Author Topic: SquareD Part 2 Here's where we depart the rebuild and start the big change (Read 118137 times)

Flyin6 · « **Reply #200 on:** October 05, 2014, 07:05:46 PM »

Here's the back side:

Flyin6 · « **Reply #201 on:** October 05, 2014, 07:06:46 PM »

I sort of like the contrast between the semi flat paint and the stainless hardware

Flyin6 · « **Reply #202 on:** October 05, 2014, 07:08:00 PM »

I have to admit to a mistake here
I ordered the wrong color OD!
I wanted the 24087 darker green OD which was sprayed on my M60A1 main battle tank way back in the day before M1 Abrams came and screwed the tank scene all up.
I ordered the WII OD green which is a lighter green with some brown in it. I sprayed that block on the bed and was immediately surprised to see it. Then I sat and thought about it and thought, what the heck, my dad's B17 was adorned with that paint, that's good enough for me!
Then I found some pics of trucks done with it and did not like it...hmmm
I spent almost $200 for the wrong paint and it isn't going back, but I don't like it.
Well Tuesday, I bit the bullet and ordered the correct paint, semi gloss OD green circa 1957-present. I guess Duane already has the paint for that SEMA award winning Cobra he has, good for him!
But I just had to paint something with that cool stuff, so I did, can you see it?

Flyin6 · « **Reply #203 on:** October 05, 2014, 07:08:48 PM »

Then I started running the brake line. After re-flaring the 60" first section so I could use the strange fitting on the proportioning valve I mounted that up.

That line will join another, then run into the adjustable prop valve, then into the flex hose to complete the circuit.

Flyin6 · « **Reply #204 on:** October 05, 2014, 07:09:42 PM »

I trust everyone is having a splendid weekend!

So on a cool Saturday evening let's build some more of Square D

Today I started with a side project. I have had some Issrpo gages on order for weeks now, and they finally showed up, well some of them. I am still missing the tachometer!

I just didn't want to add that box to the stack already there, so I decided to at least "Store" the gages in the vehicle.
You may recall, I chose a 2 gage pillar mount earlier

Flyin6 · « **Reply #205 on:** October 05, 2014, 07:10:48 PM »

I wanted simple analog gages and that's what I thought I purchased, however the Pyro gage has some sort of processor box, so it is not a simple probe with Chromel/Alumel di-electric metal.
May have to can that gage on a future mod and replace it with an aircraft part.

The 2.25" gages seemed appropriate for this application

Flyin6 · « **Reply #206 on:** October 05, 2014, 07:18:15 PM »

The gages are oriented so that the 12:00 position means trouble. That way you get a quick scan and if things are pointing at the moon, get out of the throttle. It's an old Army night vision goggle flying trick.

I prewired everything and bundled the cable up prior to mounting (of course!)

Flyin6 · « **Reply #207 on:** October 05, 2014, 07:19:40 PM »

I found the nylon rivets to be unsat. so I used wire ties instead to secure the assembly. It may not look show car pretty, but it is strong and will work

Flyin6 · « **Reply #208 on:** October 05, 2014, 07:21:30 PM »

For now, I'll leave the convoluted tube cable assembly tucked in out of the way and zip-tied to some trim. Later on I may work with that a little more

Flyin6 · « **Reply #209 on:** October 05, 2014, 07:23:16 PM »

That's enough of that for now, the parts did not get stacked, but semi installed, so I feel the project is still moving forward.

Next, back to running the lines. Yesterday I had started the first 60" of line, today I ran it all the way back. This is what it all connects to:

Flyin6 · « **Reply #210 on:** October 05, 2014, 07:24:28 PM »

The mount is a simple 1" piece of rectangle steel tubing. I looked at various mounting locations. I did not want to drill any holes into the frame, so the available holes drove the actual mounting location to a large extent.

Flyin6 · « **Reply #211 on:** October 05, 2014, 07:25:29 PM »

The lower position proved to be optimum, offering the ability to screw into the mount from two different planes.
Here it is in a test fit

Flyin6 · « **Reply #212 on:** October 05, 2014, 07:26:50 PM »

Then the proportioning valve was drilled in as well. All holes were tapped so that a fastener can simply screw into the mount itself

Flyin6 · « **Reply #213 on:** October 05, 2014, 07:28:07 PM »

That all got temporarily mounted so that the brake lines could be bent up to fit.

This setup completely eliminates the crappy rear wheel anti-lock junk

Flyin6 · « **Reply #214 on:** October 05, 2014, 07:29:15 PM »

Then the brake lines were bent up and mounted, completing the brake circuit

Flyin6 · « **Reply #215 on:** October 05, 2014, 07:30:32 PM »

With that all in the bag, the mount was removed for painting.

I think I found a use for the unused WWII OD Green!

