his favor lasts a lifetime; weeping may remain for a night, but rejoicing comes in the morning.

Romans 5:1-4
Therefore, since we have been justified through faith, we have peace with God through our Lord Jesus Christ, through whom we have gained access by faith into this grace in which we now stand. And we rejoice in the hope of the glory of God. Not only so, but we also rejoice in our sufferings, because we know that suffering produces perseverance; perseverance, character; and character, hope.

Psalm 28:7
The LORD is my strength and my shield; my heart trusts in him, and I am helped. My heart leaps for joy and I will give thanks to him in song.

Romans 15:13
May the God of hope fill you with all joy and peace as you trust in him, so that you may overflow with hope by the power of the Holy Spirit.

Psalm 64:9-10
All mankind will fear; they will proclaim the works of God and ponder what he has done. Let the righteous rejoice in the LORD and take refuge in him; let all the upright in heart praise him!
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #511 on: October 10, 2014, 04:33:13 PM »
Quote:
Originally Posted by BobbyB View Post
Wasn't it your intention (the mother of all evils') with D2 to keep it looking as you got it on the outside, as to not attract too much unwanted attention, yet still have the ability to scoot cross country if needbe? I do remember things, I just don't let on to the powers that be.
 

Yes, that is my intention, to keep it low observable and low keyed.

Now going down the road, this truck is going to attract enormous attention, just because it will look so "Rad" if that is a word.

So no hiding the "intent" part.

When you design and build something favoring function over looks, it will get all creepy looking pdq.

So I figure the best I can do is to break up the pattern with some strategic blending of colors, all muted of course.

Look at that Hmmv with it's OD and black swatches.

It sort of stands out because of the fact that it's a H1 hummer and looks like it came of a Mad-Max set.

Now consider our HMMV's and my helicopters after we have been operating them for a few days in the bush.

They start to look all muted and that base color only helps blend it all together.

I say you take my truck, drive it through a field with a mud hole and you'll be approaching "good to go"

Then take that same truck and drive it partially into a wall with maybe one tire resting comfortably on the neighbors Taurus and I think it will look like a wreck, someone abandoned.

That's how I plan to play this one out. I am just building in the ability to punch into that wall without doing any more than scratching some paint...
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #512 on: October 10, 2014, 04:33:51 PM »
Today, was a work out (Takes hours) and parts collection day. I did manage to score all the material for the roof rack. Total cost on all that steel was $88! Not too bad me thinks.
I also got more stuff for the snorkel, but the most important part, the precleaned did not show up. After three days, the warehouse just told us that even though they show one they had zero balance. So it has been ordered from the factory and I believe is 3 days out.

I got a late start so I spend some time cleaning the place since I will be painting most of the truck in a few days to a week. As far as what's next, I was thinking, I ought to fab up that rack and snorkel before the fresh paint so that that purdy green stuff does not get all sparky when I tack this or that together. Right now it matters not. So tomorrow, hopefully I have set a lofty goal of getting the snorkel and the roof rack put together.

I'll post todays progress along with tomorrows Friday evening
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #513 on: October 10, 2014, 04:35:45 PM »
I was working on the snorkel. This flat bar is the snorkel base mount that attaches to the hard points
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #514 on: October 10, 2014, 04:36:37 PM »
It was painted with the weld through copper primer from U-Pol
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #515 on: October 10, 2014, 04:37:24 PM »
In this photo(s) I temporarily reattached the fender so I could sort out the snorkel position before permanizing it
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #516 on: October 10, 2014, 04:38:07 PM »
This junky Sony/jap camera is failing, and why not?? It's over a year old, why should it continue to function?
So apologies for the out of focus pics I purposely took that way to hide my poor workmanship!

I butt welded the 5" 45 to the main tube
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #517 on: October 10, 2014, 04:38:44 PM »
Then shortened up the top part
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #518 on: October 10, 2014, 04:39:42 PM »
Then I chopped off the excess from the bottom
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #519 on: October 10, 2014, 04:40:46 PM »
The pipe is big enough to screw on with bolts from the inside, so that became the simplest concept. Since my wife tells me I am simple minded, I went with it
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #520 on: October 10, 2014, 04:41:30 PM »
And lookey there, it fits!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #521 on: October 10, 2014, 04:42:12 PM »
It even works with the opening and closing of the door!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #522 on: October 10, 2014, 04:43:16 PM »
I'll fab up the bottom piece in a few days after I get a couple more 45's from summit

Side view:
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #523 on: October 10, 2014, 04:44:10 PM »
With that fitting nicely, I removed it, the welded up all those rose-weld holes making that permanent
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #524 on: October 10, 2014, 04:45:11 PM »
After selecting some shorter hardware, I snugged the snorkel up, but not tightened all the way down
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #525 on: October 10, 2014, 04:49:26 PM »
So have you heard of the flying Wallendes?

