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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #50 on: October 05, 2014, 04:18:29 PM »
That stuff produces amazing results, don't you think?

Pics showing the current state of affairs in BDG (Big Don's Garage)
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #51 on: October 05, 2014, 04:19:13 PM »
You can see that I have made progress against the always growing stack of boxes. You can also see the jap maple...Isn't it pretty?
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #52 on: October 05, 2014, 04:20:08 PM »
Let's look into the future a little bit

Things to come:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #55 on: October 05, 2014, 04:22:37 PM »
The fuel system needs to be totally upgraded.
Starting with the stock tank, it will get this sump, 3/8 fuel line, a fuel water separator, a cool lift pump from Cummins and a new larger injection pump line
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #56 on: October 05, 2014, 04:23:17 PM »
Here's that cool Cummins high volume, higher pressure lift pump.

Again the simple beauty of this design comes shining through. No electric motor, just a simple mechanical device and costs 1/3rd what we pay for a lift pump!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #57 on: October 05, 2014, 04:23:54 PM »
This is how you remap the injection pump!

We pay an arm and a leg for a new program

12V Cummins guys buy this "Fuel pin" for less than $150. Same power increase as we enjoy and again, a simple steel mechanical unit!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #58 on: October 05, 2014, 04:24:44 PM »
I went to pick up my driveshaft

You may remember my saying it was bent. A more accurate description would be warped. I was picking it up and now talking to Joe, the owner of Cincy Driveline and I was asking how it got bent. He was explaining how the engine torque likely did it.

That's when I did the , "Excuse me..." "Engine torque" You see the stocker only has 400 ft lbs. I am turning it up to double that like, next week.
I mention this and he started shaking his head. Then spending some time looking over the shaft.

This isn't going to work, he reports, asking around the shop if anyone knew they were building a 400 HP driveshaft.
The stock Dodge driveshaft is 3" in diameter, and as it turns out, is completely inadequate for what I am going to do with the motor.
He proceeded to show me the enormous driveshaft he thinks I need. It could easily eat my whole driveshaft and still have room for a couple of kia fenders.
He went on to discover that conversion 1410 to 1350 joint and said, now what's up with this...He clearly did not like it.

He's a good guy, so he says, just give him my freshly rebuilt unit and he will find a 1410 yoke for the sterling and build a 3.4" or 4" driveshaft with way more splines on the slip shaft and make it so that I won't have to ever fuss with it again.

So that's why the driveshaft is not going in this weekend like I thought...Oh well
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #59 on: October 05, 2014, 04:25:43 PM »
Well lets get some nasty stuff lookin pretty tonight!

I continued the front axle teardown:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #60 on: October 05, 2014, 04:27:00 PM »
Ken, those roller bearings were in great shape. Looks as if someone packed the bearings somewhere along the way, the grease was everywhere and red in color...Not what I recall the Mopar guys at the stealership using.

Next the ganky axles came out.
Look at how big those are!
Any wonder why people seek out these Dana 60's!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #61 on: October 05, 2014, 04:27:53 PM »
Rust, rust, rust
I hate the stuff!
Seems like the most common substance found on my truck!
I don't know if I'm winning or it is
But I'm willing to take on the fight

The drivers side was a bit of a pickle, but it yielded after some determined strikes with my mallet
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #62 on: October 05, 2014, 04:28:57 PM »
I got industrial on this rust and these parts.
Pulled out the sand pressure blaster
Unlike that polishing cabinet, the sand made quick work of the rust, my goggles, and a stray dog
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #63 on: October 05, 2014, 04:29:37 PM »
 had the rotors trued up on a lathe...They too got the rust blast treatment
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #64 on: October 05, 2014, 04:30:06 PM »
I made quite the mess!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #65 on: October 05, 2014, 04:30:54 PM »
The parts I coated up last night turned out good. I scuffed them up, cleaned them with solvent, and hung them up in the jungle for a coat of that Purdy Lycoming gray
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #66 on: October 05, 2014, 04:32:10 PM »
The freshly blasted parts were cleaned again with brake cleaner, allowed to dry, then coated with the rust converter
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #67 on: October 05, 2014, 04:32:46 PM »
The hanging jungle, once again populated by formerly nasty parts
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #68 on: October 05, 2014, 04:33:23 PM »
I went one shade darker on the paint, but I really can't tell
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #69 on: October 05, 2014, 04:34:46 PM »
Some of the parts got a coat of the John Deere blitz black, and some got the Lycoming gray
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #70 on: October 05, 2014, 04:35:32 PM »
Like before, everything got 3 coats of the paint
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #71 on: October 05, 2014, 04:36:37 PM »
I took the knuckle back down to bare steel and recoated it. I couldn't get to all of it before when I wire brushed it, this time I did a lot better!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #72 on: October 05, 2014, 04:37:20 PM »
Dust is setting in!
If it gets much more, I'll have to scrap this project and start a new one!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #73 on: October 05, 2014, 04:37:54 PM »
Now let's use the "look ahead machine" to see what is coming up for Square D

The brakes are going to get a lot simpler. The anti lock, malfunction prone weight adding crap is going the way of this summer's watermelons!