Flyin6 · « **Reply #216 on:** October 05, 2014, 07:31:55 PM »

Next is the fuel lines. The supply line will go in after the tank is remounted, however, I wanted to get it started at the motor end with the pump fitting and the flex line that will run to the filter.

Flyin6 · « **Reply #217 on:** October 05, 2014, 07:32:38 PM »

I have to find a home for this piece of equipment:

Flyin6 · « **Reply #218 on:** October 05, 2014, 07:33:11 PM »

But before that, and in preparation for the reinstallation of the fuel tank, I cleaned and reinstalled these frame bumpers which keep the fuel tank from rubbing on anything hard

Flyin6 · « **Reply #219 on:** October 05, 2014, 07:34:04 PM »

I upsized the factory 1/4" return line to 5/16" in preparation for greater volume.
Here is the start of that line installation.
Once this line is in, I can remount the fuel tank

Flyin6 · « **Reply #220 on:** October 05, 2014, 07:35:00 PM »

The driveshaft is only a few bolts away from finding a new home and connecting propulsion to drive train.

That was it for today, here's what it looks like at the moment:

Flyin6 · « **Reply #221 on:** October 05, 2014, 07:35:49 PM »

:
Originally Posted by wally_gator View Post
Just a question here...
Did I read that you planned to Box the frame?
If so, do you plan on Boxing in the Brake and Fuel lines?
Or will you re-mount them after the Boxing?

I am not going to box the whole frame

I will box in some areas up front to strengthen the areas where new shock towers will now carry the vehicle weight, but little more

I plan to use another technique

More of an exo-skeleton approach

I have done it before, and it adds a ton of strength and rigidity to the factory frame
__________________

Flyin6 · « **Reply #222 on:** October 05, 2014, 07:36:51 PM »

Quote:
Originally Posted by nmeyer414 View Post
Here is my question.

Why did you mount the valve in such a way that it hangs below the frame? Does it have to hang that way? Would it not make more sense to mount it parallel to the marching surface to further prevent something from jumping up and snatching it off the truck or damaging the lines?

Nate

It is mounted that way so that I have access to it from the outside. Say I want to increase rear braking, I just reach in and give the knob a twist.

Now as for being protected, first it is as high up in the frame as you can get, then the axle, shocks and so forth are right in front. The chances of something getting way up there are up there with getting struck by a meteor. Finally, there is a integrated bumper/protection system coming up which is yet to be built. That will settle all questions of anything getting damaged

Flyin6 · « **Reply #223 on:** October 05, 2014, 07:37:35 PM »

Quote:
Originally Posted by Dustoff 35 View Post
X 2. Interesting location for a proportioning valve. Why not under the hood near the MC? That's where I've always seen them located.

Remember where I located the same valve on the SAS Tundra build???

Same location as with Square D.

So I have some actual experience with the valve being there behind the wheel way high up on the frame

Flyin6 · « **Reply #224 on:** October 05, 2014, 07:40:23 PM »

Quote:
Originally Posted by nmeyer414 View Post
poochie would have to go back as well! the only time I will tolerate a dog biting somebody is when he is protecting my wife or the kids/grandkids.

don, I have been thinking about your break valve that you installed and your gauge pillar. you are a very detail oriented person, and you truly display the "do it right the first time" concept. with that said, the gauge pillar with the zip ties looks kind of cheesy? also I have been thinking about the break valve that you installed. can it get turned sideways like 90 deg, so that the handle is not facing the ground? what about some sort of a shield or bracket to go around it? just offering a different perspective here?

Nate,

I would counter that what we have here is a difference in perspective. You see a zip tie as a cheesy thing, and prefer the plastic pop rivets, I'm guessing? That is all fine from your perspective, but the zip tie is way stronger and more positive. The plastic rivets failed to hold the gage pillar mount in place, whereas this zip tie will absolutely hold it. Plus I can take a pair of pliers, cut the tie and gain access quickly for a repair.

It's more a question of looks with regard to personal preference. Some would not like the zip tie look, whereas, I see it as all business, and that's all that I care about. Looks means nothing to me really, but function counts. I just see the beauty in a thing through it's function.

With regard to the prop valve, if I rotated it 90 degrees one of the brake lines would be protruding downward. If I rotated it 90 degrees in the horizontal axis, it would over complicate the mount in my view.
Finally, this is not done, only mounted. I don't know what sort of thing I am going to do back there just yet. I want to look at it after building the rear bumper/crash bar thing.

Let's look at all of that detail after the primary design gets installed.

Flyin6 · « **Reply #225 on:** October 05, 2014, 07:41:56 PM »

Quote:
Originally Posted by dkami712 View Post
Don, I think that brake valve has created the most controversy out of any of your build threads!

