REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: Flyin6 on September 20, 2014, 07:59:51 PM

Title: SquareD Build Thread, Part 1: The beginning
Post by: Flyin6 on September 20, 2014, 07:59:51 PM
Why Square D you ask?

Because this build is an ancient square fender Dodge, so Square D

Many of you are very familiar with this build or transformation or whatever it is, but to some of you this is new

Inceptually, this Dodge truck purchase was made to augument the Chevy truck and to cover for an extended period of time while the Silverado received a solid front axle. I thought I would replace the rubber, change fluids, clean it up and after maybe a month of replacing and fixing things, place it into service.

But just so many things were out of whack that as I dug deeper into it, I realized I could not resurrect a half baked thrown together truck, or just bring it down and redo it.

The redo part grew over time to the point most of the body was removed from the frame and all the suspension was completely modified and reinstalled onto a freshened up frame.

Somewhere along the way, I realized that in extremis, should the US come under nuclear attack, and I actually survived that, the EMP would render the Duramax inoperative for the rest of my life. But this ancient old Dodge would crank up immediately and never realize what just happened...It has no electronics to speak of.

Thinking and swallowing hard because of all the effort spent on the Chevy it had an Achilles heel, it's mind boggling web of electronics! It would always be the weak sister to a much older design.

I plan to correct that some day with the addition of a 12 valve Cummins engine installation and old school transmission to make it concrete proof useable forever.

But for now, SquareD is evolving to be a first rate survival vehicle that you could drive every day, has loads of power, sips (Any) fuel, and has abilities not seen outside the Army or Marine Corps.

With that all said, let's get on to the actual build which started in the summer of 2012
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:02:37 PM
OK boys and girls, let's get this thing started

For those who follow my LML build thread

Titled

"My build thread"

You already know where this thing is going. It will get very detailed, and get derailed, then back on track and who knows where.
Having said that, this is what I would like to do here:
I plan to build this Dodge truck to be an EMP proof, survival truck.
What exactly does that mean, Survival truck?
Well, it always needs to start.
It needs to be multi-fuel capable
Readily available spare parts
Reliable
Able to carry heavy loads and tow a trailer
Have a range of about 1000 miles, maybe more
Be all terrain capable as well as capable of a long day of highway driving.

It will be the backup vehicle to the LML survival truck I built as any good survival plan has many layers, each providing it's own capabilities

Before we write a book in the first post, here's a picture of it the moment I purchased it:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:06:00 PM


Another view
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:13:12 PM
It has 171,000 miles and starts right up and runs great.
The steering is shot, as is the exhaust. A brake caliper is grabbing and the shocks are nearly rusted in half
The frame is solid, the truck was Ziebart protected when new and shows it. I can find no severe rust other than the surface stuff.
Apparently it has seen some combat, since it sports this nifty area denoting it's various kills
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:14:05 PM
The front bumper thing was apparently removed from a B&O locomotive or from the set of "Mad Max, Beyond the Thunderdome
It will be going bye bye...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:14:53 PM
The theme I am going to use is simple. I mean to keep it simple.
You see I really believe "Less is more."
Therefore, expect no bling, little over-the-top, and certainly no techy anything.
Tires you ask?? Well just a set of 33" all terrain or mud terrains on some simple serviceable wheel.
Brakes: Stock, but rebuilt with good pads
Paint? Probably back to stock
Engine: Sane. Will build around little to no smoke, 400HP 20+MPG and dead reliability.
Speaking of engines:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:15:49 PM
This is the first year Dodge intercooled the Cummins. It has a way too small turbo which I will replace, an inferior VE injection pump, which I will keep and perfect.
The interior will get a super cleaning, seat replaced, and probably color changed to black.
I will likely just put a new rubber floor matt back in after I spray the inside with sound deadening lizard skin
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:16:48 PM
It doesn't have a tach, so I'll have to do something about that...
So, here's point zero before the first wrench is turned on what I hope to be an amazing transformation
I hereby name this project "Square D" (for square Dodge)
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:20:09 PM
So, although it's early in this build here's how this thing is shaping up:

First, it is unsafe to drive, so all of that is getting fixed at Roy's shop before I take it home.
That includes
Borgensen steering shaft
Replace all tie rods
Replace the rubber brake lines
Replace the calipers/rotors/brakes
Fix the transfer case output wobble
Top off fluids
pull the hubs, and repack all front wheel bearings, clean everything and reassemble
Install 4 new tires and wheels, 17 X 9 and 33"-12.50/R17 tires

Then drive it to my house
Then
Replace all fluids
Replace all rubber hoses, belts and lines under the hood
Remove that hideous bumper
Remove all lights, switches, wires, relays and everything that dodge didn't put on there
Do a massive cleaning/pressure washing, steaming/chem soak to get it clean
Remove the interior and clean and replace
Do something with the suspension
It needs 4 springs and 4 shocks
Then...???

The thing is, I need all of that done before I cut the D-Max apart because this truck is actually going to be my transportation while I build the 2011 truck...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:22:33 PM
Originally Posted by bigjohn View Post
That's cool a first generation cummins.

I think I found it at the last possible time in it's life to save it

It had been more or less abandoned by its owner and was sitting outside under a bunch of trees. It was getting rustier and started to leak water into the cab. The steering was all but gone. My money says it was about to be parted out for the Dana 60, Dana 70 and the Cummins 6bt instead of just fixing it.
I feel that by taking a sane approach and just rebuilding most things and upgrading the quirky stuff, I'll have an enormously capable truck that is actually a survivor truck. If I chose, it would fetch every penny I invested in it with no problem at all
But it needs immediate action, so it's getting it right now!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:23:52 PM
Note: there are dozens of post missing from original thread which were discussions of this and that.

I have edited the vast majority of that stuff out to condense the build to, well, the build!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:26:46 PM
While I am waiting for the steering to get fixed enough to safely drive that animal to home station, the parts accumulation has begun (As it always does!)
I already have the king pin rebuild kit. I am going to keep this one in the nylon factory bushings, where as the LML SAS is getting some cool Bronze bushings.

I am on the hunt for tires and wheels. I will only buy completely new and name brand stuff if I cannot locate good used stuff in a reasonable time frame.

I just ordered a Diamond 4" exhaust system, since the factory one is all but rotted off.
Here's the one I bought
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:31:38 PM
So the next acquisition will be the tires and wheels
I am looking for moderation and thrift.
Am even open to steelies and low end tires, or used tires/wheels.
I think a ton can be done with these trucks using middle grade stuff.
I have noticed there is not an abundance of tires in the 33 12.50R16 or 17 fitment.
There are however a bunch of 285/75R16 and 17 as well as 305/70 and 315/65 in both the 16 and 17 size. The more I think about it, that might be THE go to tire. It is right at 33" in diameter and there should be plenty around, as in in an emergency I could scarf them up. They are not huge so although they won't be able to roll over VW sized boulders, they should crawl over a Kia and the speed bumps down at the mall.
So, tomorrow it's time to get serious and lay some plastic down. It would be a berry, berry bad thing to have old square D all tightened up in the steering department only to find I can't drive it for lack of tires!
Yepper, better get on that one!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:32:50 PM
Well, I got the tires and wheels ordered
Again, my consideration is not for high end stuff, but "Real" parts that everyone can afford and not name brand necessarily.
Looking there. I purchased the Ion wheels in a respectable 16 X 8 size and Hercules DT tires in a 33" metric size, 285/75 R16
Tires were around $200 ea. and the wheels around $100 ea. The tires come with a free alignment and lifetime rotation and balance, so that takes care of that for the next few years!

I will get that utilitarian/ retro look and modern technology and low cost all woven together!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:33:47 PM
I just picked those same rims up for my truck. Love em and they are plastic dipped so I can keep the finish. Got mine for 250 for the set used.. No winters. Couldn't pass a deal like that up..

What's yr plans for interior and gauges? What exhaust will you run?


I just purchased the Diamond 4" exhaust w/muffler
For the interior, new everything, but basically stock
Piller gages I guess, EGT, Tach, Boost pressure...
Add a semi permanent GPS install
Work with the radio some
Change the color scheme over to dark gray or black sfrom the light gray it currently is.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:34:55 PM
What are your plans for fuel and air? Gonna try to stay stock?

Definitely not!
I think the smart way of doing this is to set a goal.
I think I need 400-450 horsepower and a bit over a thousand pound/feet of torque.
Why I think I need that is based on what I envision the vehicle's weight to be which is anywhere from 6500 upward to 10,000 I need that amount of power for short sprints and pulls
So based on that 400ish number I will simply modify the pump, buy the turbo, select the injectors, modify the air intake and so forth.
I already purchased the 4" Diamond exhaust based on that assumption. 4" with a muffler should hopefully support 400 HP while keeping it quiet.

Keeping it quiet is something else I am planning to sort out. The 1st gen motors were rattle cans we all know. So other than using a muffler. I plan to sue sound absorption materials in the inner fenders in spots, in the cab and on various chassis places to try to destroy all harmonics and absorb a majority of the clatter. I plan to use dyna-mat, Lizard skin, felt, and wadding to get that done.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:35:52 PM
You dog .... you get to do all the fun stuff .... this is exacty what I want to do! I have had my eye on one but I think i would have to incorperate the cost of a divorce into the cost of ownership! What did you pay for it?
I have been tinkering with alternative fuels for awhile, trying to get them to behave in modern CRD diesels, but the machanical injected cummins should be much easier to deal with. Most of my problems have been with fuel filters, I have convinced myself that most of the brands I have tried the paper (cellulose media) reacts with the WVO and B100 causing it to swell and block off. The WMO is much less hard on filters. I have had to run a stainless steel 10 micron mesh on my liberty crd for it to work right. just fyi for you when you start looking into multi fuel options.

I might have to get out of the multi fuel options for awhile and have some equipment for for sale, you mentioned 1000 mile range, I have a 90 gallon transfer tank that will fit shortbeds, and a bluegrass fuel system (google it) I might be willing to take a hit on.

I might have to live vicariously through you!


We can definitely deal on that fuel system

I did plan to run a fuel processing operation down on my farm. I can make 60 gallons a day with a $1400 unit, then just store it there. I thought of maybe setting up B100, B50, and B20. Use the 20 in the D-Max and the other grades in my dozer and Dodge and...

Ya know, divorce is too big a hill to climb...everyone gets killed...Well, you get to suffer a long time before getting killed...I definitely recommend against it! So maybe you just live through this thread and sa' live'!

Tell you what, let me know what you want done, and we'll see if we just can't do it here...Just keep it sane. Not going Coil-over wild on this one (Like I'm doing on the Combat-Max truck...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:36:42 PM
Had a 1st gen two trucks up from me in the pulls last weekend crew cab with 8' bed with a 10" stack and it sounded awesome lol. I love seeing people bringing back the past and your def doing it the right way man I am pumped for you.

I think the truck, like the square K30's is a classic. When I think what I'd have investing in, say a new silvy gasser and doing a few nice things, I'd be knocking on 40K easy. Then over time that less capable truck would spiral down to be worth maybe 5K-7K in a few years time, or 17% it's original value. So I'd lose 83% of it's value or $33,200 over 5 years or an average of $553 a month!
See where I'm going with this?? So instead I buy a 91 Dodge Cummins for 4K that after fixing the tie rods, steering and a though cleaning could fetch 6K. I could walk away from this in a week and pocket more than a grand. But over the next 5 years I'll probably put another, say 10K into it not counting routine maintenance. That will yield a perfectly painted and new looking classic that will draw all the stares, bet better mileage then the Silvy, tow more, and should I decide to sell it, my 19K investment would easily fetch that or more. So cost of ownership would effectively be zero. On one hand I'd lose 33K on the other hand I'd break even or maybe even pocket a little. By my math that has me $14,000 ahead of the game. So from a cost perspective alone the Dodge screams "Great buy!"
But if I buy it and hack the living snot out of it, then I ruin the value, negating the value. That equals a pretty dumb idea and points to my plan to keep it tasteful, and really just very well maintained, while enhancing performance, handling, braking, drive comfort, range safety, and so forth.

So that's my reasoning behind the path I am taking, and juxtapose that over the current iffy US domestic situation, and a truck again is screaming to me that not only is it a survivor, but it could well make me and mine ones as well!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:38:21 PM
Pushing the ball downfield a foot at a time.
The wheels and tires came in.
ION 16 X 8 zero offset and the Hercules tires.

I couldn't wait to get them mounted, but Shannon over at Tire Discounters called to tell me they are ready for pickup.
I had them add the balance beads in lieu of balance weights and mount the white letters inside. I almost went WLO thinking of capturing that retro look, but I have to say, I didn't like it back then and I guess I still don't.

Here's they are:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:40:57 PM
And the tires
And Duane for all of those of you who wondered what a really old Black Hawk pilot looks like
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:42:00 PM
Originally Posted by nmeyer414 View Post
The real question don is do you need glasses? I can understand those carfish boys but ?????????

Nate,
I definitely need glasses
For close up and especially nighttime
Funny Story
So one dark night I was in the gunship over around the punchbowl in southern Afghanistan. We were out doing a little, well, hunting and target practice if you get my drift.
We are listening to the radio as we always did, making periodic position reports and so forth when we hear someone if firing up the airbase with 107's. Well, I am like two mountain ranges to the north west and it's Scotty's turn flying so we both feel the need for speed and to get into the fight PDQ.
He says, "Don, give me a direct-toto Kandahar"
That means punch in the coordinates to Kandahar and hit the direct to button which will make the big bearing pointer needle point directly to Kandahar air field (KAF). I start looking all over that key pad but can't make out anything. Fearing I might enter coordinates for Ethiopia, I just keep fumbling around. Scotty finally says, "Can I have that direct to please!"
I still can't see a dammed thing so I look over my shoulder and immediately notice a dull glow in the night which is actually the airbase, some 50 miles away. "Scotty, go to the light," is all I could think of saying.
"Did you seriously just tell me to go to the light?" Inquired Scotty..."Yep, go to the light, we'll figure it out as we get closer!"
Well, we found KAF, didn't find the enemy, didn't get to shoot anything and I took a year long ribbing over that one!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:42:51 PM
Originally Posted by DIRTEEMAX View Post
I cant lie I'm a fan of the bumper too

Well, if you want it, come and get it
It soon will be going to the scrap yard
Get a few dollars out of it to use on a can of paint or something...

