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Author Topic: SquareD Part 2 Here's where we depart the rebuild and start the big change  (Read 75631 times)

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Online Flyin6

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It's difficult to call the exact point where this project changes or turns the corner between the phase it was in to the next evolution.

With the adding of the Ruff-Stuff shock brackets, double shear hard core off road parts, I'll call the ball right here.

« Last Edit: November 22, 2014, 06:38:25 PM by Flyin6 »
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The first order of business was to weld the inside piece to the body with the proper clearance
I used one of my many mock-up shocks to get that right
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Then it was welded to the housing in as close to the factory position as I could make it
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The rear axle is starting to look like something again.
This new setup will have nothing hanging below the tubes unlike the factory snag-o-matic setup. It will have a rear anti sway bar, a traction bar, and double shear and protected lower shock mounts.
Should be Hyundai proof!

The downward tilt is intentional, to match the factory geometry
Site owner    IS 6:8  Psalm 91 
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All right you worthless lot, let's get some hot roddin done here, so I can go get some extra beauty sleepin!

Today was supposed to be brake build and axle reassembly day. Well, should the truth be known, Tuesday was that day, Wednesday, axle installation, and today, door of fender pullin and fixin' on day

Life continues despite the plans we make for it I guess!

So anyhow, I assembled the other backing plate onto the axle tube using the bead of RTV
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The concept was to get all these boxes into the trash so I could enjoy a couple weeks of jap maple leaves before the ice age commeth

Wasn't to happen, but I pulled the boxes thinking...
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The new wheel cylinders were rust-o-matic gray iron, so I gave em' a coat of J Deere's finest!
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They look new don't they?

Well, that's because they are!

Here's where it got interesting.

You see those wheel cylinders are not all that is necessary to connect those hydraulic cylinders to the brake shoe.
Nope, it tales a piston "strut" sticking out fo either end to get that done.

Funny thing is mine went into the bowels of the great white and green garbage truck! Sill me, I was thinking the parts kit to replace EVERYTHING hardware related contained these pieces of hardware. I guess something in their nature precludes them from hardware status LIKE EVERYTHING ELSE in the kit...So bottom line is I was suddenly short (Litterally) 4 strut pieces/parts.

I soon found out that these little cylinder lookin things with a slot in the end are not carried in any parts store. Neither can they even reference them. It's as if all that were ever needed were already built and there is no possibility that they could ever possibly rust of corrode in the ultra
clean environment of a brake drum!

Not to be defeated so easily, I ordered 4 which an on the ball parts guy was able to conjure up some spirits of great mechanics and parts guys past and locate 4 of the things. Get this, all four are coming in from 4 different states!

Anyway I bolted in the parking brake lever.
It's probably in backwards, I'll figure that out when somehow nothing else fits right!
But I have this to help me along again!
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It's real, it's old, and it still works, kinda like me, not so much Duane, but me for sure!

First I replaced the front pinion seal...Should have done this when I had it apart, but that would have been too easy...Made too much sense!
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10 min job. all that mess got cleaned sanded smooth and put back together with precision hammer blows!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #10 on: October 05, 2014, 03:29:53 PM »
With that done. back to the brakes

Here's the parts that almost got reinstalled:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #11 on: October 05, 2014, 03:30:39 PM »
 stuck this on to get some color going on in that sea of gray
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #12 on: October 05, 2014, 03:31:27 PM »
Then I started running brake lines
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #13 on: October 05, 2014, 03:32:30 PM »
That rubber hose is a stock (new) dodge part. Fit like freckles on a redhead!

Then I got all creative and said to myself, "Self, I should drill and tap some holes in this thing to mount some clamps to!"

So I did
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #14 on: October 05, 2014, 03:33:41 PM »
I can't wait to get Shawn's cover onto that axle and really make it all Purdy!

Earlier today, I went over to a truck repair shop and had them make me up the new U-Bolts for the U-bolt flip I am doing when the axle assembly is reinstalled
They are 3.5" diameter, 5/8" X 13"
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #15 on: October 05, 2014, 03:35:11 PM »
Just getting back from a show at a local church...
The guy who did the sand table drawing...Joe _____

He did several presentations and all I can say is his work is divinely inspired. So amazing, you have to witness it in first person to believe it!

Anyway, Let's post up todays snail pace work.

The goal was to get the brakes all the way to axles installed, but I ran out of minutes and was caught short!

First let me start by saying adieu to my faithful old Fuji camera. That thing followed me all over hells half acre. Lived in my helmet bag in Iraq and Afghanistan. Saw countries all over several continents too numerous to mention. From what I can recall and piece together, that camera is responsible for some 17,000 photos stored here alone!