They are the most famous trapeze family alive, that are mostly, still alive

Why do I mention them?

Well I seem to have something in common with them

They get completely horzintal well off the ground...

Yep

Apparently, so do I

I think the difference between them and I is that safety net.

At least in my case There was a flat 8" thick layer of safety concrete to stop my fall.

I was traversing around from work stand to frame. Apparently the comforter I have laying in the frame is not permanently attached, and it moves.

The good thing is that when it moved displacing my foot, it did not scratch the paint. When I got horizontal at least there were no tricky air currents to set up the spin. When I hit the safety concrete with a perfect three point landing, those points being my buttock protrusions and the back of my skull, I didn't damage it either.
It didn't hurt because it knocked me out. Then I was happy when I awoke to discover my toes and legs still worked, and that the D_)!(&*!! red dog hadn't eaten any of me.

So it's all good. I'm sitting here doped up on aspirin if one can actually do that and for some reason the only thing I am angry about or with is that D)!&*!! Red dog and she was absent from the festivities for once.

Oh, then a few moments later my mind got the slow traveling pain signals. I was in such a state a moment after waking up from the fall and figuring out how much I was hurting to weld a little on the roof rack. I must not have been thinking straight or perhaps at all. because when I tried to stand up and the lower back said, HEY, I'm hurt here, How's bout a little help, then gave way to gravity, on the way back down, I reached out and grabbed onto the roof rack...TO the exact spot which had been molten 10 seconds before...Yea...Not my day at all

The last couple pics are normal welding battle damage...nothing to lose any sleep over...
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #526 on: October 10, 2014, 04:51:24 PM »
OK folks, no aspirin.
I started the day with them, but said to heck with it about mid day. I'll only live for just so long and the day was ah' wastin' so I donned the old work clothes and hobbled out to the garage to get a couple hours in.

I really think it's only bruising kind of injury, nothing more. I have very little functioning brain, so injuring that wouldn't hurt...
The foot was because instead of putting on my trusty combat boots to weld like I usually do, I went at it with some mid tops...mid tops act like bug funnels for sparks and hot metal...nuff said

No headache, just a really sore butt and lower back. I think I fell just about perfectly, except I forgot the PLF at the point of impact.

OK on to work...Back to the snorkel. The brown truck showed up again so I concentrated on getting the lower pipe section created
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #527 on: October 10, 2014, 04:52:04 PM »
The lower section starts with a length of pipe to get the bend in about the right spot

The camera is going to fail again, so bear with me prudy please
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #528 on: October 10, 2014, 04:53:22 PM »
The pipe needs to turn in closer to the fender. To do that I cut several wedge shaped sections from the pipe then fit them to get the radius going in the direction I need it to
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #529 on: October 10, 2014, 04:54:42 PM »
I was able to turn this pipe inward to the correct angle with just three sections
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #530 on: October 10, 2014, 04:55:54 PM »
I welded these sections from the inside, then made a pass around the outside, then ground off the excess on the outside. Once I get it all fitted, I will finish it with body filler and it will get all "One piece lookin'
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #531 on: October 10, 2014, 04:57:02 PM »
Here it is temporarily assembled to the upper pipe
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #532 on: October 10, 2014, 04:57:54 PM »
Three paint paddles supply the needed clearance from the fender I will need to build in a base plate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #533 on: October 10, 2014, 04:58:52 PM »
Here is more of the lower section, but more still to come
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #534 on: October 10, 2014, 05:00:03 PM »
The piece that will turn into the fender is another 45 pipe section with some additional wedges welded onto the end to make the complete transition into the inner realms of the fender world
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #535 on: October 10, 2014, 05:00:53 PM »
It will fit something like this:
« Last Edit: October 10, 2014, 05:02:01 PM by Flyin6 »
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #536 on: October 10, 2014, 05:03:05 PM »
I'm not super impressed with my "turnmanship" with respect to that pipe, but it still isn't done, so I'll withhold my judgment until after I get it done
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #537 on: October 10, 2014, 05:05:12 PM »
Quote:
Originally Posted by Cudakidd53 View Post
Glad you're moving around and all- now go rebuild grey matter! 

Thank all of you for the out-pouring of concern. It was just a silly fall, and didn't hurt much more than my butt and ego, really, not so much the ego.

I want to take a moment to thank all you wonderful people for showing a genuine concern. Although the fall was not a big deal, you all treated it as though it was a potential end of life possibility, and to be analytically correct, perhaps it might have been.

That made me think. It could have suddenly ended my life. One moment, I'm blissfully tacking in a weld, the next I'm asking Saint Peter "What's with the beautiful Pearly gate?