Just got the truck back home
Carried it on that trailer I heavily modified earlier in the summer.
Worked just fine...Towed along at 65 mph with no issues what so ever!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:44:58 PM
OK, I finally went over to the next county east of me and picked the thing up from the 4WD shop it was sitting at.
Here's pics of all that happening:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:46:58 PM
More
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:48:27 PM
Got it home finally:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:50:34 PM
Some ugly component pics before cleaning:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:51:46 PM
I first cleaned all the trash out of everywhere
It was loaded
I filled a trash can, but the truck yielded all this good stuff
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:53:27 PM
Those manuals are factory service manuals for this truck...quite a score!

Then the pressure washing started. I know I started sometime around 1330. I know that when my frau came home sometime around 1645, I was still at it!

Yea. I was drenched, covered with grease spatter and about nasty as a human can be and not be attending the Ranger course!

But after all that cleaning and what looked like 50 pounds of dirt and grease, the truck looked essentially the same!

Anyway, here's pictures after much gnashing of teeth and overall suffering:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:55:13 PM
More:
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:57:27 PM
And yes, I pressure washed the interior!
Hey, it's a Dodge...It ain't pretty, it just works

The whole thing looks a lot better actually.

This was step 1 of the cleaning process

Next will be removal of all the accessories to see how big of a pile I can get.

Step 3 will be another degreasing and detail cleaning where all the crap comes off the windows, the hoses get wiped down, heater cleaned out, seat and pad removed for cleaning.

After all that the truck should be ready for some new parts and the start of the reconditioning process.

I'm going for the area of a sheet of plywood covered to a depth of 6"!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 08:58:09 PM
OK, all you axle decoders

I found tags on both axles

The front was marked 3.54 (the gear ratio) and had the following two numbers: 52068190 and 610857

The rear has me puzzled

I don't know if it's a Dana 60 or a Dana 70

Both use the same cover. The front has a "60" cast into the iron webbing, but no such number is cast into the rear axle, or at least I couldn't find it just yet

In the tag affixed to the rear cover is the same 3.54 and the following two sets of numbers:

605509 (I think)
52068173

Inside the drivers door was the VIN and the tire and axle info.
It states the GVWR is 8510
Front axle is 4060
Rear axle is 6084

The transfer case is cast iron and has a tag denoting it is a 205
It bears the following number: 4428003
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:00:36 PM
From Shawn"

See item #3 Yours should have one too on that rear axle......

Hint: a lot of times taking a pocket knife and scraping off the years of dirt, grime and gear oil helps view it.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:01:32 PM
From Shawn

I'll try my best off the top of my head, if you know I'm incorrect feel free to correct me. What I am describing is mostly traits of rear axle differences some of which applies to fronts as well.

70 has larger ring gear but I believe pinion diameter is the same. Tubes are larger on a 70 than a 60. Shafts in 70's are normally 35 spline but not always. Long story short from my experience 70's are the black sheep of the Dana family of axle when it comes to hubs, widths, seals & general configurations. It would be like gathering parts from Dons' & my shop to build a frankenmobile (well maybe more mine as I'm like your grandfather farmer who keeps everything & Don gives it all away when no longer in use). It seems there was little standard to them even in the same model & year of vehicle, not sure if this was because they ran short of some parts & decided to substitute with something else on the shelf? Or if they were possibly built in different plants? Swapping them from drum to disc brake can be challenging in the fact that making a standard swap kit is about impossible unless I include 3x as many parts as needed. I've helped guys swap a lot of them but they have to buy the hard parts locally as no telling what they have until they break it down. That's my 2 cents anyhow.

Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:02:19 PM
Originally Posted by nmeyer414 View Post
That thing is sweet looking! I think there is more metal in the body than on our d-max's combined.

I did see that don almost had to remove the side rails on the trailer just to get her on there. Good thing all of that side wall rubbing will he taken care of with the new shoe's.

I must say that it does not look beat on, but that is a rats nest of messy wiring under the hood.


Nate,

You know, it's not been beat on, just well used. The VE injection pump has never even been adjusted! It's just an old stocker, perfect for a build.

The rust is all manageable as you will see very soon as I dive in quickly on the worst areas to get all that neutralized.

There is indeed some metal in there but these trucks weigh around 6K whereas our D-maxes, 7500-8500. Big difference. The old Cummins trucks with smaller motors pushing less weight at less RPM all equate to outstanding mileage. This example runs in the low-mid 20's.

And that rat's nest will soon be just a distant bad memory!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:04:15 PM
OK Shawn,
I measured the axles up
Front has a 3 1/8" axle tube give or take

The rear has a 3.5" axle tube

I scratched all over that thing trying to get the BOM
All I got was this hazy number which might be correct, who knows?

M 931099 11B150 1NA
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:05:48 PM
Here's the U-joint pics
First is rear driveshaft, transfer case end, then the rear, then the front...as if you didn't know already
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:07:34 PM
There's a lot more cleaning yet to do.
I think the next step might be with a few gallons of Kerosene and let that set on there a day or three, then follow with some scrubbing then a degreaser.

The black stuff is mostly old undercoating, but there is still some hardened and stubborn grease hanging around in there!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:09:16 PM
These mismatched, bald, oversized and ugly tires measure in a bit over 34" tall resting on the ground. Give a little for sidewall bulge, while carrying the weight of the vehicle and they would probably measure up 34.5"ish

The new 285/75R16's measure in at 32.8" which I think will be a good match for this truck
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:10:09 PM
I had the sled dog in with me to help check out things. I think she has her doubts about those brake calipers!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:11:14 PM
Originally Posted by stlaser View Post
So the rear is a 70 & those flimsy straps need to take a hike along with those rear drums....


Shawn,

If I convert to rear discs how do I do that and still get a parking brake that works?
I know how I did it before...
I ran the brake line into the console and installed a valve.
Press on the brakes close the valve and there you go!
That's how aircraft parking brakes work BTW...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:14:16 PM
From Shawn:

That's probably the best way or you can purchase a set of 76-78 caddy rear el dorado calipers from my guy. & yes you can still buy the from any local auto parts store but they are minus the actuator brackets & needed adjusted. Gm no no longer has them in stock to sell. My guy has them laser cut & formed from an unmentionable source  then he bolts them in and adjusts the calipers prior to shipment. The other downside of these is that you will probably need new cables but I have a really good source for those as well.

On a side note though, you live in ky why do you need a parking brake? There's definitely no vehicle inspections there, heck you don't even have to run plates or tail lights on trailers down your way!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:14:37 PM
Found a cool link.
If you want information on the build codes for your Dodge Ram, then copy and paste the following link onto your browser. The site provides a contact tab where you fill in the basic information about your vehicle and Dodge will in turn send you the exact build sheet for that vehicle.

I just did so, since I am having problems figuring out the information in my heavily weathered build tag



Contact Dodge
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:16:24 PM
From a member:

Great thread, I'm really going to be looking forward to seeing it develop. I have a big soft spot in my heart for 12Vs and the square Dodges. I know you're still in the research phase so I'll throw my $0.02 in on auto vs. stick. When it comes to transmissions, especially behind diesels that are meant to work, overkill is the only way. Yes, a tune up, band adjustment and a big ole cooler would probably get you by... but is that enough for you? If I understand the use case for this truck "probably get you by" is never enough. I understand this truck doesn't have to be on the "great" side of the Sears scale, but that should apply to cosmetics, creature comforts and the like only.

If it comes down to this truck being the difference for you and yours that means things are really, really bad. The D'max would be down for electronic reasons presumably and you are not going to want a questionable transmission on your mind. So with 400-450HP and 1k TQ to deal with that means a ~5k build on the auto to know it's bullet proof. That is a huge chunk of your overall budget. You also still can't push-start it. I think the NV4500 gone through to fix 5th is the way to go. A South Bend clutch and you'll be good.

I do understand and generally agree with the point about having to shift if you're runnin' and gunnin'. But I don't think I need to tell you that the driver is the least effective gunner in any vehicle. If you do need to be the one to go to the trigger as the driver you're going to want to hold a steady speed and course anyway to have a chance at a decent shot. I think it's safe to say that if you're in a situation where you have to downshift a 1k TQ Cummins to maintain speed you're not in a situation to shoot anyway. The interesting thing to me about this argument is the idea of having your kin drive so you can gun. I'm a firm believer that anybody you love and care about that is old enough to be capable of driving (notice I didn't say old enough to legally drive) should be capable of driving a stick. To me that comes down to not having to limit your options when it comes to vehicles if it all goes to hell, and I think that applies to your stable. If you were going to trust anybody enough to be driving under duress in an off/bad road situation that type of person will be capable of driving a stick with some training.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:17:17 PM
Quote:
Originally Posted by tjZ06 View Post
Great thread, I'm really going to be looking forward to seeing it develop. I have a big soft spot in my heart for 12Vs and the square Dodges. I know you're still in the research phase so I'll throw my $0.02 in on auto vs. stick. When it comes to transmissions, especially behind diesels that are meant to work, overkill is the only way. Yes, a tune up, band adjustment and a big ole cooler would probably get you by... but is that enough for you? If I understand the use case for this truck "probably get you by" is never enough. I understand this truck doesn't have to be on the "great" side of the Sears scale, but that should apply to cosmetics, creature comforts and the like only.

If it comes down to this truck being the difference for you and yours that means things are really, really bad. The D'max would be down for electronic reasons presumably and you are not going to want a questionable transmission on your mind. So with 400-450HP and 1k TQ to deal with that means a ~5k build on the auto to know it's bullet proof. That is a huge chunk of your overall budget. You also still can't push-start it. I think the NV4500 gone through to fix 5th is the way to go. A South Bend clutch and you'll be good.

I do understand and generally agree with the point about having to shift if you're runnin' and gunnin'. But I don't think I need to tell you that the driver is the least effective gunner in any vehicle. If you do need to be the one to go to the trigger as the driver you're going to want to hold a steady speed and course anyway to have a chance at a decent shot. I think it's safe to say that if you're in a situation where you have to downshift a 1k TQ Cummins to maintain speed you're not in a situation to shoot anyway. The interesting thing to me about this argument is the idea of having your kin drive so you can gun. I'm a firm believer that anybody you love and care about that is old enough to be capable of driving (notice I didn't say old enough to legally drive) should be capable of driving a stick. To me that comes down to not having to limit your options when it comes to vehicles if it all goes to hell, and I think that applies to your stable. If you were going to trust anybody enough to be driving under duress in an off/bad road situation that type of person will be capable of driving a stick with some training.

Anyway, keep it up and one vote for the stick!

-TJ


Good Discussion
I love it
Shawn on one side with his valid points
And in this corner, you with yours

Very good opposing views.

One thing I learned some years ago when I first started to become a person in charge (In command) was that I often did not make the best decisions. On one occasion Bill over here had the better idea, whereas the next time Rusty did. Bill erred on the side of caution whereas Rusty always went for the jugular. Came a time when I started crewing them together, pilot in command and co-pilot. It worked great! The killer always wanted to go, but the safety minded one caused him to pause and rethink some of his riskier decisions

Bottom line was that together they were superb...Sort of the same mix that develops on my threads. Dunno why, perhaps the subject matter is good enough to attract some thinkers, but whatever the reason, the dynamic it creates is constantly thrashing ideas, whilst bringing up various points to consider and I find myself at a comfortable and familiar spot at the helm making the final call. But no longer my call, but more of an "our call."

That's a good thing

A wise old Warrant Officer once told me well before I became something like that, was to always surround oneself with people smarter than yourself...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:17:45 PM
I think I can conclude that the transmission choice is not made, but that an intermediate step would be to stay the course with patching up the existing unit, which to my knowledge works just fine and focus on the big picture

That big picture is to freeze further degradation in it's tracks, return it to a safe and serviceable condition, then slowly bring it back, modifying various things as I go along.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:19:10 PM
From Cuddakid53:

Question based upon previous experience; how easy is it to bump/push start a Diesel?

Based upon the reliability of said answer, is that enough to pin the other rationalizations on, in making the decision?

My first Diesel was a 6.2 Chevy 1980's vintage with manual trans, 2WD. I remember trying to bump start it once living on a steady grade when battery went dead. Got it rolling and popes the clutch with key on and all it did was lock-up the rear wheels. Ended up lugging small generator down the block to it to jump it and go buy a new battery.

Were it up to me, I want the ease and less stress of pumping the clutch with the auto- build it right (like you always do Don) and you'll be good to go! Say you're shot in the leg/broke it/rolled ankle from running in sandals  or some other malady of the lower extremes- flop it in there and mash the peddle with the good one or a stick even and you'll move down the road!

Manly gear mashing is for "pleasure" driving, auto is for ease of operations or we'd all still mostly have manual trans. due to lower cost of production and higher mileage. There's a reason there are more auto trans. on the roads-

DOT signing off, heading for second cup o' Joe-
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:19:30 PM
Excellent point(s)

Pilots in my business mostly carried switchblade style knives!
Know why?
The thought was that you just crashed
Crashing oftentimes breaks things like landing gear, windshields arms and legs.
People in aircraft crashes sometimes become entangled in all the now loose wiring.
So let's say that although the broken windscreen has taken out an eye, an arm and something else. You are still strapped in and have hydraulic lines and wiring harness wrapping around your throbbing brain case group.
If you can get one hand on that knife and push a button, you can get it to open. You can then use it to cut the wires and whatever and get out before those sparks and fuel combine in the back to create some energy.

So the twisted ankle with the clutch pedal is a valid point indeed!

Now for the manual trans crowd I once had a stick shift F250 with a power stroke with a near dead battery. I rolled it down hill, stuck it in 3rd, popped the clutch and it fired right up. So I do and did realize that as a possibility.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:21:23 PM
Got some work time in today after church and lunch.

