Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 423410 times)

Flyin6 · « **Reply #650 on:** January 17, 2015, 06:42:46 PM »

Red dog is always laying in wait to steal away some unattended screw driver or pair of pliers. Today I only lost a couple of gloves!

So looking from the side, I didn't lose very much if any ground clearance

Flyin6 · « **Reply #651 on:** January 17, 2015, 06:43:44 PM »

So that does it for build day 204

BobbyB · « **Reply #652 on:** January 17, 2015, 07:47:16 PM »

I still see daylight, you can't be done!

Dawg25385 · « **Reply #653 on:** January 18, 2015, 12:53:58 AM »

Wow lots of progress! Great to see!

How'd the knee hold up???

Flyin6 · « **Reply #654 on:** January 18, 2015, 08:49:13 AM »

Quote from: Dawg25385 on January 18, 2015, 12:53:58 AM

Wow lots of progress! Great to see!

How'd the knee hold up???

Knee is OK, workable

I'm on a personal crusade to free up floor space

The more I get bolted back on that truck, the more space I have!

I finally realized doing something like this is not working in a linear methodology. No, it is more akin of problem solving. One simply solves one problem, then addresses the next, and the next and so forth. Then at some magical point in the future, you have solved the propensity of the problems and you are more or less finished...

cudakidd53 · « **Reply #655 on:** January 18, 2015, 10:04:04 AM »

Great progress-

Serious armchair QB question:

Given the considerable torque of the motor and drive line, isn't that new Transfer case mount going to potentially cause problems when it restricts those twisting forces, placing all that force around your bearing collar where that steel clamp attaches to the aluminum collar? ???

KensAuto · « **Reply #656 on:** January 18, 2015, 11:33:35 AM »

Mike, the amount of flex that the rear of the transfer case receives will easily be absorbed by that poly mount.....unless one of the engine mounts break.

JR · « **Reply #657 on:** January 18, 2015, 02:01:49 PM »

"I finally realized doing something like this is not working in a linear methodology. No, it is more akin of problem solving. One simply solves one problem, then addresses the next, and the next and so forth. Then at some magical point in the future, you have solved the propensity of the problems and you are more or less finished..."

I like that,,,,,,,,,,,,,,,,,,

And that trans mount is just darn purdy. Then your picture reminded me I still have to find these cross member trusses. I got the lower but forgot the those!!

And do I see that those are stock with grim and all the other 200k stuff on them?

JR · « **Reply #658 on:** January 18, 2015, 02:39:35 PM »

OK, lets fire that puppy up!!!!

Flyin6 · « **Reply #659 on:** January 18, 2015, 03:06:52 PM »

Quote from: cudakidd53 on January 18, 2015, 10:04:04 AM

Great progress-

Serious armchair QB question:

Given the considerable torque of the motor and drive line, isn't that new Transfer case mount going to potentially cause problems when it restricts those twisting forces, placing all that force around your bearing collar where that steel clamp attaches to the aluminum collar? ???

Dunno Mikey

very good point though

Undoubtedly it will arrest some of the twisting movement, however that's the job of those new motor mounts with their rubber imbedded steel interlocks.

And, I'd offer that this design is in service on NP205'S all over the off roading world (Read: Very low gearing with very high resultant axle torqueing)

Flyin6 · « **Reply #660 on:** January 18, 2015, 03:10:03 PM »

Quote from: JR on January 18, 2015, 02:01:49 PM

And do I see that those are stock with grim and all the other 200k stuff on them?

Nossir!, no grime on those mounts or anything else under there. I took them down to nearly bare steel then finally top coated with undercoating...That's the texturing you see there.

JR · « **Reply #661 on:** January 18, 2015, 08:38:55 PM »

Quote from: Flyin6 on January 18, 2015, 03:10:03 PM

Quote from: JR on January 18, 2015, 02:01:49 PM

And do I see that those are stock with grim and all the other 200k stuff on them?

Nossir!, no grime on those mounts or anything else under there. I took them down to nearly bare steel then finally top coated with undercoating...That's the texturing you see there.

