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Messages - Dustoff35

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1
Pictures


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2
I enlisted some help from my son assembling a body cart I picked up from the Jeg’s retail store in Columbus, OH. This makes repositioning the cab in the shop a one-man-job.


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3
What are you building? / Re: Drawer system for overlanding
« on: February 16, 2024, 06:40:56 AM »
This should help to keep all of your gear easily accessible. Looking forward to seeing it in person.


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4
Time to disassemble the PowerWagon. The bed came off easily with the forklift. Dirt and grime that had been building up for 50 years finally exposed. Underneath, the frame is in remarkably good condition.


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5
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: February 12, 2024, 05:13:58 AM »
To date, I have driven approximately 10,000 miles with the Carli Suspension System and the Method wheel and Toyo AT3 tire setup.


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6
It is a VE pump.


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7
Build Threads / Re: Don's 2022 Ram 3500
« on: February 10, 2024, 08:41:15 PM »
Looks good!


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8
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: February 10, 2024, 07:53:56 PM »
About a week after installing the wheels and tires, I drove from Northern Kentucky to Northwest Wyoming.


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9
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: February 10, 2024, 07:51:58 PM »
Time to update this thread! Method HD wheels and Toyo A/T 3’s were the choice. The tires are 35” diameter.


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10
After returning from a long trip to Wyoming, I drove out to Haisley Machine to check in and see how the engine buildup was progressing. I was pleased with what I found. The engine color is Chrysler green, which was used in the mid 1970’s.


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11
The machined parts sat in queue for most of the summer, engine repairs for racing trucks during the race season take priority.


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12
Some photos from one of my trips to Haisley Machine. At this point, all machine work to the block and head is done. They keep all parts associated with my build in a palletized crate.


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13
A few more engine parts. As I completed the restoration of groups of parts, I brought them to Haisley Machine.


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14
Oh, taptalk posts. Sometimes direct from phones they come out 90 off, but those look good!

Are those creme or what?
Actually, silver powder coating. Yes, Tapatalk is what I used to post the photos. I initially tried from my MacBook, no sizing option prior to posting. At least I couldn’t figure it out…


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15
Engine parts…






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16
I'm trying to figure out how to post the photos properly...
I seem to have forgotten...

Hit the reply tab, then the "add attachments" just below, up to 10 per post.
I think the photos are too large to display.

17
Adventure / Re: Bear Country
« on: February 07, 2024, 07:46:30 PM »
When I carry while hiking in the Wind River Range, Wyoming Range and Gros Ventre Range around Pinedale, its ALWAYS bear spray and SOMETIMES a Taurus Tracker .44 mag.  I have yet to see ANY bear while out and I have been backpacking and hunting that area for over 40 years.  We are always cautious and "Bear Aware" and I believe that accounts for not having any run-ins.

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I'm trying to figure out how to post the photos properly...
I seem to have forgotten...

19
Time to start updating this post!  Work has continued even though posting did not. I spent a good part of last summer and early Fall in NW Wyoming.  Prior to and afterwards, work on engine components and axles continued.  Here are some engine parts.  Some parts were powder coated, some painted.

20
Build Threads / Re: Don's 2022 Ram 3500
« on: June 17, 2023, 06:51:00 AM »
Did you get those greaseable leaf spring shackles installed?

21
Hide Site / Re: NWMT Cabin
« on: June 16, 2023, 12:33:42 PM »
looks good!

22
Build Threads / Re: Don's 2022 Ram 3500
« on: June 16, 2023, 12:25:43 PM »
Additionally, my truck has the Ramboxes which likely adds a couple-hundred lbs.  I also have a bed-mounted Titan auxiliary fuel tank that adds 300-325lbs.  I'm sure that helps.

23
Build Threads / Re: Don's 2022 Ram 3500
« on: June 16, 2023, 12:21:17 PM »
Well, did you get the results you wanted?
[/quote]

I did.

My objectives were simple:

1. Level the truck.  Check.
2. Eliminate the harsh "donkey-kick" from the rear when crossing an expansion joint while empty. Check.
3. No towing/payload capacity reduction. Check.

I never expected this truck to ride like a coil-sprung 2500 or 1500. I can say that ride quality IS improved.

The suspension setups ARE different. I have additional components that I believe make a difference. Besides the Carli-tuned, (NON- "Off-the-Shelf"  :grin:) King shocks, there is the torsion-type sway bar and the greaseable rear spring shackles. The Carli radius arms would not make a difference regarding ride quality.


24
Build Threads / Re: Don's 2022 Ram 3500
« on: June 16, 2023, 07:30:48 AM »
After speaking with the boys at Carli, I should not have sold you the individual components without the shocks, as they are all engineered to work around each other like one big happy family. If you found fox 2.0 try them out before throwing in the towel on the system. as they are not carli tuned they may not be as ideal as they were intended but are likely to solve 90% of your issues. He's hard to get on the phone since it's just him, but Tyler over at Carli is a wealth of knowledge. Tyler@carlisusupension.com. just let him know you're working with me on this project.
I couldn't agree more.  The Carli suspension is a well-designed, well-engineered and quality-manufactured system.  Realize that when you substitute parts, you change the system and alter the proven recipe.  The off-the-shelf, non-Carli-tuned Fox shocks are not part of the system. I will be surprised if you get the results you want.