I started out buying parts. Concentrating on the cooling system, I picked up all new hoses, clamps, fluid, and a new 8 rib belt...Yes, 8 rib!
THen I picked up the drag link and both tie rods.
THe plan this afternoon was to get the radiator flushed out and I even started doing that when I switched gears.
THe interior was wet when I purchased it and got even more so when I pressure washed it. Thinking of the rust that Duane discovered under the mat, I decided to just get on that first.
So everything came out of the interior first
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:23:10 PM
Still more removal
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:24:41 PM
Then using a variety of cleaners and several hours of scrubbing I had it all cleaned out.
I sprayed down everything from the windshield down...I need that thing clean and it was anything but
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:37:56 PM
I scrubbed the rubber floor mats, the Cummins has two layers and a felt pad as well. I saturated everything with detergent, allowing it to soak, the scrubbed and finally pressure washing everything.
I got the bright idea to launder the felt pad in the wash machine...Don't wash your felt pad in a wash machine.
So tomorrow, I'll be ordering a new felt pad...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:39:36 PM
The rust is really not so bad, just scale really.
Tomorrow I'll take a wire cup grinder to it, then wipe down and coat it with the rust converter.
I think I might spray a layer of Lizard skin over that to seal it and provide some sound deadening as well
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:40:54 PM
I went a little crazy at this point.
I was looking at the seat, and I was looking at the pressure washer and wondering, what if???

So I mixed up a half gallon of carpet and upholstery cleaner and saturated the seat and again did the wax on/wax off thing for some time. Then I sprayed it with all 3200 psi of water not caring what happened since I was planning on re-skinning the seat anyway.
Well surprisingly all those years of really nasty stains went ah flyin' and I was left with a pretty good looking seat.
If the fan can manage to dry out the 250 gallons of water still trapped in the foam, I just might reuse it!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:43:03 PM
Originally Posted by duramaxdarren View Post
no no no that will never dry out lol!!! a week in the sun maybe

Well, I've got a week, no worries!
Just checked on it...It's drying right out
And it actually looks pretty clean

Just ordered the lizard skin sound deadener, 2 gallons

My plan there is to spray the stuff up the back wall, on the floor, up in the roof and inside the fenders
I have heard that does a great job of keeping all those mechanical sounds at bay...We'll see!
__________________
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:43:28 PM
Originally Posted by Armalite View Post
Loving the progress!! Especially the seat preparation...

Yea, this thing is surprising me. It is in pretty good shape everywhere I look...Just dirty and covered up with moss, lichen, pine needles, leaves, dirt, 25 years of junk in the toolbox, crusty oil and grease, finger prints, more moss, and all manner of trash.
Now that I am starting to get to the bottom of all this, I am starting to see one pretty solid truck!
Yippee
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:44:28 PM
Originally Posted by Armalite View Post
I agree. So, what exactly are the plans for the front of the truck, after the removal of that Armageddon bumper??

Going with a factory bumper and a winch, or another road armor style??

I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:45:46 PM
From Ashley

Originally Posted by flyin6 View Post
I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do
.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!

I agree. Just cut off all that excess, and reuse the lower portion. Use those handy welding skills, and maybe even some of the cut offs, and build a bumper that will serve a better purpose, I mean prettier purpose.

You cant tell me that the current set up could get any better at protecting that front end...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:46:29 PM
Originally Posted by flyin6 View Post
I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do
.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!

I agree. Just cut off all that excess, and reuse the lower portion. Use those handy welding skills, and maybe even some of the cut offs, and build a bumper that will serve a better purpose, I mean prettier purpose.

You cant tell me that the current set up could get any better at protecting that front end...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:47:37 PM
Quote:
Originally Posted by duramaxdarren View Post
Now what about sprayin that raptor liner on the floor then put the dynomat down. not to expensive and should make for a water tight and quiet cab..

Dunno...Was thinking of spraying the ceramic heat shield stuff over the sound deadener and calling it a day but undecided at the moment. It takes all of 10 min to pull out the interior, so not a big concern if I don't get it right the first time...

Just ordered a black headliner, well just the material and glue. I figure I'll yank the old one off, then glue up a new one
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:48:40 PM
OK, let's get this thing pushed another couple yards down field.

Today was a productive one. The wiring mess got removed, as did the ugly steps, lights, tool box, switches, wiring harnesses, and that cattle gate front end. Additionally the interior metal all got treated as did some of the exterior metal.

First up was removing of the birds nest from under the hood, front grill, along the frame, inside the cab, and in the bed.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:49:27 PM
Next I pulled out the battery to see what shape all of that was in. Surprisingly, for a 22 year old living in the rust belt, there wasn't much rust or corrosion hanging out there
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:50:38 PM
In no particular order, next all the switches and myriad of wires came out of the cab
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:51:42 PM
Back to the battery tray, I used a cup brush and some hand wire and brass brushes to clean up things to get ready for the rust converter
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:52:58 PM
This stuff is around $40 a gallon and once you remove the bulk of the rust, basically the loose and flaky stuff, you simply brush on this water soluble liquid and over about an hour it does it's magic
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:54:36 PM
With things on slow cook under the hood, it was on to the bad areas in the cab. Again first with the wire cup and a way-powerful grinder
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:55:54 PM
I scratched up everything since it is all going to get coated with the Lizard Skin tomorrow or Wednesday
Then the surface was given a cleaning with lacquer thinner
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:57:19 PM
I scratched up everything since it is all going to get coated with the Lizard Skin tomorrow or Wednesday
Then the surface was given a cleaning with lacquer thinner
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 09:58:30 PM
After the battery tray and spot on the radiator dried, not quite in these pics, I coated those areas with some rust treatment paint
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:03:45 PM
Next, with the assistance of my handy plasma torch, I tore down the cattle gate.
Then I thought what the heck, I'll just leave the bottom half on there temporarily until I get more time to build a proper bumper, so I ground down the stubs, wire brushed it and shot it with some rattle can black, cheapo stuff that I purchased for wasps.
You know about that trick?
Blast them with it and first they can't see to sting you, then very quickly it seals their skin up suffocating them...Pretty effective if you don't mind having some black spots here and there!
I just tell folks it's black mold and I never have to deal with company!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:04:49 PM
Cattle gate all gone, I checked on the cab floor...Lookin' good
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:05:59 PM
Trash piles getting even bigger!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:07:20 PM
Next those creepy looking side mini steps and the offensive eyeball lights met with the flame torch...They lost
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:09:36 PM
I pulled the tool box off and treated the rusty spots beneath where it had sat for years. That all turned out great.
I might reuse the toolbox...have to think about it. But it will be John Deere Black if it goes back in there!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:10:48 PM
Running short on time I pulled the rotary wire brush out once more, tackling a 10" wide strip across the rusty roof.
After removing most of the scale I applied two coats of the rust converter, and it converted the roof into a radish garden!
Well, not really...
It blacked that sucker right up giving me ideas about the exterior color of the truck to come...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:11:42 PM
It's starting to look more and more like a normal 80's-90's truck!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:12:32 PM
I'm going to go get them this morning after my workout

I don't need to put them on, though, until after installing the new brakes and steering.
Very soon it will be coming into the shop for the first round of major parts replacement
So far on the list is:
Interior: New Headliner
New Carpet
All pieces parts dyed or painted black

Steering: Borgensen steering shaft
New Drag link
New Tie Rod ends
Possible replacement steering box

Engine: Detail cleaning
Oil change
Fuel filter
Accessory belt
Heater hoses
Radiator hoses
All clamps

Transmission: Fluid and filter change

Brakes: Rebuilt Calipers
High performance brake pads
Rear brake shoes and cylinders
or Rear disc brakes
All new brake hoses everywhere
All new hardware, everywhere

Body: Replace weather strip, both doors
Replace Windshield gasket
Replace rear window gasket
Install bushings and new pins in drivers door
Repair tail gate so that it will stay closed

So, anyway, when all that stuff gets done, and it won't take as long as you may think, Then I'll install the new prudy wheels and tires!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:12:57 PM
 had a crazy/stupid idea last night that actually might make some sense.

THe idea is to not paint the truck!

Hang on Ash, get back in your chair, catch your breath and control your heart rate.

It has a certain Patina, that I am adding to daily. Soon it will have black splotches all over surrounded by areas where various layers of paint has been ground or brushed away. It already has the faded blotchy silver, which has worn off in spots.
It already looks like it would be in home in the second row of the local junk yard.

So suppose I sprayed a low gloss clear coat all over it, preserving this moment in time so to speak. Then I could park it anywhere near wrecked cars or debris and it might look right at home...

Modern industrial camouflage...

Think about it

I might be on to something here...!!!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:14:31 PM
From Ashley:

Quote:
Originally Posted by stlaser View Post
You seem to easily forget the intended use of this build. I think it better to blend in with the local scenery than to build another flashy "hey look at me" type truck. Ever been to KY? It's a fairly poor state and I'm guessing his farm is located in that type of area. Think smart, stay alive..........

I don't want flashy... Just give it a decent paint job. Back to solid grey, or flat black maybe...

Or just leave the rust spots. The more I think about it, the more different it is, and Don is all about different...

Hmmm, now its growing on me...

You two using some secret army technique to convert my decision making process??
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:15:01 PM
Process,
Well First I suggested it,
Then Shawn liked it
Then Bobby shored up the reasoning,
Then You saw the light!

I definitely haven't decided on what to do with the outside as it is not a priority. All it really needs is rust proffing and maybe some protection against getting banged up.

In the Kintucky scheme of things, the worn out and faded look works well, but so does a factory style paint job.

Reasoning here is:

1. Statewide, Kintucky is a poorer state and most people keep vehicles forever. uite a few take pride in what the DO own (Which isn't much) and keep it painted up or waxed up.

2. Another crowd just doesn't care and welds cattle gates to the front bumper and calls it a day

So either way works...

Now that is the hiding in plain sight concept which is a good one.

Another concept is to stay in the woods, in hideouts and run at night, hopefully using NVG and no lights. For that scenario we're back to some blending camo pattern.

So the theme of this truck is
"Better" not best
Restored and not modified to look like a monster truck
Alternate and back up, not the primary vehicle
Be serviceable and useful as a "truck" to do all things truck
To be low cost to build and to maintain

I will build it around those parameters

No matter what the outside looks like the undercarriage will get the full on treatment. Completely renewed, painted, rust-proofed, and up to date...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:15:35 PM
Quote:
Originally Posted by nmeyer414 View Post
Why not do it all in raptor liner?


Too obvious...
Too different...

The more I think about this idea of just neutralizing the deterioration then freeze it in time with some flat clear, the more I like it

It is really smart...Not saying that because I have some delusion of being smart, nossir, I live with me, I am far more capable of stupid than an occasional mistake toward the smart side.

But isn't this sort of smart?

It would take an attitude to pull this look off, but talk about trend setting...

And easy

And cheap

It's like done in a few simple steps!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:16:09 PM
From Nate:

Heres my thinkin for sayin raptor line it.

The truck is from the time when the big 3 were having an issue with the new primer and technique they were using. What ended up happening to these vehicles was the paint would flake off and the primer would stay. Well after a while the primer would litteraly just wash away and you would have rust. This is an actual documented issue.

Now the reason I say raptor line it, is because there is something in the product that makes it truly stick to whatever it is applied to. Where as if don sands it down and applies a clear coat, the process will repeat itself and it will begin to ruat all over again.

Now lets face it, once don gets done with combat max, square d will most likely see most of the driving except for sundays and when ever the family goes someplace. I will also bet that square d will most likely see more farm time than combat max and why not have some sort of armor on her like raptor / linex / etc to keep it from getting worn even more.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:16:33 PM
Well, my hood and roof sure prove out your statement about paint failing. Mine is completely gone, not even a flake of the stuff left
For now, it's death by wire cup and 1 horsepower and black, magic coating...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:18:15 PM
Note: This was all happening back in the beginning. At this time, I was holding onto a much simpler concept of what this truck ought to be, and not the thing it has become that will show up a couple thousand posts from here.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:19:15 PM
Quote:
Originally Posted by 6.0 BOWTIE HD View Post
Kinda mad maxish I think it would look rough and tough. Not too mention every chip or scratch will just add more character. Just do enough to keep it from rusting through on the back side.


Sent from AutoGuide.com Free App

Well, no decisions, but it is an idea I am actively thinking about

I just came from the paint store where I loaded up on restoration products to repaint the interior, frame, undercarriage and so forth.

We talked about capturing the patina.
They have a mat clear, but it's almost $100 a quart!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:19:49 PM
No one is going to believe this one...

I just got back from the paint store and getting the tires and wheels.

Beneath the truck is a wet spot, actually beneath the radiator

I crawled under the truck and traced the fluid to the culprit spot.

Know what I found?

The previous owner had secured the transmission cooler hoses together with a nylon zip tie.

Well, that zip tie had been chaffing against the brass side of the radiator and wore a hole in the left side tank!!!

The anti chaffing stuff chaffed a hole in the tank

Now, I truly have seen everything

I have a great old trick though.

I'll have to pull the radiator, but you solder a penny over the hole and in 10 minutes, voila' no leak and it only cost 1 cent!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:20:33 PM
Quote:
Originally Posted by 6.0 BOWTIE HD View Post
But it's a 20 year old radiator with 20 years of corrosion in the cores. I know you flushed it but strictly peace of mind knowing you won't have any issues with a new one in it. Hate to have to pull it out again in a short time.


Sent from AutoGuide.com Free App

Are you saying replace it???

That's psycho!

I mean how much do those things cost

Really big brass radiator, can't be cheap
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:21:23 PM
I actually got a lot more work done today than I have pictures of. I slipped on that logging chain and fell onto the fire extinguisher and screw jack. Darn near punched a hole in me, but I guess all this working out I do made me tougher than the fire extinguisher which I broke. The camera also broke (again) but I managed to snap most of the parts back together, but now it over-exposes on some frames. About half of the pics I had taken of various processes looked like I was standing on a white sand beach wearing all white while filming the surface of the sun!

