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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #100 on: October 07, 2014, 01:02:00 PM »
Don't worry too much about that panel sitting there and all those bolts sticking out in the wind disrupting the smooth race car like lines of this truck...There will be plenty more disruption to come.

You will see a vent grid cut into each fender, all military style like this, and another transmission oil cooler mounted to the underside of the hood (Yes the underside of the hood) with a wire mesh top side, and a snorkel pipe sticking out of the right fender.

Here is where I left it all tonight so I could cook the pre-rangers up a pizza.

Oh did I mention we had a new baby grand daughter today? That's where I was all morning and what was going on here the past couple days!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #101 on: October 07, 2014, 01:03:32 PM »
OK, build time again

We are building the fuel and water/alcohol filler assemblies

I want to duplicate the stock angle so I can utilize the stock filler neck, so I'll be using nearly the same angle
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #102 on: October 07, 2014, 01:04:11 PM »
And it will fit something like this
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #103 on: October 07, 2014, 01:04:50 PM »
The backside will be capped off and have a hole to fit the filler neck
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #104 on: October 07, 2014, 01:06:56 PM »
That piece will get massaged so as not to look so crude, although it remains hidden from view. I drilled the holes in it to match up with the stock filler neck
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #105 on: October 07, 2014, 01:07:49 PM »
This is what mates the filler neck to the new fuel port
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #106 on: October 07, 2014, 01:09:23 PM »
I am working with a section of 4" exhaust tubing I pulled off the Duramax when I converted it to a side exhaust

Next, the pieces of the water filler neck were made in about the same way
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #107 on: October 07, 2014, 01:10:38 PM »
And this is how that part fits together
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #108 on: October 07, 2014, 01:11:37 PM »
Then I welded up the fuel filler neck adapter
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #109 on: October 07, 2014, 01:12:51 PM »
It was about then when I looked up on top of my cabinets and much to my surprise, discovered a new welding helmet, complete with preinstalled flames. I believe the flame helmet is faster than the standard black one
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #110 on: October 07, 2014, 01:14:11 PM »
I installed the cap ring, then test fitted the new adapter piece. I knew it was going to be tight, but there was not enough room to fit a round pipe section and still retain the nuts which are pretty necessary to hold that all together, so something creative would be required
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #111 on: October 07, 2014, 01:15:30 PM »
After tapping the marked areas in to flatten them somewhat, I ended up with a big hexagon which fit rather nicely!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #112 on: October 07, 2014, 01:16:38 PM »
I welded most of the outside except around the nuts, and welded them to permanize them to the mounting plate
I then welded the ring on the inside 360 degrees
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #113 on: October 07, 2014, 01:17:32 PM »
It seems I had grinder problems again. Tomorrow, before I do any work...I'm going out to purchase some leather gloves
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #114 on: October 07, 2014, 01:18:20 PM »
After some grinding the filler cap assembly wasn't looking too awful bad
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #115 on: October 07, 2014, 01:18:56 PM »
Once I enlarge the hole, it will fit well me thinks
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #116 on: October 07, 2014, 01:19:55 PM »
Next I welded a nipple onto the flat plate in the water/alchy filler
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #117 on: October 07, 2014, 01:20:52 PM »
Next I welded a nipple onto the flat plate in the water/alchy filler
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #118 on: October 07, 2014, 01:22:28 PM »
I gave that dude the same hexagon treatment
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #119 on: October 07, 2014, 01:23:10 PM »
Set it up and welded it in the same manner
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #120 on: October 07, 2014, 01:23:55 PM »
Using the 40 grit flap wheel. I cleaned them up
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #121 on: October 07, 2014, 01:24:46 PM »
And gave them a double coat of U-Pol copper primer
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #122 on: October 07, 2014, 01:25:23 PM »
The process went fairly well today and after about 5 hours of work, I called it a day and went over to see the newborn meet her brother for the first time

Here's the end of build day 82
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #123 on: October 07, 2014, 01:26:05 PM »
Oh, almost forgot, the white and purple truck brought the bed liner today. It will not be dormant for very long!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #124 on: October 07, 2014, 01:34:02 PM »
Before this thread falls totally away from anything remotely related to what ever it was way back when it started, let me throw in some pictures so someone else can start talking about tidal currents or problems with their girlfriend or something reverent like that!

You always hear the saying, "Safety first," right?
Well what that means is if you have pictures of safety stuff, show them first!

Considering the fact that I am taking more hits here than an average operation in the Hellmand valley flying gunship support, I thought it prudent to buy some safety stuff.

You can see rubber gloves, leather gloves, yellow fuzzy gloves, the old reliable brown ones used to warm your nose when working in a cold garage and a face mask. I didn't mention the piece of steel that got stuck in my face. It came out OK, but I'm on-to this stop work demon that is visiting my shop.
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #125 on: October 07, 2014, 01:34:56 PM »
Didn't have to waste any more masking tape on field dressing of wounds today! I did get to use the tape for what tape is meant for though!

I finished the backing plate fab by welding the nuts in place, effectively creating a big nut plate. It will make assembly, hillbilly-easy, which is what I like
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #126 on: October 07, 2014, 01:36:23 PM »
After some careful marking, I positioned the backing plate and marked it's outline with some black paint, then drilled the 8 holes with a 5/16" drill bit
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #128 on: October 07, 2014, 01:39:04 PM »
After measuring and marking the first hole, I marked the second one
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #129 on: October 07, 2014, 01:40:01 PM »
Just like before, I drilled the 8 bolt holes and checked the fit before cutting any metal.
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #130 on: October 07, 2014, 01:40:53 PM »
Then surgery was performed using a cut off wheel spinnin' really fast!