Isn't that the way life goes for some of us? You hear about this person or that who suddenly died in a violent car crash or dropped dead from a heart attack? In my line of business, I remember Sonny, a fellow pilot. He flew little bird guns. One day in Panama during Just Cause, I went out to refuel some other aircraft with my huge gas filled chinook, and he off to support the Seals we inserted, well, I inserted, the night before. I came back all tired, hot and sweaty into that packed hangar on Howard air for base in Panama city to find the mood changed. When I asked what's up, a fellow aviator told me Sonny's dead. Just like that! No, hey, Don, I have something to tell you. Nope, Just Sonny's dead, and so is Lieutenant Hunter...

I had my own moment. Happened in Baghdad in 2005. Well I guess I had more than one. Some missiles trying to turn my chinook into burning scrap metal in Desert Storm, and others. But for those of you who read my book, you would probably agree, Baghdad was a moment in time when God could easily have snatched me off the earth and that would have seemed like the natural result for what was going on at the time. But he didn't, and in some crazy way, I consider my time since then "Extra credit."

What it makes me think about is what if we die? We all do you know. Man, I hope I'm not breaking the news to anyone here, sure hate to mess up your day. But this IS THE POINT. If you are playing around with the concept of maybe getting to know God, say a few weeks, months before the date you imagine, or when the doctor marks your forehead with a capital "C," then let me tell you, you're really taking a huge chance.

Heaven is for real. Hell is for real. There is a God who created all of this and there is a devil waiting in the shadows. And he is hoping you don't get a message such as this...Just an old guy pointing out the obvious, devoid of PC or reservation. I have earned the right and now I get to tell the truth all the time, and I don't and really never have cared what anyone thinks about it and I don't now. You don't like what Don is saying, flip the channel. But if you want one guy for once to look you in the eyeball from 3 inches and tell you the spittin' truth, well, I guess I'd be your man.

That fall could have killed me. And that would have been a great thing for me! Not for my sons, or wife, but for me, no more hell to deal with on earth. No more wars. No more young men dying on board my aircraft, no more horrible stories of little girls forced into prostitution, no heroin, no disease, no bad weather or old coffee...heaven.

But God gave me (and that helicopter) more time. I plan to use it for him. He is what matters to me. I hate to burst anyone's bubble, but this truck here means very little if the truth be known. It is only important in that it provides this forum, this arena where we come to know one another and share the truth and build up each other. We get to introduce some of our readership to the creator of the universe and for that simple fact alone, I am overjoyed to the point of tears, than my Father and his son Jesus the Christ gave me the breath needed to write and post this.

Think about it...Get it done before you fall...

The Peace of God be with you my friends!
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NSDQ      Author of the books: Distant Thunder and Thoren

Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #538 on: October 10, 2014, 05:15:19 PM »
I see you all have been busy! Good, that kept you out of trouble for a while longer.

OK here's what I think of my snorkel work so far:
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #539 on: October 10, 2014, 05:16:05 PM »
My "dislocated shoulder lookin' thing got deep 6'ed. and I started anew with a new idea I had right after the entry I posted this morning.

I'm going to bring a short section of pipe down into a steel box, welded to a "Fender plate" and run a steel rectangle section forward to a hole in the fender where it will dump into the inner fender cavity

Here's the fender plate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #540 on: October 10, 2014, 05:17:50 PM »
Cleco's will hold it all in place while it gets assembled piece by custom fit piece
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #541 on: October 10, 2014, 05:19:14 PM »
I used 16 gage for the fender mount and 11 and 12 gage for the air chamber parts. That stuff is about 1/8" thick and will be pretty strong

The next thing was to fit a square section to the pipe and tack it up to the fender plate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #542 on: October 10, 2014, 05:20:16 PM »
No rocket science yet, just simple cutting of plate steel.

Next I welded up that assembly and trimmed it to the shape I wanted
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #543 on: October 10, 2014, 05:21:44 PM »
The voids will bet filled in later. Here is the trimmed panel home where it will live in harmony with lots of other parts:
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #544 on: October 10, 2014, 05:23:07 PM »
Where the pipe enters this chamber will be a collection spot for water sucked in from above. I wanted a means of evacuating that water, so I used this cool land-rover part from the British military Rovers. Suction pinches the rubber together, but the weight of water easily blows through and drips onto the ground, and out of the intake air
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #545 on: October 10, 2014, 05:24:16 PM »
That gets welded to the bottom panel of the collection-plenum
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #546 on: October 10, 2014, 05:25:07 PM »
Now the laborious process of closing in the "Box" begins, adding piece by piece
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #547 on: October 10, 2014, 05:25:55 PM »
Then the outside
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #548 on: October 10, 2014, 05:26:35 PM »
Next the transition tunnel bottom
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #549 on: October 10, 2014, 05:27:37 PM »
Then the top, and a triangle section
Site owner    Isaiah 6:8, Psalm 91 
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