Well, anyway, let's get started

Since we hurt Ashley's eyes looking at those ugly wheels and bald tires, here's a new tire and wheel rolled into place where it soon will reside
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:23:04 PM
These new tires seem to be about 1.5 inches shorter (good thing) and about the same width.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:23:54 PM
I like the semi aggressive tread on the Hercules tires
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:24:49 PM
I made a trip to the paint store where we talked through what I was doing. I came out of there a quarter of a thousand dollars poorer, but with a big box of stuff to use.
They encouraged me to use the nitrile gloves which are a much more durable rubber, and sold me some metal surface prep which I put right to work cleaning stuff.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:25:53 PM
Knowing I was about to get grinding on the hood, I removed the cowl.

Underneath I found a couple yards of mulch.
I used it to spread around a couple of my flower beds.
It used to be leaves, pine needles, bugs and the like, but it was only organic material about 2" deep everywhere in the recesses of the cowl area.

I removed all of it, then soaked the living sticks out of the area with simple green.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:28:13 PM
Next up, the hood met the wire cup and the rust went flying. Good thing, though almost none of it got on the ground. It all collected in my hair, eyes and face.
One quick shower, and I saved myself the time from washing down the driveway again
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:29:50 PM
Then the hood got coated with the rust converter
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:30:52 PM
Here's a look at how the roof turned out after curing with two coats applied
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:31:25 PM
You can see the area where rust had taken purchase is a total black, whereas in the areas of sanded paint it didn't change color all that much.

The surface is very hard now. So hard, that I am going to have to use some aggressive sand paper to rough it up for the primer which is the next step in the restoration process.
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:32:34 PM
Note: I first mention "The restoration process...Thinking back, I think I was mentally starting to turn the corner toward a much more aggressive teardown and rebuild...
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:33:23 PM
Beneath the cowl was an aluminum tag riveted in place with all the build codes for this truck. The photos didn't turn out, but everything is completely legible this time!
I'll post the codes in an edit to see if anyone can decode
I'm still waiting on Chrysler to respond to my query...

Edit: Here's the codes:
K2X
LPE
NBL
NCM
NMC
RCD
89
DGR
ETB
GPB
HAA
K1X
501
QAM90101 173 AD6L62
APC
PS7
QAC
M1S8
795
824391
XBS
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:34:19 PM
Thanks there Special K!

I just got the build data email from Chrysler, so I think I know what the truck has/is supposed to have!

Here it is:

Dear Donald:

Thank you for contacting the Ram Customer Assistance Center.

We are pleased to provide vehicle build information per your request for
your vehicle. According to our records, your vehicle was equipped from
the factory with the following:

Sales Code Description

ADAA Light Group
AHLS Heavy Duty Insulation Group
APC Center Band Two Tone Paint
BANS 120 Amp Alternator
BCLS 1100 Amp Maintenance Free Battery
BGKS 4-Wheel Anti-Lock Brakes
BKHS 12x2.5 Rear Drum Brakes
CBAP Straight Back Bench Seat
CDEP 6-Way Power Passenger Seat
CKJS Black Vinyl Floor Covering
CURP Rear Compartment Storage Tray
DGB All 4-Speed Automatic Transmissions
DGRS 4-Spd. Automatic 46RH Transmission
DHES Man Shift-on-the-Fly Transfer Case
DJFS Dana M60/248MM Front Axle
DMDS 3.55 Rear Axle Ratio
DRES Dana M70/267MM Rear Axle
ETB 5.9L I6 Cummins Turbo Diesel Engine
GACS Tinted Glass Windows
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GFD Rear Sliding Window
GNAS Rear View Day/Night Mirror
GPBA Pwr Fldg Htd Drvr Memory Mirrors
GVAC All Vehicles W/O Power Mirrors
HAA Air Conditioning
JCDS 100 MPH Primary Speedometer
JHAA Var Intermittent Windshield Wipers
JJAS Cigar Lighter
JJFS Single Low Note Horn
JKAS Locking Glove Box
LAAP Ignition Time Delay Lamp
LAFS Key in Ign/Seat Belt Warning Buzzer
LAJS Headlamps On Warning Chimes
LBAP Map/Courtesy Lamp
LBCP Glove Box Lamp
LBDP Ash Tray Lamp
LDAP Underhood Lamp
LPEP Cargo Lamp
MBBS Bright Front Bumper
MBDA Argent Rear Bumper
MFDS Bright Grille
MHAS Black Windshield Moldings
MKAS E-Z Step
NBLS Delete EVAP Control System
NEMS Exterior Sound Control
NFEA 24 Gallon Fuel Tank
NHBS Auxiliary Transmission Oil Cooler
NHKS Engine Block Heater
NMCS Heavy Duty Engine Cooling
NZAS Diesel Emissions
PS7 Dark Silver Metallic
QAC Silver Star Metallic Clear Coat
RAAC All Radio Equipped Vehicles
RAS AM/FM Cassette Radio
RCDP 4 Speakers
SBAS Power Rack and Pinion Steering
SCBS 2-Spoke Steering Wheel
SFBS Front Heavy Duty Shock Absorbers
SGBS Rear Heavy Duty Shock Absorbers
TBB Full Size Spare Tire
TBMP Tire Carrier Winch
TZHP Michelin Brand Tires
WDAS 17X7.5 Steel Styled Wheels
WLBP Steel Spare Wheel
WLYC All Steel Wheels
WMAS Black Hub Caps
XBSA Pickup Box
XEFS Transfer Case Skid Plate Shield

Thanks again for your email.

Sincerely,

Christopher
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:34:54 PM
^^^^How cool is that!

I sort of doubt it had 17 X 7.5" wheels in 1991!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:35:47 PM
From Duramaxdarren:


nice work boss!!!! lotta elbow grease went into that....not to derail the thread but since you are now the resident rust buster and i am torn on how best to spend my money and prep the underbelly of my bed. So you know i wanna use the raptor liner as my final coat....so after seeing your use and results of the rust converter stuff but i also saw this stuff called rust destroyer from advanced protective products. what should i use? can i use both? which is best as a base for the raptor. I have just a bit a scale on the bed crossmembers and on the pumpkin. the bed belly side is very clean and barely any rust spots and scale...whats your thought big don corleonie?
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:36:30 PM
Quote:
Originally Posted by duramaxdarren View Post
nice work boss!!!! lotta elbow grease went into that....not to derail the thread but since you are now the resident rust buster and i am torn on how best to spend my money and prep the underbelly of my bed. So you know i wanna use the raptor liner as my final coat....so after seeing your use and results of the rust converter stuff but i also saw this stuff called rust destroyer from advanced protective products. what should i use? can i use both? which is best as a base for the raptor. I have just a bit a scale on the bed crossmembers and on the pumpkin. the bed belly side is very clean and barely any rust spots and scale...whats your thought big don corleonie?


Well, I like the rust converter.
It's a one stop shop
If you use a rust destroyer (remover/dissolver/dis-come-boob-u-lator) then you'll have to top coat that
So, I'd use the converter on the rusty spots, then top coat with something like a quality paint. I really like and use the heck out of the John Deere semi flat black called "Blitz." I know the gentleman who runs that paint program so I have detailed knowledge of it. Normally you would not be able to buy such a high quality paint so cheaply, however the make so much, you have the principle of "economies of scale kicking in.
Once I got the paint dried, I'd buy a bunch of paraffin wax, heat it up on the stove to liquefy it, then start brushing it on heavily everywhere
Novel approach, but cheap and it's just wax. Come spring get a bug sprayer full of kerosene, spray the old paraffin and hose it off...Done for the summer!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:37:10 PM
Quote:
Originally Posted by Looby321 View Post
So the creeper side step was factory? Creepy...

No, it was some poorly designed and hillbillized aftermarket piece of junk intended for jap and kolean kars
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:38:18 PM
From Cudakidd53:

Don-

I can see you going either way on paint- seal it to encapsulate nostalgia of use/abuse. I can also see you painting it back to stock later too, as it'll look sharp, blend in as a local with pride in ownership, and last much longer than just clear coat.

Not feeling the flat black on the wheels though- you could have just painted the steel ones and saved a bunch of cash.

Penny trick is cool, and "old school" like the truck not to mention paying homage to a former "tucky" boy Abe! You could have a radiator shop run a pressure test for you to double check your repair and clean/repaint it prior to re-instillation.

Looking good!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:39:28 PM
Quote:
Originally Posted by tjZ06 View Post
I think you have half the members of this board out looking for a similar rig!

-TJ

You know...I'll bet you're right.
And when you think about it, if you buy a custom tune you're in for $700ish, right?
Do you know you can add about 100HP to this tractor engine for less than $50!?
Buy a fuel screw and a 3200 rpm spring and then tune the various screws on the fuel pump and enjoy all the new found power!
You can score one of these trucks under 5K like I just did and have a great truck, although your John Deere will ride better, you'll have a reliable truck all the same
For me it's sort of like a Huey
Hueys are all mechanical
Always start always fly al long as they get fuel. See the pics of that one in my book all shot up? Well, all those holes were discovered after landing, it flew along just fine!
Hueys just always worked. So when the Black Hawks came along, the Hueys went away for the most part. They still serve here and there, but mostly they're gone.
But when the Army retires the last Black Hawk in some distant year, and parks the think at Davis Mothan Air Force Base for permanent storage, the crew will be picked up and flown to the airport in in Huey!
Title: Re: SquareD
Post by: Flyin6 on September 20, 2014, 10:40:43 PM
Today was cooling system day. Didn't quite get it done, but's it's 85%.

I thought I'd address the hole in the radiator before going on to priming the rust spots and spraying the lizard skin

Here's the start of the days activities:
Title: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:27:25 AM
Part 1 took us from the purchase day in the summer of 2013 until 9-11, 2013 with tear downs and cleanups and essentially just some rust repair, but no significant building or modification. Here is Part 2 we will start to get more aggressive, still holding onto the idea that I would bring the truck up to spec on the warmed over chassis, but with no commitment to a total remake, which the truck eventually goes through.

I purchased a lot of stock parts to recondition the truck in this section which have since been removed/ changed/ or no longer apply as whole systems have given way to a more modern approach.

Let's continue to watch this thing evolve!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:28:11 AM
 won't be typing very much tonight, you'll see why shortly

The radiator comes out easily, it's a very mechanic friendly design. A couple of bolts on the top and two clips and with the rad hoses disconnected it lifts straight out with the fan in place!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:28:51 AM
You're left with this:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:30:13 AM
The radiator repair took all of 5 minutes. I cleaned up he area with a brass brush, then cleaned the penny, then just soldered it into place...Simple

All Fixed:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:31:02 AM
The radiator had some rust and corrosion, so I cleaned it up, and first applied the rust converter. Here it is healing the sheet metal bottom of the unit
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:32:12 AM
At this point I started the second cleaning of the engine compartment, this time with simple green and a couple hours of scrubbing
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:33:22 AM
Here is some of the rust converter doing its thing to the engine, brackets, bolts and whatever...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:34:41 AM
I purchased a new water pump as added insurance along with a new clutch fan, so off came the fan mount and water pump
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:36:23 AM
That was about when I found a sharp edge...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:37:35 AM
Clear the airway, stop the bleeding, treat for shock and continue the overhaul are the 4 lifesaving steps, right?

So with everything apart, time for more rust treatment, detailing and painting, and installing new parts
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:38:56 AM
The radiator cleaned up nicely and looks good with my favorite John Deere paint and gun lube...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:40:29 AM
Reassembly continues
Using all new hardware and parts here
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:41:39 AM
New fan belt, some other new stuff
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:42:26 AM
Then the upper radiator hose
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:43:39 AM
And that is where I ran out of time for the day

Plan to finish the cooling system tomorrow, do the battery and maybe prime the roof and hood

That lizard skin is just sitting there staring at me as well.
Today also saw the carpet and the headliner come in!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:44:35 AM
Originally Posted by lutzjk913 View Post
Nice! That's a standard procedure for any country gentleman! Electrical or duck tape?


Actually some medical stuff
Once the bleeding stops, you can squirt some super glue on it while you're holding the parts in proper alignment, then I chase with this stuff some medic from the Rangers showed me. Works around sticky blood, so I used that. I'll survive, lots worse than that has happened to this old carcass
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:46:30 AM
From a member:

Right on par for the course, I find myself up at all hours of the night frantically trying to catch up once again. I may be deserving of disciplinary action at this point. I do want to say that I am pumped for you, this build, and concur with everything done to this ole classic thus far. These oldies hit a soft spot for me every time! I saw a mention of Dynamat and/or lizard skin for sound dampening. I can attest first hand to Dynamat as I covered everything but the roof panel on the interior of my truck and it does indeed make a drastic and noticeable difference in the reduction of road noise and improved the interior acoustics a bit. I thought about going as far as to lizard skin the underbelly to further reduce noise, so Ill be interested in seeing the use of that stuff and how well it works.

Carry on sir master of the builds!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:47:28 AM
From Dustoff35:

Excellent Progress. Just to put things in perspective, We picked up this truck exactly a week ago, on Sept 6.

At this rate, you will be back on the Duramax in no time.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:48:28 AM
Quote:
Originally Posted by WrightBros View Post
Right on par for the course, I find myself up at all hours of the night frantically trying to catch up once again. I may be deserving of disciplinary action at this point. I do want to say that I am pumped for you, this build, and concur with everything done to this ole classic thus far. These oldies hit a soft spot for me every time! I saw a mention of Dynamat and/or lizard skin for sound dampening. I can attest first hand to Dynamat as I covered everything but the roof panel on the interior of my truck and it does indeed make a drastic and noticeable difference in the reduction of road noise and improved the interior acoustics a bit. I thought about going as far as to lizard skin the underbelly to further reduce noise, so Ill be interested in seeing the use of that stuff and how well it works.

Carry on sir master of the builds! 