Just making sure,,,,,,,,,,,,,,,,,,,,

Flyin6 · « **Reply #662 on:** January 19, 2015, 08:35:41 PM »

Today I finished the crossmember

Starting with some angle plates, I attached them to the frame through some existing holes, and I had to create a few more

Flyin6 · « **Reply #663 on:** January 19, 2015, 08:37:22 PM »

I decided to use 4ea 3/8" bolts on each side with 3/16" steel to use that cross member to help stiffen up the chassis some more

Flyin6 · « **Reply #664 on:** January 19, 2015, 08:40:49 PM »

Those plates fell in at the point the frame bends upward so I made them larger to span that region to prevent flexing at what is likely a weaker point

Next I made the side plates. The concept of the operation was to drill a hole in plates the size of the pipe OD, then use the plate to completely capture the tube. I wanted to completely control the torsional movement of that cross member steel tube

Flyin6 · « **Reply #665 on:** January 19, 2015, 08:43:19 PM »

Then I massaged the plates to make them more finished in appearance and remove sharp corners that might hang up on Kia body parts

Flyin6 · « **Reply #666 on:** January 19, 2015, 08:45:32 PM »

Then the parts were assembled and tacked together, then skip welded while they were bolted in place to minimize warping

Flyin6 · « **Reply #667 on:** January 19, 2015, 08:46:29 PM »

Then for a complete finish welding

Flyin6 · « **Reply #668 on:** January 19, 2015, 08:48:36 PM »

The ends of the tube were closed up with these steel plugs, then the whole thing was ground down and wire brushed in prep for the paint process

Flyin6 · « **Reply #669 on:** January 19, 2015, 08:49:50 PM »

Then the painting. Here is the last coat of Nason acrylic enamel laid down

Flyin6 · « **Reply #670 on:** January 19, 2015, 08:52:32 PM »

A little foreshadowing...

These are new springs meant for a 2003ish Silverado 2500HD. These bad mommas are a full 64" in length. Stockers are a paltry 52". With 14" extra spring this truck's road manners will likely put a caddy to shame!

And that's it for build day 205

JR · « **Reply #671 on:** January 19, 2015, 11:04:44 PM »

Now that is a stout cross member. Looks like it will withstand a skid plate easy to protect that purty 205.

If that tank wasn't there I would have said bend that pipe up out of the way!!

cudakidd53 · « **Reply #672 on:** January 20, 2015, 06:29:36 AM »

FORESHADOWING:

You put it next to the dog bowl- those springs are now property of the Red Dog and it's minions! :o

Nate · « **Reply #673 on:** January 20, 2015, 09:51:57 AM »

Either my eye sight is going or it may even be a bad pic, that cross member looks as though it is already bent?

JR · « **Reply #674 on:** January 20, 2015, 10:18:39 AM »

Quote from: nmeyer414 on January 20, 2015, 09:51:57 AM

Either my eye sight is going or it may even be a bad pic, that cross member looks as though it is already bent?

I think that is just the picture but no gusset???

EL TATE · « **Reply #675 on:** January 20, 2015, 10:45:49 AM »

Or Nate and I have the same bad eyes. It looks warped up on the right hand side (looking at the picture perspective). too much heat on the center mount welds?

Flyin6 · « **Reply #676 on:** January 20, 2015, 11:16:10 AM »

Quote from: nmeyer414 on January 20, 2015, 09:51:57 AM

Either my eye sight is going or it may even be a bad pic, that cross member looks as though it is already bent?

Eyesight is 20/20 Nate

I put a slight bend in it to help clear the gas tank better

Flyin6 · « **Reply #677 on:** January 20, 2015, 11:18:53 AM »

Quote from: JR on January 20, 2015, 10:18:39 AM

Quote from: nmeyer414 on January 20, 2015, 09:51:57 AM
Either my eye sight is going or it may even be a bad pic, that cross member looks as though it is already bent?

I think that is just the picture but no gusset???

JR<
I was looking at it and decided it didn't need no stinkin' gusset

It either supports weight or counters torsion, so gussets aren't really necessary, although would add extra security against possible cracking, which I don't believe will ever happen. Remember, these trucks (As most) never had transfer case mounts.

JR · « **Reply #678 on:** January 20, 2015, 01:56:41 PM »

Ok, but it does need some protection from KIAs??

Flyin6 · « **Reply #679 on:** January 20, 2015, 06:43:50 PM »

Quote from: JR on January 20, 2015, 01:56:41 PM

Ok, but it does need some protection from KIAs??

