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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #50 on: October 07, 2014, 11:28:54 AM »
Here is the epoxy, two part sealer I will be using:
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #51 on: October 07, 2014, 11:29:39 AM »
And here is the first cup sprayed out.

I used the second gun of the set with the largest 1.8 nozzle which did a great job of laying down that paint
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #52 on: October 07, 2014, 11:30:17 AM »
A second cup of paint finished the bed top surface
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #53 on: October 07, 2014, 11:31:04 AM »
Then a final cup of paint finished the detail areas inside and covered the inside of the tailgate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #54 on: October 07, 2014, 11:31:38 AM »
I had taken some pictures of that Cherokee with the correct OD green color on it down to the paint shop to show them. That started quite the buzz. Before long they were pulling out formulas for US Military paints, but with each case there was some sort of a problem. One would be a single stage without hardener. If I add hardener, then the paint turns glossy. Then some of the paints was a 2 stage with the second stage being a flat clear which costs $100 a quart.

It got these guys so interested that they started mixing up 3 oz paint samples. They plan to call a the Air Force museum curator up at Wright Patterson Air Force Base and see if all of them can figure out how to mix me up a single stage semi flat correct green with hardener.
I think we are in the process of inventing a new paint for this project!

Here is the bed a couple hours later and nearly dry
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #55 on: October 07, 2014, 11:32:44 AM »
To wrap up build day 78, here is what it all looked like when I kicked the dog, sprayed the katz and threw in the towel
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #56 on: October 07, 2014, 11:33:37 AM »
Quote:
Originally Posted by duramaxdarren View Post
looking great...i have a few concerns...rear end articulation and ground clearance of that tank, plus the elements getting at the battery back there. those open batt terminals and wiring under bed need a sealed enclosure some how. plus the filler neck. is it just gonna come up through the bed?

The battery terminals do not need to be in a sealed enclosure.
Military vehicles by the thousands do not shield their batteries. When I was a tanker, I sometimes buried the batteries, all 6 of them under mud...soaking wet mud.
The air pump is more or less waterproof, and the fuse IS waterproof. Only the relay is questionable, but unless I wade 4 feet of water it will be high enough.
Finally, there is protection going in under the tank when the rear bumper thing gets built
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #57 on: October 07, 2014, 11:34:12 AM »
Quote:
Originally Posted by duramaxdarren View Post
I'm very interested in the bumper build. plus im writing down part numbers of the paint supplies you got.

...Happy to be able to blaze the trail so to speak.
There are lots of great products out there. I have always preferred DuPont paints and Centauri acrylic enamel in particular. This Nason paint is essentially a newer Centauri. The Centauri product has grown spendy over the decades and this Nason product is priced better in the market while maintaining all the quality.
I started spraying Nason in 2003 when I was building the Tundra. I built a hefty rear bumper for that truck, and painted it an anthracite color. It had good gloss and laid in nicely. When I sold the truck this year, that 10 year old bumper looked nearly as good as it did day one out of painting.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #58 on: October 07, 2014, 11:36:51 AM »
Once I sprayed the epoxy primer/sealer on the bed underside, I had 3 days to spray the bed liner on it and be done. The last two days it has been a super humid, rainy mess...not to mention Christmas shopping and social commitments.
Bottom line is nothing has yet been sprayed since I don't want to take a chance with so much moisture in the air!
It's Sunday and it's...yep...raining and super windy, but in the 60's! Coming right up is a plunge into the artic temperatures, which with the judicious use of the heater just might open a window.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #59 on: October 07, 2014, 11:38:00 AM »
Quote:
Originally Posted by streetrodchev View Post
Just got it, haven't had chance to fire it yet. Need to add/change a few things yet.

Saigas can be very squirrely

Definitely not a novice gun

The gas port system is very, very touchy. If you change anything expect the gun to start to run funny.

I own one, had $1500 worth of modifications done to it to get it to run reliably. Find the ammo it likes to digest and stick to that. Do not use a Saiga 12 as your go to combat gun...back up gun or evasion gun, but not primary as it will let you down.

Mine likes Remington 1 oz slugs and Remington 00 2 3/4" buckshot and some cheapo Spanish 00 buck and little else.

Do not mess with the gas port system at all
Do not mess with the barrel length, if you do you will have to rework the gas port system.

Find which mags run, most will not. Those MD arms drums are marginal. I don't know...I'd have to say given the utter reliability of the AK-47, this gun is not up to standard.

Here's mine:
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #60 on: October 07, 2014, 11:39:08 AM »
Had a chance to spray the underside of the bed in between the monsoon and the tornados.