I'll need some tuneability for those big rear brakes, so I got this adj. proportioning valve
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #74 on: October 05, 2014, 04:38:25 PM »
More suspension stuff so I can hook things up!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #75 on: October 05, 2014, 04:39:38 PM »
I'm adding a water separator in the new larger size fuel line. This little beauty was sub $40...all mechanical...simple...
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #76 on: October 05, 2014, 04:41:07 PM »
Got some more done today.

First I had to drill the front hubs and mount the new larger wheel studs
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #77 on: October 05, 2014, 04:41:52 PM »
I redrilled the hub so as to have an interference fit, stud to hub body. And interfere it did!
I had to resort to using the tried and true method of using an impact gun and a bunch of spare nuts to pull down the stud.
With this design, the stud actually pins the rotor to the wheel hub
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #78 on: October 05, 2014, 04:42:50 PM »
Using lots of both penetrating oil and 90 weight, it took quite some time to get all 16 studs pulled down tight
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #79 on: October 05, 2014, 04:43:56 PM »
Next up, the bearings were cleaned and repacked with grease

Then new seals were tapped into place. Finally, the front bearings were repacked and dropped onto their races
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #80 on: October 05, 2014, 04:45:03 PM »
The knuckles and axle housing were cleaned again, then the freshly painted axles slid home
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #81 on: October 05, 2014, 04:45:56 PM »
Then the top hat after some more grease
and the brake caliper bracket
I decided to leave the rotor splash guard off since it had a small rust hole in it. In hind sight I should have added it, so tomorrow, I will disassemble to this point and bolt it back on
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #82 on: October 05, 2014, 04:47:07 PM »
I smeared a little grease onto the nuts to weather proof them a little. Next the hub/rotor assembly was placed onto the spindle.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #83 on: October 05, 2014, 04:48:57 PM »
Then all the various internal parts followed in sequence
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #84 on: October 05, 2014, 04:49:53 PM »
I repeated the process on the drivers side, only that's when I decided to bolt on the dust shield and to follow up on the right side tomorrow or Monday.

It's looking a lot better already!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #85 on: October 05, 2014, 04:51:27 PM »
I'll start the update, but there is a pizza warming up in the oven that is going to cause a minor delay

I spent some more time sorting this drive shaft issue. I have definitely decided to build a much stronger shaft, but I want it to be 1410 all the way through.
I did manage to find a yoke which fit the Sterling that fit the 1410 joint as well.
Check out the size difference between it and the old 1350 spicer original (In black)
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #86 on: October 05, 2014, 04:52:17 PM »
OK, pizza operations complete, moving on...

So I test fitted the yoke and it was almost perfect. I say almost because the nut didn't have enough thread remaining to catch about the last thread. You see, way back when, Ford produced these Sterling axles with different length splines on the pinion gear. The yoke I found would fit a late 10.5" Sterling perfectly, however since the splines in this yoke are deeper, and I am using it with a pinion gear with the slightly shorter threads, I ended up with what you see in the pic.
I think it's fine, so I lock-tited it and tightened it down until I got good crush sleeve contact and started to feel resistance in the gear, then backed it off a tiny bit.
I'm calling it done and ordered the larger drive shaft to be built!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #87 on: October 05, 2014, 04:53:38 PM »
Moving on, next I mounted the rear shocks.
I really like those Ruff Stuff shock mounts with their double shear and built in skid plate
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #88 on: October 05, 2014, 04:54:37 PM »
The bolts came in finally, so I can now button some things up, starting with Shawn's diff cover.