The secret of the stuff in in harmonics, not blocking
You may have noticed from the build code breakdown I got from Chrysler (Thank you Chrysler), my truck was built with extra sound insulation. That translated into a physical piece of rubber with some felt on the back which resided beneath the rubber floor covering.
That was old technology, old thinking. Make it thick and make a lot of it.

Newer thinking is in controlling the harmonics (Vibrations) in materials. Essentially muting or destroying their ability to transfer sounds. That's what this new line of products does...Stops thin steel from ah' shakin'. Then the molecules near your brain case group aren't ah' shakin either and the world is a more balanced place...Probably accumulate a few hippie friends when they learn my planet killing pollutin' diesels are doing something earth friendly.
No worries, I have weeds that need pullin' I'll just tell those idiots you can eat that stuff and away they'll go! Come to think of it, I can sick the dogs on the
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:49:27 AM
Quote:
Originally Posted by Cudakidd53 View Post
As his neighbor, slow him down just a little or he'll only be able to count to "9" if he continues to file rough edges with just his skin!

Don't need to count anymore
I hire people to do that
Besides the only countin' you need to do is, countin' the number of times you pulled the trigger
But I found a way to not even need to do that!
Load the last three as tracers
When you see the light
do a mag change and keep em' dancin'

I won't admit some grunt showed me that trick...

Oh and to you civies reading...Don't load your mags to 30...only civies do that.
Then one day when you shoulder your weapon, the mag will fall out of the well...Because you didn't seat it!
Yup
Load them to 28 instead and you'll be a mo-happier man...!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:51:16 AM
OK, still having trouble typing...darned finger didn't completely heal in 24 hours...
Anyway it was a mixed bag today. I was working all over the place but still got a lot done

First of all I wanted to get some more sealant on the cab floor. Pressure washing the engine compartment yesterday pumped some water in there, so that was job 1

I prepped the area then sprayed a layer of rubberized undercoating on it.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:52:16 AM
That turned out pretty well and the stuff dried quickly, so it was on to the roof.

I picked up this DA sander which uses Velcro pads and attaches to a vacuum to suck up the dust it generates.
Using 80 grit I sanded the entire top
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:58:10 AM
Next I coated the sanded area with this gray primer

BTW, DO NOT buy this primer

Not that it is a bad product, no it's fine. But the nozzle is total junk concentrating the spray in a tiny area that makes for heavy and light areas in the painted area. I'm not concerned as the top will get a couple more layers of primer to cover up this blotchy mess
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 06:59:47 AM
In that last picture you can see that I finally removed those awful decals. I did have a bit of a problem scraping the Harley wings off, but with some sweet tea, I got through it!

Next I went after some of the window tint...Man that stuff is hard to get off!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:01:21 AM
Next I got back on installing the cooling system hoses. The big holdup there is an improper fitting AutoZone hose. The lower hose they sold me was this trim to fit thing that was the same size end to end. The correct hose actually flares on the engine side to fit a larger diameter nipple. I ordered that hose (Again) hoping to get it tomorrow. In the mean time I replaced more elbows and lines with new hose and clamps.

Here's a little trick to keep those hose clamp ends from sticking out:
First open up the last slot in the stainless band
Then thread through a nylon zip tie
Pull the zip tie and in turn pull the clamp loose end back in tight. It also keeps anything from loosening up later on
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:02:52 AM
Easier to see here:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:04:07 AM
More to finish under the hood with the hoses, but that nasty bed was bothering me, so I sprayed it down with simple green and power washed it again
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:05:26 AM
While back there, I removed a tacky aluminum tailgate trim piece or protector. Anyway, it looks bad and apparently did not protect very well!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:09:27 AM
I made one wet spot, and wouldn't ya know it, the little ranger found it!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:10:51 AM
Santa came early in the form of a box from Shawn at Great Lakes Off Road or GLO

His company manufactures this stuff. You have seen me use his diff covers in the past, and am using another one on the LML, SAS build, and now, I'll use two more on this Dodge's Dana 60 and 70.

The brackets are to adapt disc brakes to the rear, and the steel parts are U-Joint girdles. The factory uses flimsly steel straps all thin and liberal lookin'!. Sometimes the u-joints can walk out of the saddles, but not with these in place!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:12:23 AM
More detail on those caps:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:13:38 AM
And the caliper adapter plate/mount
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:16:00 AM
And those wonderful diff covers.
This stuff is art work!

Shawn (Same one on this thread) places the fill hole up high, well above the factory location. This little adjustment immediately allows you to run more fluid!
Brilliant!
Say it will blow seals or cause leaks???
NOSSIR! I have run one of his rear covers on my AAM 11.5 diff in my LML Duramax truck overfilled by half a gallon for a year now with nary a single spot of a leak!
His stuff works!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:17:09 AM
From Ashley:

Love the way that interior is shaping up Don. Anxious to see the turnout of that lizard skin. I've never heard of it, so I'm looking forward to this write up.

The parts from Shawn look American built of course... Big and stout, just like we want them.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:18:34 AM
Note: I am literally skipping dozens of other posts so that I can keep this all shorter and more focused.

Here's a link to the original write up:

http://www.duramaxforum.com/forum/diesels/236098-12-valve-dodge-survival-truck-build-thread-46.html
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:20:36 AM
I'll show a picture of the 2 gallon container, but no spraying yet.

I was concentrating on mechanical and made a lot of headway!

We'll get started with something easy.

In preparation of the differentials getting their fluid changed and cleaned out internally. I had to prep the differential covers for paint.

They were new, so only a rotary wire wheel to scratch them up, a good cleaning then I sprayed them with some acid etching primer.

I'll paint them the Lycoming gray in the next couple days...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:22:20 AM
More:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:23:05 AM
The super duper beefy one is going on the Dana 60 which is going into my LML D-Max

I finally got that pesky lower radiator hose. See why it is so special...just like me!
It gets a little bigger in girth at one end...just like me!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:24:24 AM
Then I pulled the turbo inlet hose to get some working room and to inspect the turbo.
There was almost no play in that thing! I tell ya, this truck does not seem like it has any miles on it. Everything is coming off in a serviceable condition and only needs cleaning.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:25:24 AM
Those compressor blades were not nicked like they look in the pic, I cleaned them up with WD-40 and they were as pretty as apple pie!

I now had access at the right side of the motor.
looking it over, I decided to pull the hard lines to clean and paint them, then replace the rubber and clamps
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:27:14 AM
The lines turned out great looking
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:29:17 AM
While I was waiting for the paint to dry, I decided to secure the battery

After I was done, I still am not satisfied with just how that battery might be in a jumping situation, so I think I'll fab something up to hold it in there mo-better
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:30:01 AM
As part of house cleaning. I pulled this 20 year old piece of mud flap looking stuff that was isolating the engine compartment.
I can do much better than that, so I'll get something to replace that nasty collection of rubber molecules!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:30:51 AM
Now you can actually see the ground!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:32:21 AM
Quote:
Originally Posted by WrightBros View Post
Are you running any magnets with these diff covers?


Nossir, but that's a good idea

I bought a dozen flat neodymium magnets this summer to plaster all over my fuel lines to turn the diesel into plutonium and get a nuclear fire going in the combustion chambers, but never thought of using them to collect iron filings
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:33:52 AM
OK, let's get some more stuff fixed here

Keeping in mind a couple facts and my premises for this build, I know Diesels like air and a lot of it, and I am doing a thrifty build at this point. More of a restorative effort than expanding the envelope, again at this point in time.

So I was looking at the air box and I had an idea...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:35:26 AM
 like how and where the factory air box mounts. It's out of the way and cavernous. But it has only one duct to draw from leading from the front grill. The area there is not totally unobstructed so I decided to alleviate that restriction some while keeping the stock parts.
I will add a K&N or similar filter in a couple days, but it how can choose from which hole to breath through
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:36:30 AM
 think that more than doubled the air flow possibility from that nicely designed factory setup.

While that was out I scrubbed and cleaned yet again to get it looking all brandly newish like (BNL)
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:38:04 AM
Next I rebuilt the heater control valve assembly
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:39:00 AM
Then reinstalled that pretty coolant hard line assembly
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:40:14 AM
Next I pulled off the old oil filter and installed a quality WIX unit and 13 quarts of Rotella-T 15W-40

I went cost effective this time, but next time I will be using Willie's Amsoil products, most likely with a remote dual bypass filter setup
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:41:45 AM
Finally, I pulled and cleaned the radiator overflow tank and added a quart of properly mixed fluid, then topped up the radiator
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:42:32 AM
The engine compartment is starting to look descent for such an old, err, vintage ride!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:43:23 AM
Here's the infamous "Lizard Skin" which is soon to skin various body parts of this truck.
This gets us current through today...hopefully more tomorrow!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:43:47 AM
BTW, so far the total cost of the project is $6,906
That includes the truck, the tires and wheels, and all the parts sitting on the shelf awaiting installation...
I won't consider it safe to operate until the brakes are totally overhauled and all the steering components are replaced or upgraded, and the shocks are replaced.
I think I'll keep the 6" lift for now and sort that out later.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:44:34 AM
Quote:
Originally Posted by nmeyer414 View Post
Just imagine, if the orignal owner had actually maintained it like you are doing now how much he would have actually asked fforit or possibly kept it.

Indeed!
But I look at this as my gain
I would have purchased one of these a long time ago if I had realized what it was. One of these in a crew-cab version is actually a better survival vehicle than the Duramax for a number of reasons.
Straight front axle
No electronics
Same horsepower capability
Less expensive
Will run on B100, WVO, Vegetable oil, homemade fuel, anything really
Everything is extremely simple and easy to fix
Fewer gadgets to break
Real shift lever transfer case
Parts are cheaper and on and on...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:45:36 AM
Quote:
Originally Posted by Armalite View Post
Looking newer each day Don. I like it...

Ash, it sounds good as well...Even with a rotted out muffler!
Just wait till I show everyone the so called exhaust, all six feet of it.
I just haven't cut all that off yet, but maybe this week, I'll get to it.
Even with the crappy exhaust, it sounds good, tight, well tuned.
And it always fires up with the slightest bump of the starter.

I was talking to a guy who owns a couple of these last night. He said he is finding all of them with retarded timing. He said to advance it a couple degrees and turn up the fuel screw and it makes at least another 100 horsepower!
Just hearsay, I can't verify any of that, but you do hear it a bunch
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:46:59 AM
Quote:
Originally Posted by je942010 View Post
What is the plan on this one for storage and sleeping quarters?


None at the moment
Keep in mind we are very early into this project.
The short term goal is simply to provide transportation while the LML gets a Dana 60.
Subsequent to that, this truck will continue to see daily service, and become more and more of a real back up to the D-Max truck.

I see this truck with some aggressive bumpers, pioneer equipment, perhaps and exo-skeleton, some roof storage, and maybe a cap. It will be able to pull any of the trailers I choose to use. the 35 foot camper, the 18 foot utility, or the yet to be built emergency off road shelter unit.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:47:33 AM
It's sunday, and a day of rest, but I have been very busy ordering parts for the coming week
So far today I have ordered
front Skyjacker shocks
Rear Skyjacker shocks
New shock bolts
Steering gear box
Power steering lines
K&N air filter
Left/right motor mounts
Transmission rubber mounts
Tail light lenses
Parking light lenses
Door hinge and bushing kit to repair sloppy door hinge
Air conditioner master control module
Air conditioner clutch solenoid
Air Conditioner dryer and accumulator
Steering damper
Sway bar bushings
Voltage regulator
and a scad of other pieces parts

The concept here is to baseline the vehicle to a like new mechanical condition, replacing all wear items with good quality reman stuff.

What that gets me is probable reliability and the opportunity to drive it to see what I have and what it needs. I suspect everything will take a couple more weeks, then I'll have a reliable and serviceable ugly truck...perfect really!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:50:07 AM
lets get some interior completed on Square D.

First up was to remove enough trim to get the headliner out. That was fairly easy and happened PDQ
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:51:28 AM
You can see that wrinkled mess was failing all over the place!

After the trim was out, I pulled the remaining seat belts
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:52:11 AM
Again, I was finding everything in pretty good condition.

With that out, the headliner pulled right down
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:53:15 AM
With some light tugging, the old material came right off exposing the foam shell
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:54:11 AM
The underside of the factory top looked as good as it did the day it was built!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:55:29 AM
I pulled a few pieces parts from the interior while I was up in there, but not for long as I wanted to see how that new headliner would turn out
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:56:37 AM
The old glue (darker brown areas) came off easily by using a brush on a vacuum and a sawing motion
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:57:36 AM
The new headliner is a lightweight charcoal colored felt like fabric with some thin foam rubber open cell material attached to it's backside.

Attaching the new material is with some super-duper spray wasp encapsulater! Really, anyone ever shot a wasp out of the air with this stuff? It's cool and instant. Man if the Taliban shot that stuff at me, someone else would be writing about this truck, showing off it's new single 12" stack and star mags!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 07:58:44 AM
First roll out the new material and square it up to where it's about right, of if you follow Duane, then 1.354" off center on a corrected 54.2 degrees (Measured at a standard day and calibrated for recent solar activity!)
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:00:14 AM
Start in the middle somewhere (or id you're like Duane exactly 26.886" from the left side and up 14.646" from the bottom edge) and spray some of the wasp and mud dauber anti aircraft spray in a small area (or if Duane, from a dead flat, certified surface of hard granite up 12" exactly plus or minus .002" spraying at an angle of 23.6 degrees for 1.34 seconds while applying 4.5 inch pounds of pressure to the spray cap to produce approximately 39 joules of energy which minimizes overspray to within the 2.34" cone of active spraying you have surveyed and done an exhaustive study on)
Of if me just spray it a bit and check left and right for a possible target and press the material down
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:01:54 AM
Keep working away from the center for the next few minutes until it's all glued down if using my technique or slowly over the next thirteen weeks if using Duane's method.