A quick check of the back side showed I had gotten a goodly amount of material sprayed down into those recesses
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #131 on: October 07, 2014, 01:41:49 PM »
Note to everyone wondering about the yellow gloves: They are not suitable for scratching one's nose...They leave hairy fibers all over your face that bother the living heck out of you until you break camp and wash your face off!

And lookey there...Uniformity. Holes that look like they duplicated themselves on either side of the wheel well...Purdy
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #132 on: October 07, 2014, 01:42:49 PM »
With that done, it was time to do some painting.
First up was to finish spraying the remaining spots of bare steel with the acid etching yellow stuff, which I did
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #133 on: October 07, 2014, 01:44:05 PM »
Then the nut plates and the fuel cap panels
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #134 on: October 07, 2014, 01:45:21 PM »
Next up was a couple of coats of John Deere blitz black with hardener.
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #135 on: October 07, 2014, 01:46:10 PM »
After spraying those fuel cap panels, I have to say I do not think they will pass muster. I could see grinder marks in the paint and it occurred to me, that this is unlike everything I have painted so far. This part shows! It is part of the finished appearance of the truck and needs to look straight and flat. So my money says I'll be pulling it out of the hanging jungle tomorrow and sanding it and doing a lot of smoothing before repainting it, we'll see

The side of the bed came out OK after a coat of the yellow stuff blended it all in and sealed those cut edges.
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #136 on: October 07, 2014, 01:46:53 PM »
So there it is boys and girls, the end of another build day on Square D

OK, DOTs take over and derail to your hearts content!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #137 on: October 07, 2014, 02:03:08 PM »
Well, no compressor showed up today, so the projects just sort of fizzled out.

But I can post the incomplete build day from Tuesday when things went sparky.

I started off the day with the knowledge that my new gloves did not survive the night with the Red Dog (Soon to be dead dog
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #138 on: October 07, 2014, 02:03:41 PM »
After inspecting the paint job on the fuel cap plates, I'd have to say I'm not happy with the results
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #139 on: October 07, 2014, 02:04:35 PM »
I'm giving them a thumbs down!

I'll sand that mess down and coat the whole business with some body filler to get the whole thing even, then repaint with that good Blitz JD 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 #140 on: October 07, 2014, 02:05:50 PM »
Before the light and spark show on Tuesday, I started the body work.
First of all, I used some 40 grit or was it 36 grit??? Anyway using a good solid straight edge...Duane's forehead was not available, so I grabbed something just as good, a 2 X 4 and wrapped the paper around it and sanded around the dented area to allow the scratch marks to show me the high and low spots. It worked fairly well.
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #141 on: October 07, 2014, 02:06:25 PM »
After tapping down the high spot, I ran over the area with the 40 grit flap wheel to roughen it up so the body putty would adhere
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #142 on: October 07, 2014, 02:07:01 PM »
...And hit two small dents.

That's it! That's all of the dents in the whole bed! Well on the outside surface. The bed has seen WW2 apparently, but I don't care what that looks like, it will be covered
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #143 on: October 07, 2014, 02:07:48 PM »
The standard of body filler, Bondo, was given the nod to do the filling of the dents after I got as much of them knocked out as possible
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #144 on: October 07, 2014, 02:08:33 PM »
After mixing up a liberal amount, I spread it over the affected areas with a 6" paddle
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #145 on: October 07, 2014, 02:09:17 PM »
If you want to save yourself a bunch of sanding, then as the stuff hardens and gets to a point where it is setting up but not hard yet, you can use a body filler file on the stuff and plane it into the rough shape, that you will later work from to sand to the final shape
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #146 on: October 07, 2014, 02:10:18 PM »
We'll have to await the arrival of the much anticipated Eaton V-4 compressor to watch this process play out.

So in the meantime, let's look into some boxes

The Diesel Performance Parts high flow exhaust manifold showed up
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #147 on: October 07, 2014, 02:10:59 PM »
This manifold will make more power, and will not crack, adding to the reliability of the truck.

The port size is larger and flows well, utilizing the existing pulse to help flow, but not too large so as to slow down velocity which is what spools the turbo
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #148 on: October 07, 2014, 02:11:35 PM »
This manifold is actually three pieces which have been lightly pressed together. As it expands and contracts, a stock manifold will grow as much as 3/8" in length. That movement will now be accommodated at these two machined joints
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #149 on: October 07, 2014, 02:12:44 PM »
Quote:
Originally Posted by nmeyer414 View Post
Definitely looks as though the red dog needs to go.


It almost went tonight
The sled dog was at the front door barking
That's odd, she doesn't do that
I opened the door and she and the cats dog-piled me getting in the house.
Note that the cats don't come in the house very often and neither does the sled dog. That's when that icy blast of artic air hit me.

Hmmm

There's a stack of locust logs burning up a storm in my fireplace and everything in the casa is toasty warm, but outside its a different story
So I check the thermometer.
Not good, it's reading 6
And the wind is howling.
A quick check of the weather channel tells me it's 1 outside. Where in hades did that come from.
Anyway, I suddenly realized the red dog is not well equipped for 1 degree temps. So I go out and just before I froze solid myself I find her. She was definitely not doing well, so I hauled her inside. Dammed dog snagged one of my boots on the way out to the garage!

I should just shoot her and be done with it, but I guess I'm just a big softie inside. So much for the steely eyed killer thing...
Site owner    IS 6:8  Psalm 91 
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