At the end of it's life, shown here the batteries would only last an hour on a full charge...The lens was pock-marked with welding spatter, and the battery lid was held closed with tape!

Goodbye faithful Fuji-son
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #16 on: October 05, 2014, 03:35:50 PM »
Finally got around to painting the axle bolts
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #17 on: October 05, 2014, 03:36:44 PM »
Had to make another parts run today to fetch these little wheel cylinder feet
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #18 on: October 05, 2014, 03:37:44 PM »
Next I finished running and mounting the new brake lines

Nate, I moved the line on the drivers side...Meet with your approval?
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #21 on: October 05, 2014, 03:40:56 PM »
The hub received a new seal before being installed
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #22 on: October 05, 2014, 03:41:48 PM »
Then that piece went on and was tightened with this strange looking socket
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #24 on: October 05, 2014, 03:44:21 PM »
I had just started on the other side when I got the call to cease and desist operations and get ready for church. When the woman calls, I start hopping!

I hate that about myself!

Here's how far I got today
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #25 on: October 05, 2014, 03:45:32 PM »
Quote:
Originally Posted by nmeyer414 View Post
fat fingers on a cell phone. sorry.

what is the new camera? did mr.fujison get a proper burial or did he just get the chunk?

Mr, Fuji-son will go out in style...

If I go down to the farm this weekend

I plan on putting him on a fence post

Then back off about 100 meters

Then using a single 168gr national match 7.62 boat tail fired from my M1A national Match Springfield...

Send Mr. Fuji-son out with a proper soldiers death!

Remember in my book, the picture of me holding the roll of 100mph tape shot in half by an AK? He took that shot!
The pic of the AK-47 modified rotor system...same thing
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #26 on: October 05, 2014, 03:46:07 PM »
Remember how my first laptop went out back in Kandahar?
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #27 on: October 05, 2014, 03:53:27 PM »
Got some more done and again, some parts came in and I installed them within hours of showing up at the door!
How cool (and different) is that!

Anyway, I finished building up the axle starting with the remaining brakes install

I brushed everything with the Shark Hide preservative. It is a strong thinner based material. It had softened some of the black which I managed to drag all over the pretty gray stuff...
Oh well, it did look pretty once, and now it's starting to look weathered already
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #28 on: October 05, 2014, 03:54:05 PM »
I followed that up with the remainder of the axle assembly
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #29 on: October 05, 2014, 03:54:48 PM »
Even though I had previously planned to install Shawn's excellent cover after bolting in the axle, I decided to stick it on now. I was anticipating the bolts I ordered to arrive tonight (Which they didn't) so I temporarily slapped on a few bolts to hold it in place while the RTV set up
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #30 on: October 05, 2014, 03:55:55 PM »
Next I started prepping up the parts to actually bolt the axle back to the springs.

I had the U-bolts already, but the mail man dropped off a box containing the spring plates from Ruff Stuff
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #31 on: October 05, 2014, 03:56:46 PM »
While all that was drying in the sun, I coated the U=bolts with the shark hide. It is all that is needed to keep those bolts looking good for hours, if not days!
No really, the stuff looks and works pretty well for a couple of years.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #32 on: October 05, 2014, 03:57:27 PM »
Back to the axle, time to tidy everything up and ready it to slide in place under the truck.

I secured the parking brake cables and adjusted some brake lines
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #33 on: October 05, 2014, 03:58:58 PM »
Allowing some time for the shark hide to properly dry, I started disassembly of the front hubs

I need to have the rotors turned and trued up and convert the hubs from 1/2" studs to 9/16 long studs
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #34 on: October 05, 2014, 04:00:28 PM »
The hide dried, some chicken got fried, and a skunk died (really!)

So I decided to slap in that big sterling tonight
Here it is going in:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #35 on: October 05, 2014, 04:01:24 PM »
It's in!
Torqued and hangin

Now if the driveshaft still fits....
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #36 on: October 05, 2014, 04:02:12 PM »
Well, close but no Ce-gar!

The factory shaft is about 1/2" too long!

Pretty close, but it needs to be shortened

I'll drop it off for the surgery tomorrow
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #37 on: October 05, 2014, 04:04:26 PM »
Quote:
Originally Posted by dkami712 View Post
Where's the evening update? I need my littercher, can't finish your book too fast otherwise I'll have nothing enjoyable to read!

Funny...

OK, here you are:

Today was a bunch of running around and a little work

Duane and I went up to Cincinnati driveline, a driveshaft and hydraulics shop with a big selection of mandrel 3",4",5",6" mandrel bends for semi trucks.

I was sort of starting to think shorkel...but I'm drifting again.

So I decided to have them do the whole schbang on that driveshaft so's eyes kan put it rite bak in thar wit know problem whatsoever!