Thats unfortunate...I would say that was the soul of the organization and maybe still is sort of. Now I see the BSA as being a daycare for parents who don't want to actually parent their children. Most drop the boys off for meetings and love when they're gone for a weekend campout. 10% actually are engaged and care about what they are learning. I wouldn't have half the skills I do if it weren't for great leaders that cared and my parents.

Controversy??
Or discussion?

I welcome it!

There are a bunch of smart guys reading this. Who wouldn't welcome constructive criticism? I certainly do! I don't have to respond/do/change anything, but more than once we have seen a reader catch something I did that was wrong (Front brakes!)
So, no, not controversy but just guys talking, and when is the last time guys agreed over anything?

Reminds me of a joke I heard

What's the only thing that two pilots can agree on?

Answer: The incompetency of a Black Hawk pilot who is not there to defend himself!

Flyin6 · « **Reply #226 on:** October 05, 2014, 07:44:11 PM »

Rotate the valve up 90 degrees, temporarily remove handle. Stick thru frame reinstall handle on outside of frame rail, make new mount protected from below, re plumb lines. All better now......

Quote:
Originally Posted by flyin6 View Post
With regard to the prop valve, if I rotated it 90 degrees one of the brake lines would be protruding downward. If I rotated it 90 degrees in the horizontal axis, it would over complicate the mount in my view.
Finally, this is not done, only mounted. I don't know what sort of thing I am going to do back there just yet. I want to look at it after building the rear bumper/crash bar thing.

Let's look at all of that detail after the primary design gets installed.

I figured I had better chime in, well because I normally do when Don makes something fugly. Anyone recall that 11.5 AAM cover paint job????

Flyin6 · « **Reply #227 on:** October 05, 2014, 07:45:22 PM »

Enough of this DOTT
(DOT Talk)

Let's look at some pictures

I didn't do squat today

But the big yellow truck showed up with some heavy parts:

Flyin6 · « **Reply #228 on:** October 05, 2014, 07:46:35 PM »

I'm sure the neighbors are more than thrilled that ANOTHER stack of tires has materialized in my driveway!

No worries, they won't say anything (To my face anyway)

You can see there is a bit of a difference between the 285/85's and the new 37" 12.50 R 16.5's

Flyin6 · « **Reply #229 on:** October 05, 2014, 07:47:49 PM »

The tires were new to very slightly used

Tall and narrow, a perfect recipe for good traction in the woods and in mud.

The tread seems to measure somewhere between 9" and 10" and the height is 36.75"

Flyin6 · « **Reply #230 on:** October 05, 2014, 07:48:32 PM »

Ya know, when Shawn called me out the other day over chickening out and going coil-overs he really got me to thinking.

Coilovers are easy. Tab on the bottom, hoop on the top and yer dun!

OK, I'm good with that, although I do enjoy more of a fab challenge (FABCHAL)
ANd, yesterday while talking to Beau at WFO Concepts, we really started to kick around the coil spring/shock thing. I admit I am drawn to the idea because it is dirt simple...hmmm...combat stuff

complicated: not so much
Simple: good

Sorta matches my mind...

Anyway, Beau is quite the character. When you talk to him about something, he really gets into it.

He and I were talking for some time about how to do the brakes on this upcoming D-Max SAS, me wanting to use 14" rotors, anti-lock and the factory calipers and so forth. Well, Beau goes out and buys everything and starts mocking up and CNC'ing parts to see what he can figure out. That has been why the SAS LML project got delayed, we just need more time to figure all that out.
Well, he did it again
A few weeks ago I was talking to him about linking up the Dodge and he was off figuring out how to modify his existing HPD60 Ford F350 brackets to friendly up with the Dodge, when he bought a Dodge Dana 60! One of the guys who worked in his shop has a square Dodge and Beau was using that truck and his axle to figure out the brackets. Once those are figured out (I decided to just let him science it out while I mess with paint, wheels, and cylinder heads!
Anyway, last night we really got into the coil spring conversation. Using second gen coil springs, Beau says he wants to get in there and see how everything might fit together using that stuff. That would be easy (easier) since those springs already know a Cummins engine. Figure I get a set of 6" or 8" lift springs and I should be in there. Then just put a longer shock in there and voila, coil spring link suspension.
Anyway, without a 100% commitment, I am marching in that direction at least to do a feasibility study.
We'll see...

Flyin6 · « **Reply #231 on:** October 05, 2014, 07:50:49 PM »

Originally Posted by nmeyer414 View Post
all the while sittin and listenin to the barking bird, wonderin what the sled dog is chewin on, drinkin some leaded sweet tea, wonderin what animal of the neighbors the dog is tryin to kill and eat...............

There's a lot of stuff to ponder there Sergeant Nate.

You'll appreciate this.

First mod, fix the cheesy wire tie instrument thing

Here's how that happened:

You satisfied?