The plated body bolts are pretty high quality, I'm happy I found them!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #89 on: October 05, 2014, 04:55:34 PM »
This time I used stainless frame bolts (With a built in washer) to secure the GLO rear axle cover

The axle was filled with 4 quarts of Valvoline full synthetic 75W-90
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #90 on: October 05, 2014, 04:56:35 PM »
Next, moving forward, I pulled the old rubber hood bumpers off and installed the new ones
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #91 on: October 05, 2014, 04:57:41 PM »
After pulling the right side front hub back off, and reinstalling that missing rotor splash shield, it was finally front brake installation time

Here's some of the lubricant products used on various parts of the calipers and pins that hold it all together
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #92 on: October 05, 2014, 04:58:53 PM »
With anti seize compound spread generously around, the calipers slid in like they were always meant to
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #93 on: October 05, 2014, 04:59:33 PM »
Sorry, Shawn, I didn't have a GLO sticker!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #94 on: October 05, 2014, 05:00:23 PM »
So here's the SOB (State of Build) at the moment:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #95 on: October 05, 2014, 05:02:18 PM »
Let me share some thoughts about this build

This truck is going to be extremely capable as an escape vehicle and off roader. It has a few weaknesses which I have been addressing as we come to them.

Talking to Beau over at WFO yesterday, when we started talking about the inherent poor ride characteristics of these trucks and why. Primarily, well, almost completely it's due to these trucks having a really short front leaf spring. That is good 1950's-60's technology, but is very much outdated and even presents limitations other than the poor ride.
So if we jumped into a buck board wagon on wood and steel rims being horse drawn, well we would still be leaving town, so the bottom line, getting off the "X" would be accomplished.
The Dodge with it's diving boards for suspension does that. You get out of Dodge so to speak, but you aren't going to be arriving anywhere rested!
However, if one replaces that front suspension with something that works better, then all that hard ride stuff is right out the window. Suddenly, you have a great riding truck that is old school mechanical reliable.

I was pondering the conversation and looking over the truck yestertag while I was working on it. There might be room for coil springs in there, and there is definitely room for Coil-overs in there to be sure.
Stick on a set of WFO's spiffy links and figure out whether it's coils or coil-overs and voila' One koul truck!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #96 on: October 05, 2014, 05:02:43 PM »
Quote:
Originally Posted by Dustoff 35 View Post
Good catch on the brake calipers! Bleeding the air out of the system may have taken a while...

Concur!

That was an outstanding catch

Can you imagine the frustration that just saved me?

I'm indebted to the man with the strange looking avatar!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #97 on: October 05, 2014, 05:03:46 PM »
From Lbajo1

Don I have a question for you. Have you ever felt overwhelmed by a project? Like stopped and thought, wow what did I get my self in to? Was this whole thing even worth it?

It's just a question i want to know if you have ever been there. I have found my self in that position in couple times and felt confused lol.

Like I said I only ask this because you take your projects to a whole other level.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #98 on: October 05, 2014, 05:04:33 PM »
Quote:
Originally Posted by Lbajo1 View Post
Don I have a question for you. Have you ever felt overwhelmed by a project? Like stopped and thought, wow what did I get my self in to? Was this whole thing even worth it?

It's just a question i want to know if you have ever been there. I have found my self in that position in couple times and felt confused lol.

Like I said I only ask this because you take your projects to a whole other level.

I say sincerely that if you think I take things to a whole other level, you have to see what my friend Duane does. His Cobra might arguably be one of the very best in this country. His garage project is text book. Yesterday, he was telling me how he lapped his new scope into it's mounts on his AR! I do OK I guess, but I'd have to say, he has achieved the masters level. Well in all things except for his poor choice in flying machines...nope he missed in that category!

I guess I sort of got there with the SAS Tundra. But with that one it was more like hitting a wall.
I needed more reliable power for it and was wanting to install a 6BT Cummins...Well, that didn't work so I recalibrated and thought about a 4BT Cummins. Well these are only 125 HP and for some reason cost an arm and a leg. Additionally I'd have to cut the firewall and move it aft and do a body lift so I threw in the towel and decided to either get a Cummins truck or convert a square fender Chevy to a 6BT.

Come to think about it, the Tac Topper project went from good idea to "Sorta stupid" as it rolled out. Some things were starting to look hacked out and I wasn't happy with how heavy it was getting. It seemed at that point that if I pushed ahead it would be the rough equivalent of trying to get Obama Care to work...Just wasn't going to happen
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #99 on: October 05, 2014, 05:07:23 PM »
Note:  Folks this long multi part thread(s) is actually a much easier to read "Readers-Digest" version of the original which is hundreds (thousands) of posts longer. Some of what I did not post is somewhat relevant, but a lot is not.

In the interest of saving time and actually getting all this transferred to my site, you get the easier to read picture version!
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