Either way, it ends up looking like this:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:03:16 AM
At this point you can trim it up close and personal to the edge or glue a short strip up the backside to hold it better. I also cover the edge with masking tape to prevent from critter infiltration.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:04:19 AM
And here it is completed and ready to reinstall:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:06:12 AM
Back to tearing the interior all to hades and back again:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:07:15 AM
I was going to pull the actual dash out, but the farther I dug, the more I discovered I was going to have to disconnect to actually get it out!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:08:55 AM
So I sez to myself, "Self, what the hay are we doin' here? Note: You can talk to yourself, that's OK! You can even answer yourself, still OK, But if you say "Hugh?" you have a problem.
So anyways I am having this one person conversation and it occurs to part of me that the other part doesn't really want to fuss with pulling every screw, including the rear bumper license plate lamp mount just to get that sucker out.
So the other part of me decides that both of us can paint that quill right where it lives! Problem solved and we are now getting along once again!

Anyway, the both of me pulled both door panels and interior removal was officially concluded
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:45:15 AM
Now I remember...I masked off the stuff I only wanted some overspray on! I used pretty blue tape because Kentucky is busy getting beat up on the SEC gridiron, and I wanted to honor them!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:45:56 AM
SEM makes some great paint products. Their interior paint for plastic and vinyl comes in a perfect color which is called landau black. Not glossy, but with a touch of flattening, but not dull either
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:46:59 AM
The first, then the second coats produced a great finish, don't you agree?
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:47:56 AM
Then I started on each piece, one at a time. First scrubbing with detergent, then wiping with prep sol, then rubbing with this adhesion promoter, washing again, another wipe down, then spraying the color
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:49:23 AM
From the previous pic, you can see the instrument cluster bezel and trim going through the process...
It continues here"
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:50:12 AM
Some trim pieces had cracked and were in need of repair. I scratched up the back side and applied some layers of fiberglass cloth and resin
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:50:51 AM
But they patched up just fine!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:52:27 AM
The door panels took some time and finished the clock out for the day.
Tomorrow I am in good shape to reassemble some of the interior, and maybe get el lizard skinimus sprayed all over creation!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:53:40 AM
From Cudakidd53:

Had my doubts about the spray dye, but WOW really nice results. You could put it on the concourse at one of Duane's car shows -

Don at SEMA with both trucks, parlaying that into a Build Thread TV show, kind of "OverHaulin'" meets Duck Dynasty......you all may laugh, but who'd have thought a show about a Duck Call manufacturing family would catch on AND a network shows a family eating together each night and saying a blessing mentioning "Jesus" at the close of each episode?!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:54:02 AM
I think it's turning out quite nicely!

I need to find a drivers armrest...Parts geek was a strike out. then I wanted to order new weather-strip, but again parts geek struck out, because they can only ship it truck freight!
Truck freight for a coil of rubber? Seriously, they wanted $135 truck freight for a $28 part that weighed 3 pounds!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:56:05 AM
Didn't get a chance to post up last night

I started in the lizard skin process, but it was getting dark and I only got one thin coat on.

The reason I got started late was that I thought this stuff sprayed. I mean it says a spray gun, and references of up to 80 psi. So I put some in one of my cheapo spray guns and immediately clogged that thing up...

You see Lizard skin has the consistency of paste, not really liquid, unless you consider lard liquid...

So I quickly clogged up my good gun, then in a panic had to clean those guns out while the stuff was thickening (Read: Ruining my guns!)

About this time I also discovered those nitrile rubber gloves are useless. Yep, they were sitting about 15 feet away in their box and provided absolutely no protection for my hands.

I can report that there is a reason they call this stuff "Skin"
It has to do with the fact that is sticks to skin, it acts like skin, is about as easy to pull off as your real skin, and when you do pull it off, you pull the real stuff off as well. Apparently wearing shorts is not recommended when working with this stuff as well...

About this time, while I was piling on my winter and spring layers of new synthetic skin to my hands, forearms and legs, something the Marines always say came to mind, "Improvise, Adapt, and Overcome."

Well that universal statement works on just about any instance including failed lizard skin first attempts. Is I decided to grab up a cheapo paint roller. First thing I noticed was that when I placed the roller on and yes, I mean to say, on the lizard skin, it just sits there. It does not sink and the stuff does not slowly ooze around the roller, nope, it just sits there.

So it's thick...

That means no splatter when you're rolling overhead. But that means it falls off in stick muddy blobs which if not attended to quickly will dry on one's face and hair. What the heck, time for a hair cut anyway...

After wrestling with this paste for awhile I had rolled out a first coat mostly in the dark which accounted for my rolling it over my opposing hand, consolidating the previously unattached blobs into another non removable layer of epidermis.

Actually I exaggerate the stuff readily comes off as long as you hold your hand under live steam and scrub with tooth brushes and wire brushes... for awhile. No worries.
But if you also discover the nitrile gloves don't work sitting in the box, be sure to schedule two hours in the emergency room before supper
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:58:05 AM
Notice in the first set of pics it is daylight

Notice here it is night

If you do the math you will find many degrees of sun movement missing. That would account for trying to salvage the spray guns, both of them...

So now, before I applied another layer or three of skin to me, here is the frantic work to roll out what one cannot see!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 08:59:27 AM
Not too pretty but

1. Not the final coat
2. Everything here is covered up and (gladly) never to be seen
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 09:01:17 AM
Oddly enough that stuff is a fairly close match to the color of the truck!

Well, all the stuff I ordered on Monday is starting to filter in

Here's the front shocks

Talk about nostalgic! But those old gas shocks did an OK job in their day, and that's what I'm looking for, OK!

And cost effective

These shocks were $45 each, $180 for the set

Bu comparison, the set of shocks I just ordered for the Duramax build totaled $3,300!!!!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Dustoff35 on September 21, 2014, 11:21:03 AM
The radiator repair took all of 5 minutes. I cleaned up he area with a brass brush, then cleaned the penny, then just soldered it into place...Simple

All Fixed:


So that penny that was soldered to the radiator, What vintage was it?  The reason I ask is that the newer pennies are actually copper-plated zinc, not copper through and through.  I know that it won't give you any problems in the future, but it might give me some...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:21:39 PM
I actually discovered that it takes pre 1982 pennies (Pure copper, so I chose one that was like 1950 something
You're good to go!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:22:28 PM
That baked on white shoe polish was known to crack, flake, and rust. I plan to scratch these down, then recoat with a layer of zinc followed by a clear coat. All so I can get one week of rust proofing this winter.
Kentucky uses the 2:1 rule

Meaning dump twice the thickness in salt as snow.

We seldom have more than 1/4" of snow which the highway department immediately responds to with 1/2" of salt. The fact that the salt is dirty, also containing some grit is what really gives us the traction we need to drive off to the nearest thirty car pileup!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:23:18 PM
Those suckers are thick, measuring some 2.4" O.D.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:24:06 PM
I even purchased some pretty new hardware which cannot be seen!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:25:50 PM
Finished most of the interior reconditioning.

Should be reassembling tomorrow...finally!

It takes a lot of time to repair every piece which had multiple cracks in it from age and a million hot/cold cycles.

But they are all repaired and painted at this moment.

First a look at some of the parts which are now trickling in.

First is the Rancho steering stabilizer.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:27:03 PM
And now, all of the shocks are here
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:28:00 PM
And one of the many light lenses showed up

Little things like this not only ensure things like the brake lights work, but make for a very clean restoration
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 01:28:47 PM
Today, the rubber gloves worked much better, especially since I actually put them on!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:00:38 PM
The Lizard skin is a latex based material (I think) so it cleans up and acts like your basic interior house paint.

Today I slopped on a second coat. The working thickness of this stuff is only one half of a millimeter! I have that or more on everywhere. It's not pretty, but it has sealed up the interior pretty well.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:02:57 PM
In the pictures it is still wet in places, but by tomorrow morning it should be thoroughly dried and ready for another top coat...Oh, yes, we're not done yet! I still need to waterproof that, since it's basically water based, it could probably use some help.

Back to fixing chipped and cracked trim pieces
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:05:36 PM
The pieces are not nearly as fragile with the fiberglass backing as they were.

Now with some paint, they aren't perfect, but I achieved the "good" specification I am shooting for.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:40:11 PM
Painted and cured
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:41:23 PM
I forgot to mention the bulldog adhesion promoter I am using on the plastic to help the paint bond. It is working well as you can see. No paint has fallen off yet!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:42:57 PM
The last few parts are prepped and painted
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:43:52 PM
Had a freakish accident happen today.

Two of the newer cats were playing around. One would run over and jump up on that bench seat to secure the high ground to spring on chalk 2 who would come ah' sneakin'

So this stupid cat leaps over and hits the headrest, tumbling the seat over. Now on the bottom of that very same seat were two of Shawn's differential covers. Yea, heavy and steel. Well, I guess one of the covers found it's mark, and landed on the black cat...I guess it's true that they have bad luck! Unbelievably, I think that cover, broke the cat's hind propulsion unit. It screamed, crapped all over the place and went running, sort of dragging the gimp leg. I'm just shaking my head holding onto a roller and dripping lizard skin onto my shoe.
Haven't seen the cat lately, but the red dog and the sled dog have been very interested in the trailer ever since...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:44:44 PM
Speaking of seats, I ordered some custom built Canvas seat covers today. They will be made out of the black/gray digital camo material and will get here in a couple of weeks, Here something like what it will appear:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:47:37 PM
I'm getting hung up on this weather thing...
It rained the first part of the day which threw me off cadence. Knowing I was losing time I went off doing other stuff.
That cost me valuable time, so in the end with picking up kids, answering pointless phone calls, watching fox news, napping, parts lookin', and messin' with the dogs, I didn't get very much done.

So enough with the excuses!

Here's what I did do. I cleaned up and painted some parts. Using the excellent Nason (Dupont) acrylic enamel, I gave Shawn's (GLO) diff covers a good coat of Lycoming gray.

Compared to how I butchered the first diff cover he sent, he should be proud of me for making things right!

This time I actually used proper safety equipment!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:49:26 PM
I sprayed three coats both inside and outside.
From my experience it dries pretty hard and stands up well to heat and oils.

Way back when, I owned a single engine airplane, a Piper Commanche 250. Well, I can't leave anything alone so I actually hot rodded that engine, bumping the compression from 8:1 to 10:1 and porting the jugs (heads). Well, anyway, I painted that engine with this same paint and the day I sold that plane the motor looked like the day I painted it!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:50:35 PM
Here's the paint
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:51:27 PM
I thought about spraying the steering linkages as well, so I test painted the drag link to see how that turns out.

It's a good color as it shows cracks and leaks pretty well. It's the factory Lycoming aircraft engine manufacturer color that goes on their engines everywhere.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:51:55 PM
Other than that I also got some important parts ordered.

I bit the bullet and purchased new rear springs from Super lift. The springs I ordered have the same weight bearing capacity, ride smoother and have 4" more arch built in. That means I will be able to drop that hideous 4" block in the rear.

Deleting blocks makes the truck safer, and in everyday driving, it keeps the truck from wanting to roll as much in a corner.

I also ordered new 9/16" U-bolts. That should update the suspension pretty well along with the shocks and sway bar bushings...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:52:56 PM
Quote:
Originally Posted by nmeyer414 View Post
So heres a question for yah don. Whats the nbc drill for pilots while in flight?

More DOT stuff

Well, why not junk up this thread as well!

In flying we identify the guy doing the flying as the "Flying pilot" and the guy checking his stocks as the "Non flying pilot"
Pilot and co pilot refer to the actual crewing and not who's actually going to pilot (fly) the aircraft.
In the Armee, the guy on the controls practices not breathing while the non flying guy masks up, then takes the controls, then the guy who is thrashing about gets to mask up.
Flying jets, believe it or not, we mask up as well!
There are oxygen masks in compartments beside every pilot.
Really cool masks with tentacle like arms...You pull it out of the cabinet and squeeze the front which has some levers. Immediately the tentacles expand into a huge ball. slide the ball over your brain case group and let go, when you release those paddles/levers, the arms/tentacles immediately contract sucking the thing onto your face like that creature in the Alien movies. In fact the whole thing sort of looks like that...Really creeps me out. Now if you're claustrophobic, you're definitely having a really bad day, cause that thing does not come off without depressing those levers.
But while everyone in the back is dying you're back to thinking about your stocks and mowing the lawn after you land
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 02:57:59 PM
Quote:
Originally Posted by BobbyB View Post
Rock,paper, scissors on who has to fly while the other throws the gear on? Assuming more than a couple mins warning?? Isn't the the official unofficial rule?

New game

No longer Rock, paper, scissors

For now on

Its

DOT, paper, scissors

Paper covers scissors

Scissors cuts paper (Thus confusing everyone)

And DOT offers nothing and always loses and makes every serious person wonder why they are playing this ridiculous game
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:01:36 PM
Lets get on with some new stuff.

First a look of Shawn's front diff covers in that Lycoming gray
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:12:30 PM
Yesterday I ordered two rear springs from SkyJacker suspension with 4" more arch built into them so I can drop the blocks.

I also ordered new U-Bolts and new shackles as well as new bolts. That Dodge uses 5/8" bolts on those rear springs as factory stuff! That's big burly strong hardware!

The U-bolts showed up today
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:13:16 PM
I'm cycling boxes from the jap maple window to the floor, where they will eventually either get thrown away, or carried off and chewed up by the red dog
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:15:03 PM
So today was interior put-em back together day. I didn't finish but punched a major hole in that pile of new lookin' old pieces

First I sprayed the interior with rubberized undercoating, over top of the lizard skin. That L S stuff was like something between rubber and concrete. Once it dries, it's done and so is any part that has any on it.
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:16:29 PM
While that stinky stuff dried I went to work on the instrument panel. It got dissembled, cleaned, light bulbs replaced, and reassembled.
Heck, it looks new!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:18:01 PM
Some of the old bulbs were burned black!

The plastic bezel was a bit cloudy, but cleaned up nicely with vinegar and water. Windex streaks so the vinegar is mo-better!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:18:59 PM
I replaced all the various interior bulbs, 21 in all, then mounted the instrument panel
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:19:54 PM
I'll get some LED lights in a little while to update those, but incandescent will work for now.