25
Build Threads / Re: Don's 2022 Ram 3500
« on: June 08, 2023, 07:05:25 AM »
Good job on the suspension install. The Carli requires a bit more technical fortitude than any other system I have put on, but the end result is excellent. I have Method HD wheels on order for mine…

26
Hide Site / Re: NWMT Cabin
« on: May 31, 2023, 09:08:30 AM »
Nice progress. You will be in there fabricating soon!

27
Frame looks pretty good. No obvious pitting and just surface rust.
It’s not all that great. Apparently mud, leaves and debris were trapped where the tank abuts the frame. A bit rusty there. Additionally, one of the previous hillbilly owners tried to weld reinforcement plates and traction bar mounts onto it. Must have been his first time using a welder.

28
Here are most of the additional parts as they are restored by electrolytic rust removal, abrasive or bead blasting and then primed and painted. I also use Evaporust on a lot of the bolts and small hardware and brackets.


Evaporust actually works?? My boss got some and he dumped it in a wash tub. He soaked every tool he could find with a little rust on it. After a few weeks it turned into a thick tar and now those tools are forever trapped. Actually I think we have 2 of those tubs of sticky tools in the shop somewhere.
Yes, I have had very good results. I keep the soaking container covered to prevent evaporation. Perhaps that’s why it became like tar? It only takes perhaps a day or two to remove rust, some parts are ready after an overnight soak.

29
Not sure what your build plan is, but I didn’t measure any brackets going from the 92 donor onto the 74. Just bolted it all together.

Had to cut out the divorced transfer case cross member on the 74 frame, and drill some holes for the 92 transmission cross member. Everything else was direct bolt on.
Good to know, thanks.

30
Everything we want to keep is stripped from the ‘91 chassis. We will put it outside in an out-of-the-way location in case we need to check measurements or bracket locations in the future.

31
Looks like a clean axle.
It’s OK, rusty but not too much pitting.

32
We continue to strip the ‘91 chassis. Here is the Dana 60 front axle. Once the frame is stripped and moved out of the way we will dig into the axle to see what surprises await…

33
With the engine out, disassembled and at Haisley Machine, it’s time to start stripping the remaining parts from the chassis. We will definitely need to take out the king pin Dana 60 front axle and the fuel tank.

34
Would you build another 6000 sq ft structure if you tear down what you currently have?

What is the condition and thickness of the the present concrete slab? Does it have stem walls or is it a turned-down slab?

35
Mines been undercover and rotated free when I got it, some time ago! Only had 80K I was told.

Keep it covered! This engine did get water/moisture in it at some point.

36
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 18, 2023, 05:51:48 AM »
I spent yesterday morning poring over the underside of the truck, checking and re-checking torque values and placing witness marks on fasteners with a paint pen. Once complete, I drove the truck a few miles to a local Tire Discounter’s for an alignment. There is still a good amount of tread left on the OEM tires so I will run them for another 1000-1500 miles while I decide which route to take regarding wheels and tires.

37
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 17, 2023, 02:54:32 PM »
I may consider using those Daystar bottom cups on this truck at some point in the future. I do not have time to do this right now. This install has taken up more time than I anticipated. It is scheduled for an alignment this afternoon.
I ordered a pair yesterday after Dave posted the link.
BTW, those daystars are $86. Exact same product, different vendor cost me $35... Should be here tomorrow.

I’d like to take a look at those before you install them if you don’t mind.

38
With the engine block completely stripped of parts, we power washed everything and placed it on a pallet until it goes to Haisley Machine in Indiana.

39
We removed the camshaft, crankshaft and the pistons. Only one of the two pistons with corrosion in the cylinder bores required additional effort to remove. The Evaporust did an excellent job of loosening the pistons and rings. The two affected cylinder walls don’t look as bad as they did right after cylinder head removal.

40
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 17, 2023, 07:16:24 AM »
I may consider using those Daystar bottom cups on this truck at some point in the future. I do not have time to do this right now. This install has taken up more time than I anticipated. It is scheduled for an alignment this afternoon.

41
Disassembly of the 12v begins. The Evaporust appears to have done its job, and although the cylinder affected cylinder walls look a little rough, we should be able to get the piston s removed.

42
Very nice engine stand.

43
Hide Site / Re: NWMT Cabin
« on: May 16, 2023, 06:28:43 AM »
Nice work. The boom attachment on the skid steer is a big help.

44
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 16, 2023, 06:22:27 AM »
With the spacers welded into place, we primed and painted the lower mounting plate and re-installed it onto the axle with longer bolts. The last item(s) to install was the Carli-King 2.5 reservoir shocks.

45
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 16, 2023, 06:14:55 AM »
We cut some solid stock into the correct size for spacers and cleaned it up in the blast cabinet. We then prepared the airbag axle plate and welded the spacers, ensuring we maintained clearance for the mounting bolts.

46
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 16, 2023, 06:06:56 AM »
I’m really not concerned with over-extending the airbags. The truck doesn’t see that kind of use. Primarily highway towing with perhaps 5% gravel and dirt roads. Occasionally forest service roads to trailheads and the like. I have the airbags to level the truck while towing. A level truck keeps the steering and braking predictable.

47
I have an almost identical stand, to which after grinding out welds and rewelding it I then built a side mount for the Cummins. Stand may be 2k rated but that Cummins is long front to back.

Agree. It’s a heavy engine. If I do another one, I will make a side mount.

48
Build Threads / Re: 2021 Ram 3500 Crewcab
« on: May 15, 2023, 07:49:40 AM »
The rear springs are removed in order to get the new grease-able shackle in place. Very heavy and bulky to get the spring out and back in. A 1-inch billet block is also inserted between the spring pack and axle. We are going to have to fabricate a spacer for the airbag platform to prevent over-extending the airbag.

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The forklift makes removing the engine from the chassis almost easy. We bolted the block to a new 2000lb capacity engine stand.

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