SquareD Part 5: The build continues and gets more aggressive

[Flyin6]

After replacing the temp bolts with the permanent ones and torqueing the trans to the bell housing adapter, I secured the oil cooler to the back side and installed the transfer case shifter. The handle got another coat of paint (again)

[Flyin6]

Then just like that another build day was all used up.

I still have to secure the torque converter to the flywheel, but that can wait for now

The goal remains to get this thing reinstalled back into the truck so it will all start to look like something that belongs together and not a pile of disassociated parts.

[cudakidd53]

Dear Santa-

For Christmas this year, we'd ALL like to see a video w/sound of SquareD running!

Looking good there Don'a Claus!  :D

[Sammconn]

I'm with Mike. Wanna see and hear this thing running too. Think we're all probably in that boat though. Good to see the ball get pushed a bit farther down the field. One sharp looking power plant!

[Flyin6]

We'll hear it
But
Like always
There are a few wrinkles coming right up
The knee
I get a new titanium one 26 Dec.
The recovery from that
then back to a normal life...

[JR]

What a Christmas present Don. Mom had both hers done. You spend 1-2 weeks in rehab, much less really getting back on your feet.

When this is done and you healed up, there has to be some civil unrest just to try it out for real. Not that I'm asking or advocating it, but should Don should not be denied.

[cudakidd53]

We'll hear it
But
Like always
There are a few wrinkles coming right up
The knee
I get a new titanium one 26 Dec.
The recovery from that
then back to a normal life...

The Great Candy Bar Fire comes to a close!  Suggestion: don't do a build thread on the knee nor post it on the medical thread!  The photos might cause me to break a cold sweat and ruin morning coffee.

[Nate]

Things are coming right along, lookin good.  Bad news about the knee.

[Flyin6]

Things are coming right along, lookin good.  Bad news about the knee.

No, good news about the knee

I am nearly crippled right now...have been for some time. Can't lift my leg from the gas pedal to the brake without using my arm to lift it. Other surgeon really screwed me up. I will get a chance to get back to who I really am inside this barely able to walk current shell...NOSSIR it's a berry, berry good thing

[Sammconn]

Well good to hear the knee will be fixed up finally. Have a few folks I know that have had them done. One fella was nearly crippled, hobbled along with a cane, really done. He had both done at separate times, and is a new man now. Wouldn't say he could run a marathon, but that was never his style either. Wishing you good luck with the knee when the time comes.

[Flyin6]

Well good to hear the knee will be fixed up finally. Have a few folks I know that have had them done. One fella was nearly crippled, hobbled along with a cane, really done. He had both done at separate times, and is a new man now. Wouldn't say he could run a marathon, but that was never his style either. Wishing you good luck with the knee when the time comes.

Thanks!

Yep, all I need is the right equipment. This old stuff is failing me. Body is worn but spirit is young and willing...

New parts will fix me right up!

[JR]

You know, that motor and tranny is just darn purdy, the white still needs to grow on me though.

Scored a 14 bolt FF with looks like 4.11s (matches the dana 60) for just $120 yesterday.

[EL TATE]

You know, that motor and tranny is just darn purdy, the white still needs to grow on me though.

Scored a 14 bolt FF with looks like 4.11s (matches the dana 60) for just $120 yesterday.

do you know what year that housing is? ^^ 84-85 are the bad years with the small pilot bearing.

[JR]

You know, that motor and tranny is just darn purdy, the white still needs to grow on me though.

Scored a 14 bolt FF with looks like 4.11s (matches the dana 60) for just $120 yesterday.

do you know what year that housing is? ^^ 84-85 are the bad years with the small pilot bearing.

Real bad or just not as good? Good info to know, now,,,,,,,,,,,,,,,,,,,

I think it has a locker, but not sure. Both drums turn solid the same way where an open they normally go opposite. Looks OK inside, solid gears but a little rust as it was sitting. It will get discs.