Then I installed the instrument panel bezel with it's components

I found these interior screws at the paint store so I put them to work!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:21:14 PM
Then, piece by piece the dash came together
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:22:13 PM
It's all plain looking and devoid of flash, but it's clean and functional!

I decided to install some 2 X 4 roll bar structure.

I told you I was keeping it simple and low cost! At least I'm using galvanized nails!
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:23:34 PM
OK, so maybe I was only holding the headliner up in place!

That wasn't easy, BTW. Finding the holes beneath new fabric is nearly impossible, and of course the L S covered the holes completely making it nearly impossible to actually find them!

First the visors anchored the front in then the rear cabin light to complete the need for 2 X 4 bracing.

That's as far as I got today...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:24:32 PM
Quote:
Originally Posted by duramaxdarren View Post
Rofl! Wife and I just bought your book


Sent from AutoGuide.com Free App

She will really like the chapter where I compare a helicopter to a woman...
And the one about going on leave, then returning to war. Most of the ladies who have read it liked those chapters most.
I'll warn you and everyone before you crack the cover. That is real stuff in there...real emotions. I know very few people who read it without sheading a tear, and laugh out loud. I had one veteran who couldn't get through it...just too real.
So if there are any real traumas in your past and you have difficulty with those feelings, then maybe you should close it if it starts to draw you in. Hell, I can't read the darned thing and not get shaken up again...
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:25:14 PM
Cost/parts so far




1991 Dodge W250
Cost ea Total to date Date Reason

$ 4,000.00 $ 4,000.00 8/30/2013 Purchase Price
$ 330.97 $ 4,330.97 9/2/2013 Exhaust system, Summit Summit Racing
$ 174.72 $ 4,505.69 9/9/2013 tie rods, drag link, rad hose, clamps AutoZone
$ 195.32 $ 4,701.00 9/10/2013 Water pump, belt, hoses, clamps AutoZone
$ 248.62 $ 4,950.00 9/11/2013 Paint supplies and coorsion treatment Kentucky Motors
$ 59.00 $ 5,009.00 9/10/2013 Rust converter Rust city
$ 1,381.82 $ 6,391.00 9/11/1023 Hercules 285/75 R16 Tires Tire Discounters
ION 16" X 8" Wheels
$ 249.39 $ 6,640.00 9/12/2013 Rad fluid, oil, trans fluid, hoses, clamps AutoZone
$ 107.00 $ 6,747.00 9/12/2013 Axle fluid, rad hose, clamps, Fuel line Kentucky Motors
$ 159.13 $ 6,906.00 9/13/2013 Paint supplies primer and quart of paint Kentucky Motors
$ 188.00 $ 7,094.00 9/15/2013 Shocks and rear upper shock bolts Summit Racing
$ 602.00 $ 7,696.00 9/15/2013 PS line, voltage reg, tailights, parking lights Parts Geek
Sway bar bush, steering gearbox,motor "
mounts, trans mounts, door hinge pins "
steering damper, Ac control mod, AC "
clutch control, AC accumulator,turbo "
gaskets, P.S pressure hose, K&N air filter "
Door striker, axle gaskets
$ 89.00 $ 7,785.00 9/20/2013 Rear spring shackles General Spring
$ 36.00 $ 7,821.00 9/18/2013 Rear axle U-Bolts
$ 480.00 $ 8,301.00 9/18/2013 Sky jacker rear springs Summit Racing
$ 69.00 $ 8,370.00 9/20/2013 Bolts, spring and diff covers Nuttys
$ 136.00 $ 8,505.00 9/19/2013 Door weather strip, Door felts, seals Rock Auto
$ 34.00 $ 8,540.00 9/20/2013 Dash and interior light bulbs AutoZone
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:26:43 PM
I had to clean out shop space for Square D to move inside for the big teardown. Soon it will look like a scrap heap, even more so that it currently does. But it will emerge victorious with many, oh so many new moving and non moving parts!

Here it is waiting expectantly for what is to come:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:28:48 PM
Starting almost immediately, I am launching off on the BRI (Box reduction initiative)
The BRI will pursue a diligent course to restore the view of the Jap maple which has become obscured from some angles. See for yourself:
Title: Re: SquareD Build Thread, Part 2: The build Continues...
Post by: Flyin6 on September 21, 2014, 03:31:18 PM
We will conclude Part 2 here

We are about at the end of September, some 3 months into the build.

At this point the truck has moved into the shop and will not be driven again

The repair stuff continues and we start to get much deeper into this project. In section 3 you will see the change from simple repair toward a much more serious restoration effort.
Title: SquareD Build Thread Part 2: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 03:59:09 PM
The truck was driven into the garage, where it still sets today. It seems that getting it there and out of the driveway changed the way I was thinking about it. I stopped looking at repairing and began eyeing everything from an upgrade perspective. I became unsettled about the surface and scale rust, and wanted the truck to look much better than it did. I also became concerned with the tractor like ride it had and knew there was much better suspension science available now than existed when the truck was built decades ago.

So we will continue the build and the truck will start to get torn much farther down.
This all starts the last week of September, 2013
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:01:10 PM
Here's that drag link that I experimented on with the Nason paint. I think it's a winner!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:02:53 PM
Quote:
Originally Posted by nmeyer414 View Post
Hopefully everything will go right and he will be able to start the tear down.

The goal for today is to have the frame resting on jack stands, tires and wheels off, shocks off, rear spring off, brakes and brake parts off, and driveshaft out, and the steering stuff all torn off.

If UPS and FedEx are true to their words, I have most of that stuff arriving today in yet another pile of boxes!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:03:49 PM
Well the primary teardown went well. I had some good surprises and one not so good.
I started the day with my camera of many moons crapping the bed...It died a sudden death when I dropped it (again) and that proved to be just too much. I just checked, it took over 3700 pics for the D-Max build thread and a few hundred more for this one. Add to that several thousand of everything you can imagine of consequence except for a Liberal with a brain, and I'd call it a good run!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:05:16 PM
Today the FedEx guy, the UPS man, and the mail guy all delivered multiple boxes.
I fell well behind on my BRI efforts
Here's some of the stuff that came in
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:06:53 PM
Not wanting to put everything up, I decided to install a few things before I continued tearing Square D down more

I replaced the voltage regulator and kept the old one as a trail spare
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:08:02 PM
Here is the steering stabilizer and Mr. K&N
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:09:35 PM
I decided to install the K&N and button up the intake tact
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:10:15 PM
So far I was able to get rid of this much without adding anything to the window blockin' box stackin' that's taking place daily!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:11:05 PM
More stuff that kept coming in!

The bolt box from Nutty's contains the frame bolts for the GLO differential covers
The bigger bolts are for the springs and the shackles that will be going on pretty soon
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:11:53 PM
Not sure what was in that Rock Auto parts box, guess I'll have to cut it apart and look-see

The BRI seems to be a failed effort at this point!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:13:02 PM
Finally after way too long those horrid wheels and tires are forever off and gone
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:14:00 PM
The start of todays trash pile
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:15:11 PM
First the front shocks
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:16:00 PM
Then the rears
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:16:36 PM
Trash pile spreads some
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:17:29 PM
Next, the drag link and the steering cross over link went bye-bye
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:18:24 PM
Then the exhaust was removed. It had failed 5 years ago, but I guess no one noticed!
I even pulled all of the hangars off of the frame...I am starting with my own design and all new stuff
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:20:37 PM
Then I made the one surprising discovery for the day. The read Dana 70 is trashed! I mean GONE
That big donut around the magnetic drain plug is all metal. Ranging from filings to inch ling slivers. There is so much play between the ring and the pinion, one of them has obviously failed. The ring gear felt good, so I imagine it's the pinion gear. Bummer!

Well I was debating getting a locker, now I guess that decision will have to be made for sure, since I will need new gears and bearings
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:22:36 PM
Conversely, the Dana 60 in the front looked like new
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:23:43 PM
I know, crappy cell phone pics, but about then, the back up camera stopped working as well! Bad day for cameras!

The trash pile grew throughout the day

You can see a good side by side of the front and rear covers. Any question which one is no good???
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:24:21 PM
Next I pulled the drive shafts. THey will get sanded down, rust neutralized, then painted with that good Lycoming gray before reinstalling
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:26:09 PM
Then I went pressure washing again with hot water.
This is not all it is getting, but removing the tires opened up areas that I could not get at earlier.
Tomorrow the entire undercarriage will get soaked with the purple cleaner and skin remover, then pressure washed until the vehicle weighs at least 200 los less.
After that will be the wire brushing and coating with the rust neutral stuff. My goal is to spray the entire underside with more J Deere Blitz paint and gun lube before reassembly
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 04:27:57 PM
It may not look like it, but the truck is getting a lot cleaner
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:50:29 PM
And this is where it sits as of COB today!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:51:54 PM
Quote:
Originally Posted by lutzjk913 View Post
I guess you are right. You doing new brakes right? Calipers and lines included?

Yes, Rebuilt loaded calipers, turned rotors, new rubber brake lines everywhere.

Shawn sent me some of his rear disc brake conversion brackets, but for now I just want to get the thing up and going. SO I might just rebuild the factory 12 X 2.5" drum brakes.

I don't want to spend anything on the master cylinder since later on I want to convert it over to chevy hydro brakes
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:53:28 PM
Quote:
Originally Posted by 20DirtyMax05 View Post
I've got to tell you that I look forward to seeing what has been added each day to this thread. I thoroughly enjoy the stories and life inputs that you provide as well as love to watch this truck come together. Thanks for both and a huge thanks(can't say enough) for all of the service men and women out there and what they have done for us!


Glad you are enjoying it. Although in all truth, I guess I really don't care if anyone enjoys it or not, It's a good thing that some do. Let me explain. I do not live my life to appease others, I just live it. I don't take a lot of interest in the interests of people, unless I am serving and they are issuing orders or I see a genuine desire in their heart to do good, change for the better, do something selfless or the like. I have found most people to be self centered and at heart disinterested in what is going on around them. Therefore their opinions mean nothing, and since that attitude is so prevalent in American Society, well, you get the drift.
I guess I'm just doing this because I genuinely hope it might help or inspire someone, but foremost because they might see the Jesus in me and have that cause some thought.
Admittedly, I am a pretty poor example of what Jesus would call us to be, since I seem to be harboring a bigotry for the Islamic culture, but I'm dealing with that. But maybe I just see the truth of what they really are and that just runs so counter to my Red blooded American freedom loving heritage that I can't help but for the hairs on my neck to bristle when I consider them and the danger they, and now the liberal retards populating the dry places between out two oceans.
OK, I'm done, and I'm happy that you like this!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:54:03 PM
Quote:
Originally Posted by EL TATE View Post
Ugh... did you happen to find a tag# on that pig?

Yup there was a tag right on it

Two lines of information printed out like this:

52068173
3.54 605509-1

I believe it to be a Dana 70 based on the larger than the D-60 axle tubes.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:54:46 PM
Quote:
Originally Posted by stlaser View Post
Don, normally you don't need to do anything to that master cylinder to run disc brakes in the rear. Some guys add an adjustable proportioning valve (wildwood $40) but that is it. Also some point early 90's thinking maybe 93Dana changed to a larger hub on the 70 units. Those particular axles need the hub OD turned down on a lather slightly so the rotor I use will then still slip on.


Well, Shawn,
I was not planning to get that deep into the axles just yet, just get the thing running and well and drive it around for awhile to learn it's strengths/weaknesses, then address them after the SAS was in and installed.

But now I have to do something. I checked with Roy today over at Performance Off Road, and he is ready at the drop of a hat to take it in and install anything we decide on.
I was about to contact Tate at Randys Ring and Pinion to get his recommendations for what would fit this build best.

Duane threw an interesting curve ball in the mix just this afternoon. It seems he remembered I just happen to have a 14 bolt sitting here in my garage!

Not a good fit though, I measured the spring pads at 43" outside to outside and the Dana 70 is a bit over 45". So at a bare minimum I'd need to cut off and weld on new spring pads, but that isn't too big of a deal. Secondly, I counted the gear teeth, 41-10, so it's a 4.10 ratio. Finally it's an open diff as well so really I'd need to buy the same gears and install kit, same locker, weld up spring pads, and adapt the parking brake cables. Not so sure that would same me any money at all.
So far it's looking like a big $$$ dump on a worn out Dana 70!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:55:54 PM
From El Tate:

Sure is.
605509-1 DANA 70 3.54 STD open differential
Ring & Pinion kit # 708015-1
Differential case # 708016
Diff inner parts kit # 707252x
Axle shaft left and right # 43811-1
Not sure if this will work, but this link is invaluable: Dana Holding Corporation - The Expert Axle Bill of Material
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:56:15 PM
Oh and no workie on Square D today. Had a Dr's appointment along with parts gathering, a great sandwich for lunch, more parts gathering, running one of the pre-rangers to x-country practice, then tending to the critters.

I did get the spring shackles in, so that block is checked

I picked up 32 black splined lug nuts for the wheels...Check!

ANd a quart of J Deere Blitz black and some other chems for tractors which ought to work fine in that tractor like Square Dodge!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:57:55 PM
If you go 14 bolt we have the perches, top plates, girdles, disc kit, cover & cool pinion guard available. Not that I'm pushing you towards a 14 bolt or anything even though it is the better choice versus that worn out black sheep 70 you own.....



Quote:
Originally Posted by flyin6 View Post
Well, Shawn,
I was not planning to get that deep into the axles just yet, just get the thing running and well and drive it around for awhile to learn it's strengths/weaknesses, then address them after the SAS was in and installed
.

From Flyin6:

But now I have to do something. I checked with Roy today over at Performance Off Road, and he is ready at the drop of a hat to take it in and install anything we decide on.
I was about to contact Tate at Randys Ring and Pinion to get his recommendations for what would fit this build best.

Duane threw an interesting curve ball in the mix just this afternoon. It seems he remembered I just happen to have a 14 bolt sitting here in my garage!