Needing a fix of proper wrenchin myself, I had to do something.

I thought about my PRI (Parts reduction initiative) and my hawkish eyes fell upon the shiney painted stuff that is starting to crowd up the bed of the truck.

So's eyes grabs up a sway bar and git to wrenchin'

Here's the situation before the frontal assault of shiny new parts:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #38 on: October 05, 2014, 04:05:15 PM »
The reinstallation of the factory F350 sway bar was straight forward. I purchased some replacement rubber bushings which fit like they were made just for this application!

I decided to stick with rubber because this is no canyon racing slot car and I feel a bit of give will trump razor sharp handling, considering we're talking about a crossover vehicle here (Cross between a truck and a tractor)
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #39 on: October 05, 2014, 04:06:18 PM »
The alignment with the bar ends and the frame rails is about perfect!
All I'll need to do to get the end links to connect up will be to fab up some simple "L" brackets with a hole for a simple factory single shear mounting
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #40 on: October 05, 2014, 04:07:55 PM »
I took the original end links which had been previously painted and fitted them with some new hardware and just like that, they are almost ready to make leaning and rolling over in turns a thing of the past!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #41 on: October 05, 2014, 04:10:05 PM »
Quote:
Originally Posted by TexasRedNeck View Post
Yeah, actually 11K aint bad. Between the built tranny and injectors in my 2001 I have 12K in it not counting the CP3, etc etc. The more I think about it the more I need to sell that money pit. I like the mechanical injector SHTF EMP proof concept of what you have going. Carry on sir!

I like both
And that's why I have both concepts going on. The D-Max is by far the more capable vehicle, but any shenanigans by the N Koreans or Chinese and all that electronic stuff is just in the way. Good to have a farm-all tractor wrapped in a Dodge chassis to handle the worst case scenario.

The more I look into these 12 valves and the horsepower you can get out of them vs cost, we ought to just shut our traps and observe. The mech injection Cummins crowd have something going on.
My truck comes with 160 HP/ 400 torque. You can adjust the pump to add about 90 horsepower. You add a fuel pin @ $150 and a gov spring @ $25 and you added another 40 or so and RPM for days. A turbo and injectors adds maybe $1600 and you are making more power than a LML and with 20+ MPG

One guy I know pours the used engine oil right into his fuel tank when he changes it! THey run on anything that you can fool the motor into thinking is fuel.
Motor mounts are $15 ea., everything is just cheap. And there isn't a maze of wires everywhere. Plus the thing without all the modern crap which we really don't need, barely weighs 6,000 lbs! That's amazing...Our LML's weigh in excess of 8,000! Mine is 8700!
Yup, these 12 valves at a minimum make great backup vehicles, and for the time being, the 1st gen trucks are largely overlooked because they don't have inline P-Pumps which are capable of 600-700 or more horsepower easily!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #42 on: October 05, 2014, 04:11:00 PM »
Got a call, the driveshaft is done, but guess what?

It was bent!

Cincy driveline said they had to straighten it when they balanced it, so in the final analysis, I'm darned happy I had them do it. I'll go up and pick it up tomorrow and get a new coat of paint on it. Should have it mounted by Saturday...Another foot down field!

My goal for today was just to get the front axle disassembled, hub out and evaluate those parts. Did that and moved on from there

Here's how far I had already gotten on the hub
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #43 on: October 05, 2014, 04:12:07 PM »
The second pic shows my discovery, a large outer snap ring holding the hub locking mechanism in the hub. With that out it was a straight forward removal deal
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #44 on: October 05, 2014, 04:13:04 PM »
8 studs actually pin the rotor to the hum, they are simply pulled or tapped into place.
I am upgrading from 1/2" up to 9/16" so I banged them out and separated the two units
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #45 on: October 05, 2014, 04:14:02 PM »
I ran the rotors over to O'Rileys auto parts to be turned. While there we fished around until we came up with the new replacement stud. Old shank was .658", new shank is .677" so I'll open up the holes in the hub just a tad
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #46 on: October 05, 2014, 04:15:16 PM »
There's a whole bunch of additional holding power with those new studs, and since they are longer I can use a deep lug nut as well

Back to the front axle I continued tearing it down
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #47 on: October 05, 2014, 04:15:59 PM »
Leaving me with this:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #48 on: October 05, 2014, 04:16:53 PM »
That will get cleaned and painted as well so the reassembled unit will look as good as it can.

Since the blast cabinet failed to function again, even after me fussing with it for longer than I cared to, I went to work with the wire cup on the big grinder, ultimately producing these:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #49 on: October 05, 2014, 04:17:34 PM »
Then the rust converter went to work doing it's thing
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