[Dustoff35]

Scored a 14 bolt FF with looks like 4.11s (matches the dana 60) for just $120 yesterday.

Excellent!

[Dustoff35]

Not wanting to trust that old HF 1500 lb engine hoist leveler, I opted for their biggest one today. Here it is:

I have one of those hanging on my tool-room wall…

It hasn't been used since I dropped the engine into the Cobra.  I should have sent it with the engine hoist.

[Flyin6]

I see my build thread has once again turned into a DOT chat room....

Well no stoppin' it I guess, kind of like the tides or women's illogical statements...just gonna happen!

Whew, got away with that one...being a man's site and all, I'm hoping there is little danger here, and fewer girly men as well!

OK with the new knee coming right up I am working toward getting the heavy stuff installed and looking down the road a bit. In doing so I was looking at the truck the other day. It had 48" springs in the front, and now has 52" ones. Oddly enough the rears are also 52". That means there is room for a vast improvement back there. Late chebby trucks use 63"-64" springs making the newer offerings more than afoot longer! That is HUGE. There is an absolute ton of better handling and flexibility to be had with those newer springs. So eyes sez to meself, "Self, we needs some knew springs, we do!" So's eyes get on and git ta orderin and measuring' and wonderin' and in the end, just emailed Jungle Jim. He sez "U gonna like thems knew springs you R, git U some and stick em on!" So eyes think i'm gonna do just that

The working theory is that I stay at least one to two projects deep at any given time on this truck...

[JR]

Or, leave the 52's so you have or upgrade them all. Keeping the same length keeps spare parts handy and leave springs do break!

[Flyin6]

Or, leave the 52's so you have or upgrade them all. Keeping the same length keeps spare parts handy and leave springs do break!

Naw, I'm going to swap them out.
My chevies always drove great...much more comfortable than the tow Dodge W150's and one Ramcharger I owned back in the day.

It was the springs!

Besides it's a cool project with a good result!

[KensAuto]

Get that sucker done.....almost time for combat max!!!

[Flyin6]

Get that sucker done.....almost time for combat max!!!

Done!!!!!!!!

That's crazy talkin right there

And on this site we will not tolerate the personal use of street pharmaceuticals!

Ken, stop smoking that stuff!

OK, I'm all better

So with all the runnin' around and such I managed to get a couple hours in on Square D

And I made a decision about the front diff without even realizing it.

I'll explain as we roll tonight's story out

So with the thought of getting the front axle back under the truck so I can reinstall the motor, I wanted to finish out the new spring plates.

Two things. First the old ones were pretty severly pitted on the underside. Although they cleaned up nicely, I didn't like how all that turned out, so it was just a matter of time before they got renewed.

Secondly, the sway bar needed a place to hook to and I wanted something better than just the factory setup...I wanted adjustability because the axle can now move forward and aft as I desire, I wanted the sway bar end link to do so as well.

So Ruff Stuff had this neat three hole setup which would work with the supplied front mount, so I built the new plates first

[Flyin6]

Here's how they will get welded up:

[Flyin6]

And welded they are!

[Flyin6]

And fit they do!

[Flyin6]

Next up, the new 35 spline axle stubs (outers) were installed.

First you have to remove the C-clips, then press out the old joints

[Flyin6]

It's a little scary using a 30 ton press and nearly stalling it before "BANG" the sticking parts let go all at once. Mine did one big bang and flew apart...No more pressing required!

[Flyin6]

A bit more pressing to get the last cap out and the old 12" 30 spline stubby shaft is all done and ready for the scrap heap

Here are the recently divided parts:

[Flyin6]

The new U-Joints are Spicer units that will work fine with the torque and tire size this truck has

They're pretty big!

[Flyin6]

Then back to the press and the reassembly starts with gingerly putting a cap onto the U-joint then getting that to seat, then getting the opposite cap to seat as well without any of the rollers falling out. I was 3 for 4, so I got a little more practice!

[Flyin6]

It presses back together much easier than it came (Exploded) apart!