Here is the underside of the bed with the epoxy sealer all cured and black lookin'
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #61 on: October 07, 2014, 11:39:59 AM »
The kit, Defender Pro, comes with 4 cans of part "A" Epoxy, and 4 cans of part "B" which is also loaded with Kevlar for strength
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #62 on: October 07, 2014, 11:41:35 AM »
Each can comes half full and mixes up to the consistency of hot tar. It is nearly impossible to spray all of it out of the can, so a good bit of it is lost, just due to it's thickness and the fact that it has to come out of 8 cans.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #63 on: October 07, 2014, 11:42:29 AM »
One can does not go very far at all. The paint guys say 4 cans is enough to spray out a 6 foot bed, but I would not agree unless you just want it on there paper thin.

You need to take care to mask off everything you don't want to get coated or over sprayed
I bumped the trigger and now I have a nice pattern on the maple tree side of that pretty new red toolbox!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #64 on: October 07, 2014, 11:43:04 AM »
Here is the bed after the first can was used up. It takes about a minute of spraying at 50 psi to empty the can
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #65 on: October 07, 2014, 11:43:56 AM »
Allow me to correct myself, that is after 2 cans were sprayed, not 1!

Here's some in-progress shots
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #67 on: October 07, 2014, 11:45:33 AM »
And here it is after the end of a very short Build Day 79
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #68 on: October 07, 2014, 11:47:30 AM »
Quote:
Originally Posted by FBJR View Post
Does look good, all 4 cans did it??


All the more reason for a tilt bed. It is lined with kevlar, just tilt and you have a 007 rear shield

To bad there isn't a foam type sealer/anti rust for places like those closed under-bed rails and such.

I would have felt better with 5 cans. If I had to do the inside of the bed (Oh wait,...I still do!) I'd vote for 6-7 cans min. I'll just buy two more kits and use the rest to spray that red dog. Remember that tape I was using? When I wasn't looking, the da@#$! thing carried it off and chewed it up!

I have a product which seems like a sprayable cosomoline that had to wait until the end. That gets sprayed next into those recesses. Best to leave them open and ventilated, rather than filled with some foam which might breakdown and allow moisture in and trap it
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #69 on: October 07, 2014, 11:48:07 AM »
Quote:
Originally Posted by Cudakidd53 View Post
Great progress, glad the weather broke some for you!

Tomorrow, the bed will be ready to flip to start on the top side. Get the body work done, then scratch up the thing and paint it with real color, then finish with spraying in the bed liner, and that part of the truck will be done. All I have to do is get the back side of the cab sprayed and all the wires and lines run and the bed can go back on.

It will look like a mo-complete truck for a short time until I take the fenders/hood/doors off
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #70 on: October 07, 2014, 11:53:07 AM »
Here's the manifold I ordered yestertag:

It's a 3 piece design that prevents cracking and is actually made from Ductile Iron, same stuff as our turbo exhaust housings are made from
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #71 on: October 07, 2014, 11:53:28 AM »
That thing is a "Pulse" design designed both to improve flow and to keep velocity high. This manifold along with that 14 CM exhaust housing will allow the 6 to spool very quickly.

I have to be judicious in the adding of power here. Considering the fact that the truck starts out nearly 1.5 tons lighter than the Duramax truck and given that it should be coming out the chute at somewhere around 1000 ft lbs, it is going to be pretty fast, as in losing traction and getting uncontrollable.
I only need enough power to do what I need to do in some of the situations I have described, so I think with the twins and much bigger injectors I AM there.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #72 on: October 07, 2014, 11:54:36 AM »
THe power upgrades will happen in two stages I think.

About anytime I think I'll drop all that stuff into the injection pump and perhaps get that running.

I may have found another cylinder head. If so, then get that O-ringed, bigger valves and ported. Install that with the ARP studs and goddin' head gasket, then get to the turbo stuff.

That will commence with the overhaul of the stocker center section. Followed by the addition of the 14CM exhaust and the 60MM compressor. Mounted up to the new manifold and prudy painted stuffins' I'll fab in the second turbo and get that all sorted out.

I'll need to add in the mucho bigger injectors and sort out the exhaust, but that will soon, be that as they say in the movies. That's when things are going to get a little custom. I'm thinking I'll have the fenders all dipped, cleaned and primed and remounted by then, so It would be time for something wild with respect to the air intake. I'm thinking the air needs to be coming from the level of the top of the windshield.

So getting a 6" ID pipe to come out of the fender, then snake around and up the windshield pillar to arrive up top is going to be quite the chore. But, I have done it once before so I know that I can.

That is the plan for all that, oh, and the addition of an intercooler twice the size of the stocker...



Note:  I was so wrong here as you will discover in pages to come...
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #73 on: October 07, 2014, 11:55:43 AM »
Quote:
Originally Posted by FBJR View Post
I was wondering when you would get an exhaust manifold. Sounds like you may as well just do another motor and drive that pup as is for now.

I may hunt another motor...I am always looking.
It is a real possibility of "Upgrading" the survivability aspect of the D-Max truck by transplanting a Cummins in there and taking a huge leap backward!

If I can score a cyl head it will make the build just that much easier...