Flyin6 · « **Reply #232 on:** October 05, 2014, 07:51:30 PM »

The goal today was to mount the fuel filter, plumb in the lines and be ready to hang the fuel tank.
I did not meet my objectives.
I did get down that road pretty well though. First here is the chosen location for the fuel/water separator:

Flyin6 · « **Reply #233 on:** October 05, 2014, 07:53:04 PM »

It is well protected next to the transfer case and attaches to the cross member and to the frame.

First I fashioned up the lower foot

Flyin6 · « **Reply #234 on:** October 05, 2014, 07:54:25 PM »

Then the bolt holes using preexisting holes

Flyin6 · « **Reply #235 on:** October 05, 2014, 07:55:38 PM »

Now the frame foot
I captured two bolts which secure the parking brake cable and a pre existing hole below

Flyin6 · « **Reply #236 on:** October 05, 2014, 07:56:44 PM »

Then cut off a 5.5" length of 3" strap and bent it into an "L"

Flyin6 · « **Reply #237 on:** October 05, 2014, 07:57:49 PM »

Next, to connect the two feet, I chose some trusty 1 X 1 salvaged from the tactical topper project, may it rest in peace...

Flyin6 · « **Reply #238 on:** October 05, 2014, 07:58:41 PM »

Then for some welding and reinforcing, over to the handy stool/welding table

Flyin6 · « **Reply #239 on:** October 05, 2014, 07:59:54 PM »

Then, plasma torch in hand and a piece of 1 X 3 x 3/16" the sparks went ah flyin' and this came out of the mayhem:

Flyin6 · « **Reply #240 on:** October 05, 2014, 08:01:09 PM »

I went with 1/4" bolts welded on one end and suspended through 3/8" holes so that there would be room for vibration attenuation and an even pull on the bolt shanks, and because I just wanted to do it that way!

That got welded onto the developing filter mount

Flyin6 · « **Reply #241 on:** October 05, 2014, 08:01:50 PM »

Then I shaped up the brace somewhat

Flyin6 · « **Reply #242 on:** October 05, 2014, 08:02:37 PM »

I tack welded that to the feet, unbolted the assembly, then finish welded it.
I forgot to take pictures because the red dog was up to its stealing tricks again and I was distracted with thoughts of strangling small animals and things like that.

So after some wire brushing because Duane still hasn't brought over the blast cabinet spray gun, I placed the things into the hanging jungle and did the paint dance

Flyin6 · « **Reply #243 on:** October 05, 2014, 08:03:25 PM »

The brown truck brought something:

Worlds smallest tach!

Flyin6 · « **Reply #244 on:** October 05, 2014, 08:04:13 PM »

And this is what History recorded as the CGS (Current garage situation)

Flyin6 · « **Reply #245 on:** October 05, 2014, 08:06:37 PM »

Quote:
Originally Posted by jms89 View Post
I love the new wheel/tire setup! After you are done with suspension modifications, are you going to need to trim the fenders up front for clearance?

I am going to cut a portion of the front fender away.

If you look at the part that hangs below the top plane of the bumper...Say your good-byes to that piece. It includes the side marker light, so I will recess that light into the wrap around road block ramming bumper thing I plan to construct.

Now, mostly, the tires catch on that front corner, which will no longer be there. I'll taper the bumper to afford more room, after I look at what might hit.

The rear of the truck bed will get the same treatment. Everything on the bed below the top plane of the rear bumper will be removed, then the warp around rear bumper/armor deal will occupy that space and protrude outboard some so I can rub against things without getting into Dodge epidermis.

We'll have to see how it all wraps up when the wheels get re-centered and I roll them up there. I have a sneaking suspicion the truck is going up a bit more in height (suspension) so that I can build in bump stops that control all that without carving up those classic lines too very much.

Flyin6 · « **Reply #246 on:** October 05, 2014, 08:07:51 PM »

I'd answer more questions, but the woman is yelling at me to come spend some time with her.
So, it will have to wait
Oh, gotta mention the gray Shepherd is talking up a storm.

We were sitting at the dinner table tonight and that darned bird said, "You better eat everything on your plate, Dammit!"
Can you flippin believe that? I said that to the little Ranger last night...Darned bird was paying attention.

Today I kept hearing the smoke detector beep. I was looking all over but no flashing lights

You guessed it, the bird!

It's in there doing wolf calls and barking like a Chihuahua!

OK, I fan some fuel lines and stuff like that.

Here's the scene of the release of energy:

Flyin6 · « **Reply #247 on:** October 05, 2014, 08:08:52 PM »

After running down some fittings, I built up the filter assembly

Flyin6 · « **Reply #248 on:** October 05, 2014, 08:09:33 PM »

And the fuel tank sump

Flyin6 · « **Reply #249 on:** October 05, 2014, 08:10:31 PM »

Then installed the new filter mount