[Flyin6]

Two new clips keeps the joints from vibrating out

[Flyin6]

Then the new forged short shafts are assembled to the original short and long axles

[Flyin6]

And that's the end of build day 198

[cudakidd53]

Fine, leave us in suspense...... ???  Axel decision was........ ::)

[JR]

Yep, got us DOTs again.

I need to run up to Ruffstuff, they are just 45 minutes away. Just have to remember lots of $$$ as they have a lot for the 14b.

[Flyin6]

Fine, leave us in suspense...... ???  Axel decision was........ ::)

Oh, that...

Yea, got busy and went temporarily insane

While building up the axles for some reason I started to think, Oh No! What have I done??? Now I created 35 spline axles and they require the new diff! I got that turned around in my brain as you see, the stock diff is already a 35 spline! I was thinking I just compelled myself to have to install the Zip Locker but in fact, no change other than now I can use the 35 spline manual hubs Randy's makes.

As for the air locker...let me give Duane a call this morning, see if he can hook that smaller trailer up and get over here and carry those diffs over to Pro Transmission. Steve said he could knock that swap out no problem!

[DDS]

Big D,
just an fyi, this guy seems to have it all.http://hartford.craigslist.org/ptd/4786438970.html

[Nate]

bit of a nice selection there

[Flyin6]

Big D,
just an fyi, this guy seems to have it all.http://hartford.craigslist.org/ptd/4786438970.html

He does have a lot of Cummins stuff!

[Flyin6]

Short update: Dropped the axle off at Pro Transmission. Decided to install the locker unit, now I just hope it fits. Thinking they may get into it some today...

Should be installing a zip locker, using the factory 3.54 gears with the full 35 spline axles and the new Yukon hubs.

[EL TATE]

Real bad or just not as good? Good info to know, now,,,,,,,,,,,,,,,,,,,

I think it has a locker, but not sure. Both drums turn solid the same way where an open they normally go opposite. Looks OK inside, solid gears but a little rust as it was sitting. It will get discs.
[/quote]

you can verify by checking the od of the pilot bearing. 2.050" or 1.625". (smaller is NLA)

[Flyin6]

Wrong thread bro...

[EL TATE]

missed all the DOT stuff before I responded 8). Be at peace big D; all the parts are going to sing a symphony for you in that front diff.

[Flyin6]

missed all the DOT stuff before I responded 8). Be at peace big D; all the parts are going to sing a symphony for you in that front diff.

Cool

[Flyin6]

I mentioned that I dropped the two Dana 60's off at the trans shop where Dr. Steve is going to do the magic. I don't have a case spreader and I don't like dropping air lockers onto my footies anyway.

Shawn was really jealous of my stocker D60 cover painted all John Deere green...It's only a dust cover I use to keep bugs and red dogs out of the innards of my rather expensive axles. This one was destined for C-Max and is a super desirable 84-88 Ford high pinion, king pin left drop housing. Pretty much the best that Dana ever built in the 1 ton sizing.

[Flyin6]

Remember recently when I built that new tie rid bar? Well, I might have mentioned I cut it twice and it was still too short!

So I had two ways of dealing with that. 1. would be to leave a lot more of the tie rods sticking out of the threaded adapter than I would prefer, or 2. Buy more DOM and two more threaded adapters and start again.

I had marked the cut line on the earlier piece with 1" tape. Then I cut the inside edge instead of the outside edge.

This is how much thread I had sticking into the threaded end in the "too short" bar

[Flyin6]

I would have liked to have had the extra 1/2" of tie rod threaded into that steel bar.

So

I just started all over again and did it right this time. I measured 49 times then double checked that

This time I got it right

[Flyin6]

With that all looking like it should, the ends were welded up and then everything I had laying around that needed painting got attention...

Heck...

Just realized

I forgot to paint that ugly crane/lift of Duane's....

First came vigorous cleaning

[Flyin6]

Next the acid etch paint

[Flyin6]

Then three coats of the Nason acrylic enamel with hardener