Note: Is this where I got the idea for what is to come???
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #74 on: October 07, 2014, 11:56:19 AM »
Darren, you paying attention?
With this installment we will finish rust proofing the underside of the bed and essentially be done with it

here's what we will be using, a long flex line and a 360 nozzle
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #75 on: October 07, 2014, 11:57:14 AM »
The line is a couple of feet long and the nozzle is a cool brass gizmo with a bunch of cones drilled into it
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #76 on: October 07, 2014, 11:57:55 AM »
All you need to do is to find an opening and fish the hose into it, spray and pull out with an even speed
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #77 on: October 07, 2014, 11:58:49 AM »
The material got all over everything as evidenced by the extra stuff running out from the seams
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #78 on: October 07, 2014, 11:59:52 AM »
The excess wiped up easily, but within minutes the stuff started to thicken and get sticky

You can see some pretty good coverage inside the bed between the inner and outer skins
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #79 on: October 07, 2014, 12:00:34 PM »
After wiping down, some still shows, but it's not too much and I don't think it detracts from the new appearance of the bed
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #80 on: October 07, 2014, 12:01:24 PM »
The inside of the bed looking from the inside got a coat as well. This will be a moisture collecting area
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #81 on: October 07, 2014, 12:32:28 PM »
I wasn't bashful at all about letting it rip in and around the tail light cutouts.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #82 on: October 07, 2014, 12:33:31 PM »
With that stuff thickening up nicely, it was time to flip the bed and get it on the work horses to finish it off

None of these pics show it flipped, but do show it in the light of day, outside, finally!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #83 on: October 07, 2014, 12:34:38 PM »
Next project is to remove the stock fuel filler and install the aircraft style unit, and cut in another filler neck for the water/alcohol tank.

Here is the cap unit(s) we will be using
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #84 on: October 07, 2014, 12:35:39 PM »
First I made up a template that I will use to construct a plywood piece from.

That plywood will help me cut the pieces out of metal and accurately locate the holes
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #85 on: October 07, 2014, 12:36:20 PM »
The fuel filler, will, obviously, go back into it's factory position

The new plate measures 7" X 8"
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #86 on: October 07, 2014, 12:37:22 PM »
Then the H20/Methanol filler will go aft of the wheel well at the same height and equidistant from the wheel well arch
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #87 on: October 07, 2014, 12:38:53 PM »
I'll chop off a short section of the 4" pipe and weld it to the filler cap mount, block off the back, and then weld a 1.5" nipple to it to attach the rubber fill pipe to
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #88 on: October 07, 2014, 12:39:39 PM »
I'll try to keep from using the bed as a welding table, but the temptation is high since all my other welding tables burn up!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #89 on: October 07, 2014, 12:40:20 PM »
I need to prime the naked strips in the bed floor and the top of the bed itself, but that is easy stuff!

Here it is at the end of build day 80
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #90 on: October 07, 2014, 12:45:08 PM »
Well, let's get some more of this thing built.

I have been focusing on the back end of the truck because the bed was off. That theme continues with today's project.

I need to install reliable fuel ports that are large enough to pour right out of a can if necessary and seal up well.

No fuel cap that I know is better than the cap from an aircraft, a military aircraft that is. SO that is what I decided on and purchased a couple weeks ago.

The alcohol tank is in, and the main fuel tank is refurbished also, time to connect everything.

Since it involves sawing on the bed, it too, is necessary before I can paint the bed and call it done.

First up was to finish the patterns and check all that out
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #91 on: October 07, 2014, 12:45:58 PM »
That pattern was transferred onto some 1/4" plywood, which I will use to cut the steel plate
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #93 on: October 07, 2014, 12:56:35 PM »
The plywood was clamped onto some 10 gage plate and the cuts were made with a plasma torch
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #94 on: October 07, 2014, 12:57:23 PM »
Two sets were cut out
A set consisting of the outside plate which will hold the cap, and a stiffener which will bolt on the inside of the bodywork, sandwiching the thin steel of the bed and making it much stronger
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #95 on: October 07, 2014, 12:58:07 PM »
After some close up and personal time with a grinder and a 40 grit flap wheel, the pieces were looking better and beginning to fit.

THe hole for the cap is still somewhat crude, since it is still not done. I'll wait until I figure out what the 4" tube that fits on the inside is going to look like.
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #96 on: October 07, 2014, 12:58:53 PM »
Then the drilling commenced.

I had to drill a total of 44, 1/4" holes to fit all these parts.

That is going to be a pretty good drain on my hardware stocks!
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #98 on: October 07, 2014, 01:00:07 PM »
THis is how the outside parts stack up
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Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
« Reply #99 on: October 07, 2014, 01:01:03 PM »
And here it is fitting over the stock fuel cap recess:
Site owner    IS 6:8  Psalm 91 
NSDQ      Author: Distant Thunder