Well...Not really

OK, got some more done today. Good working day, it was mid upper 40's all day so I kept up a bristling pace for maybe 6 hours.

First up I undercoated the inside surfaces of that new cross member

Flyin6 · « **Reply #680 on:** January 20, 2015, 06:46:03 PM »

While that was setting up, I painted the transfer case upper mount with the acid primer then two coats of my favorite JD stuff

Flyin6 · « **Reply #681 on:** January 20, 2015, 06:48:51 PM »

I also got on the new(er) Great Lakes Off-Road front diff cover. This one is extra special. One of Shawn's creations it is made from steel 1/2" thick at the flange, and either 5/16" or 3/8" thick cover and on this one an added 1/2" thick piece of Hyundai crushin' ex naval battleship armor to the bottom...Yup, it's stout

Flyin6 · « **Reply #682 on:** January 20, 2015, 06:50:18 PM »

I glued the gasket to the diff cover leaving the diff surface untouched. This will make this gasket reusable should I ever need to remove it again

Flyin6 · « **Reply #683 on:** January 20, 2015, 06:51:04 PM »

The last set of frame bolts I used rusted, so I painted this new set black first

Flyin6 · « **Reply #684 on:** January 20, 2015, 06:51:54 PM »

And, on it goes

Flyin6 · « **Reply #685 on:** January 20, 2015, 06:53:41 PM »

That is Randy's (Yukon) Zip air locker shinin' there in the sunlight for the last time (I think), as it now is wading in 3.75 quarts of Valvoline 75-90

Flyin6 · « **Reply #686 on:** January 20, 2015, 06:54:57 PM »

OK, that's in the bag...time to get one more little something done. The speedo transducer, yup, that'll do!

Flyin6 · « **Reply #687 on:** January 20, 2015, 06:57:05 PM »

Yes, JR, it's clean!

Undercoating was dry, so next the new cross member was permanized!

Flyin6 · « **Reply #688 on:** January 20, 2015, 07:00:45 PM »

Next up is the exhaust.

To fit the HX-49 style turbocharger to this generation truck requires a different, special pipe. Whereas before I had a 4" pipe necked down to 3", this pipe is 4" all the way through to handle the much increased exhaust flow this bigger turbo will produce.

THing is, the pipe will not fit the existing exhaust system, so some custom fitting is needed

Here's the new down pipe and the old mid pipe which I cleaned up

Flyin6 · « **Reply #689 on:** January 20, 2015, 07:26:34 PM »

Here the mid pipe is temporarily installed, so I can get an idea about where I need to trim it

Flyin6 · « **Reply #690 on:** January 20, 2015, 07:28:47 PM »

The down pipe interfered with everything.

First the dip stick had to go

Next this cowl to pan flange needed to be bent inward flat to the firewall

Flyin6 · « **Reply #691 on:** January 20, 2015, 07:30:37 PM »

With those things done the down pipe almost fit but was touching the heater box weather boot and insulator in these two spots

Flyin6 · « **Reply #692 on:** January 20, 2015, 07:32:18 PM »

While the down pipe was loosely bolted in place, I marked where it was to be cut

Flyin6 · « **Reply #693 on:** January 20, 2015, 07:32:49 PM »

Removing this much:

Flyin6 · « **Reply #694 on:** January 20, 2015, 07:33:49 PM »

Then I notched the heater box weather boot

Flyin6 · « **Reply #695 on:** January 20, 2015, 07:34:55 PM »

That resulted in a pretty good fit that will leave room for some heat wrap

Flyin6 · « **Reply #696 on:** January 20, 2015, 07:37:21 PM »

Then I cut the mid pipe and we can see that the fit is good enough. I'll clamp it together with a stainless 4" butt clamp and seal up the gap and clamp it tightly together

Flyin6 · « **Reply #697 on:** January 20, 2015, 07:39:19 PM »

Still wanting to get more parts off the floor, shelves, bed and so forth, I went after one more install, the rear driveshaft.

Again I used the GLO U-joint caps which are three times bulletproof

Flyin6 · « **Reply #698 on:** January 20, 2015, 07:40:25 PM »

And that, boyz and girlz is the end of build day 206

cudakidd53 · « **Reply #699 on:** January 20, 2015, 08:46:31 PM »

Wow- really starting to look like its ready to roll over hybrids and mulch beds! ;D