Not a good fit though, I measured the spring pads at 43" outside to outside and the Dana 70 is a bit over 45". So at a bare minimum I'd need to cut off and weld on new spring pads, but that isn't too big of a deal. Secondly, I counted the gear teeth, 41-10, so it's a 4.10 ratio. Finally it's an open diff as well so really I'd need to buy the same gears and install kit, same locker, weld up spring pads, and adapt the parking brake cables. Not so sure that would same me any money at all.
So far it's looking like a big $$$ dump on a worn out Dana 70
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 07:59:43 PM
Well, I got the thing cleaned and ready for the rust conversion process.
That was a lot of work
I decided to get full industrial on it. Went through 2.5 gallons of the purple degreaser stuff. It loosened all the mud/dirt/grease/undercoat. bugs/old jap car parts and so forth
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:01:15 PM
I sprayed it all over the undercarriage, several times and kept it soaking for several hours
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:02:00 PM
It looks like a hazardous chem spill, because...It is!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:03:46 PM
That's when all the nasty spraying and scrubbing happened. I got under that thing and started on one end and went to the other. It took me like 2 hours of spraying to get all the crap off that the purple stuff had softened up.

I was covered from head to toe with all manner of crap...probably some of that too, come to think of it.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:04:56 PM
It may not look it, but that puppy got a whole lot cleaner!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:06:31 PM
Then I attacked the driveshafts and steering link with the wire wheel and prep sol
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:08:03 PM
Then the rust conversion process after cleaning the parts with lacquer thinner
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:09:31 PM
course more new parts come in
This time Rock Auto anted up with all the weather-strip and door window seals.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:10:43 PM
Bad thing about that is that it blocked more of the view of the jap maple!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:11:18 PM
Tomorrow I think it will be all about painting a lot of the pieces parts in preparation for some reassembly.

I just realized, I didn't show any pics of the borgensen steering linkage which will soon replace all the stock stuff.
I'll get it tomorrow
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:11:58 PM
Quote:
Originally Posted by Cudakidd53 View Post
Pretty large undertaking, being on your back dodging falling junk! That rust converter really makes a difference on the drive shaft and other parts. Thanks for sharing yet another cool product from Don's Garage!

I hope to be painting a whole bunch of pieces parts tomorrow with that kool Lycoming gray paint. I decided to paint the shocks as well, since they always manage to rust up pretty quickly.
I'll paint the steering linkage, brake calipers, steering gearbox, Borgesen linkage, steering stabilizer, shocks, spring shackle, and anything else just hanging around awaiting installation.
Might not look as cool as some of these neon green undercarriages, but it will be mo-rust proof!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:15:01 PM
Worked for hours today on the rust. It's yielding, but it's a lot of work.

First I pulled the front calipers off as well as some questionable steel and rubber brake lines to make way for shiny new pieces parts
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:38:37 PM
I already have the new Bendix calipers, pads, hardware, hard and rubber lines. I decided to just put everything in there new to give me peace of mind and a good baseline. The brake fluid I pulled out was pretty clean and the MC was clean as a whistle on the inside!

Then I started applying the Rust converter
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:39:51 PM
still cookin' in the pictures so far. Some areas were worse than others, but in 4+ hours, I went from the front to the back. Checking just now, I see where I missed some areas which will get my attention tomorrow.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:41:06 PM
these pics you can really see the difference between the uncoated spring and axle and the treated parts.
That spring and axle will be coming out for good PDQ!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:42:18 PM
Here's that new Borgensen steering shaft that gets rid of all the slop from quick wearing factory components. This thing will not wear out and give good steering for years to come
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:43:46 PM
The truck will be getting a rebuilt steering gearbox as well
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:44:40 PM
The hanging jungle of parts will be getting a coat of my new favorite Lycoming gray in the morrow!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:45:09 PM
Got some good news
I found a used Dana 70 out of a Dodge W250 newer than mine with a 3.54 gear set and the anti-lock setup.
We agreed on a selling price of $250!
I'll pick it up Saturday
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:46:34 PM
Quote:
Originally Posted by EL TATE View Post
Good to hear; were you able to confirm the finer points with that Dana BOM lookup link? They only major recommendation I have for you is to disassemble and fully inspect the PowerLok limited slip unit if it has one. They are known for being self destructive especially on the smaller spider gears. That being said, if you do have the limited slip, you have one of the strongest, most aggressive units ever released to the general public.
 

I still have to look up the BOM # which he supplied.
I only asked if it has a 3.54 and anti-lock brakes which it did. It did have a rear sway bar attached which I plan on scarfing up, but I'm thinking that is not common. Therefore it probably came from a well optioned truck. Well optioned trucks usually come with some sort of anti-spin diff. I might just score, time will tell
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:48:00 PM
Man my head is just buzzing. Been painting for hours. I wore a good mask, but from the way I feel right now, I'd have to say it didn't completely block the vapors.

OK let's get started

First I opened up the rebuilt Bendix calipers and prepped them for acid etching primer, the first of several coats they are to recieve
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:48:54 PM
The reason I use the weld through stuff is because it is zinc. You put zinc on any metal and it will sacrifice itself first to rust and corrosion before any of the parent material. So I locked down the surface with several coats of this zinc rich product to keep it from ever rusting
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:50:22 PM
Then I removed the tie rod ends from the cross steering bar. I just didn't gingerly unscrew them, nope, I beat them with a hammer while soaking them with PB Blaster then used a 4' piece of pipe on the stud end to grudgingly twist them off a little bit at a time. It seemed like they only got easier to turn when the thing fell out. Right up to that point it was squealing so much both dogs came in and set to barking at me!

I cleaned the piece up and coated it with some of that zinc primer
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:51:46 PM
Then after studying the frame some, I decided I wasn't happy with the results of the rust converter on some areas so I ground all that stuff and the rust off with the wire cup. I then recoated it with the converter which definitely worked well this time!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:52:39 PM
Next up came the lacquer primer step. Prior to painting everything got a wet coat of black primer just to aid in adhesion and get one more layer of protection on there
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:54:01 PM
The hanging jungle got sanded and wiped down with prep-sol then painted with two coats of primer. Then the under carriage got primed is some areas, but not everywhere
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:55:47 PM
Why the shocks? Because that white coating might as well be white wash hardly suitable for Tom Sawyer to paint up a fence in Mississippi!

While the jungle cured, I mixed up that John Deere (Valspar) Blitz paint with the thinner and hardener and sprayed the suspension, chassis, drivetrain, and parts of the body underside. I guess I just went a little wild!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:57:41 PM
It has just enough flattening without being full on flat black. It does a good job with corrosion and minor abrasions such as tractors might often see.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 08:59:02 PM
The photos show a reddish haze, which I believe is some sort of reflection. The whole undercarriage is as black as midnight in the desert in the interior of the Stan up beside some mountain with... Well, you get the picture!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:01:00 PM
Next I got on the hanging jungle. I cleaned out the gun and mixed up a batch of that Nason Acrylic Enamel with hardener and sprayed the Lycoming gray on everything.
This step is not to make anything pretty. Not competing with the "Blacked out Chevy emblem crowd", nope, just getting a neutral color that will show leaks and cracks and keep things from rusting any more
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:02:09 PM
I kind of like the color
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:03:06 PM
The undercarriage paint was starting to set up about when I finished over spraying everything including my hair, two cats, the welder, plasma, and a bunch of other things!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:04:12 PM
And this is how it sits as of this moment
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:05:05 PM
Originally Posted by nmeyer414 View Post
Somebody was a busy little bee this morning!

Nate,
Yep, not just this morgan.
Every day this week.
Get the knuckleheads off to school, do workout. Finish exercise, eat vitamins, change clothes, then out to the garage.
Work fast and smart. Come in around noon. Eat a fast lunch. Today 6 peanut butter crackers, then back out and keep at it until the boneheads come home.
Every day same drill
Trying to keep this thing progressing.
I didn't intend to get this deep into it, but every time I get into something like this it turns into a restoration. That's why I'm short cutting some things. I just want to get this truck driving and soon!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:05:55 PM
Note: I was still thinking I would be driving this truck soon. Hadn't turned the curve to a complete restoration yet...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:06:58 PM
Had a change in heart about the color

Considering the purpose of the truck, a back up survival vehicle, driver, farm truck, and project hauler I have perplexed for some time over the colors

I already purchased some of the dark silver base paint and planned to just do that in lieu of changing in the hopes of just getting the truck on the road quickly.

It would look "Classic" and like many trucks do around here, that is older and well maintained. It would fit in any parking lot without drawing much attention other than to appreciate a good survivor example.

But, that does not really play well into the possible scenario of running and hiding, and most likely in wooded, rural areas.

One color that always works well is OD Green. By itself, it's low sheen does well in the shade. Smear some of the local mud on it and you have a pattern of natural materials.

So, that's it. The truck will become OD green, specifically, WW2 OD Green which is the all time classic. The bright stuff will be painted with the semi-gloss John Deere Blitz that I just sprayed the undercarriage with. I'll add hardener to the paint to give it descent abrasion resistance to branches and the like.

Decision made, on line ordering the paint!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:08:19 PM
OK, something really weird just happened

I went up to pick up the Dana 70 axle I found for $250.

I get there and there is a big old meaty somewhat Dana looking axle there which the guy selling to me says is a Dana 70.

I am staring at the fact that it has a rear sway bar attached and has the anti lock reluctor ring as well with the cool little sensor.

Then we just started talking about this and that and before long I fork over the $250 and we use a bobcat to load the axle onto my trailer.

Well, I drive home and get my tractor to unload it and that's when I really took a good look at the rear cover........

Hmmm, seems larger than that Dana 60/70 cover sitting right beside it. Hmmm, the Dana 50/60/70/80 all have 10 bolts on that rear cover, but this one has 12 bolts....

Yea, seems like I didn't just purchase a replacement Dana 70, but a Sterling!

Yup, from what I can see looking at those really big lumpy axles, that's what I now own! Just like that I made a big bonehead mistake...Or did I??

Shawn, others who are smart? So, I own a Sterling with a 3.54 gear and a rear sway bar. I buy a set of spring perches and just like that, I think I have a Sterling rear axle sitting in my W250 Dodge.

Dunno, does Dodge and Ford mix??

I mean I'm installing a F350 HPD60 in the front of my Chebby, so does the sterling add up to being a good rear axle?
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:08:59 PM
Quote:
Originally Posted by BobbyB View Post
So I'm no axle genius so I assume that you came out WAY ahead in that deal?

Well, I don't know
I think a used Dana 70 is worth the $250 I paid, however, not so sure about this Sterling.
I did get a complete rear sway bar out of it, and that has to be worth something, but the 10.25 and 10.50 Sterlings axles have not caught on like the GM 14 bolts or to a lesser extent the Dana 70.

From what I know the Sterling is basically Fords answer to the Dana 70. The D70, 14 bolt and Sterlings all posses about the same strength, although this sterling has some massive 35 spline 1.5" axles that would have to be awfully difficult to break.

I mean the thing would fit and work in my Dodge, but I'd have to be the first guy who ever replaced a Dana 70 with a Ford Sterling if I actually go through with it.

Then there's the drive shaft length, is mine going to fit???
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:09:36 PM
Quote:
Originally Posted by nmeyer414 View Post
Gotta a pic of this here new to you axle?

It was dark when I tried to photo it.
It's sitting in the front bucket of my tractor.

It's a big greasy mess, but actually has very little rust.

I've been reading about these axles. Apparently they are similar in strength to the Dana 70 and possibly Dana 80.
At 333 pounds it is no lightweight! It does have the rear sway bar which would be a nice addition, and I just checked and Shawn DOES make a cover for it!
So, the driveshaft length is a question, the width of this axle, which is 66" WMS-WMS as compared to the Dodge. IT has huge brakes, heck it's odd, but it might just be a go!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:10:25 PM
Quote:
Originally Posted by Dustoff 35 View Post
Seems I should have gone with you.

You have a tendency to get distracted by bright, shiny things like reluctor rings, anti-sway bars and cool little sensors!

I have to take some personal responsibility here.

I really screwed up!

That was a huge miss

A Ford Sterling instead of a Dana 70

Totally on me, I blew it...

But I woke up thinking of making lemonade out of a lemon

That sterling is out of the normal box, hell, it isn't in any box (Too dammed bog!) It's the right ratio...It's uber strong...It could fit...It's newer technology...It has the best axle sealing system made...And in line with things I build, it's definitely different...

Just sayin
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:11:03 PM
From Shawn:

Not necessarily a screw up, I read an article once about the sterling axles. Technically (at the time) there were three versions of them & I'm sure Tate can help you confirm which one you have. From what I read each had a weak spot internally (if you want to call it a weak spot) IMO, no different than a D-70. I have put over 300k hard miles on two different sterlings with no issue & one was snow plowing duty. I do make a cover & also disc conversion can't recall if you said yours was disc or not? I also think that article said you could swap some internal better parts from one of the other three to make the axle you had better. I think a lot of it was larger bearings etc but again Tate is the guru there. All in all it was worth $250 & they put them behind their 6.0l diesels which do make decent numbers while they are running. I used one for 150k single rear wheel 1 ton pulling around a 36' enclosed gooseneck for over 150k until the 6.0l decided it wanted to start puking, 18k trailer fully loaded all the time
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:11:51 PM
Quote:
Originally Posted by stlaser View Post
Not necessarily a screw up, I read an article once about the sterling axles. Technically (at the time) there were three versions of them & I'm sure Tate can help you confirm which one you have. From what I read each had a weak spot internally (if you want to call it a weak spot) IMO, no different than a D-70. I have put over 300k hard miles on two different sterlings with no issue & one was snow plowing duty. I do make a cover & also disc conversion can't recall if you said yours was disc or not? I also think that article said you could swap some internal better parts from one of the other three to make the axle you had better. I think a lot of it was larger bearings etc but again Tate is the guru there. All in all it was worth $250 & they put them behind their 6.0l diesels which do make decent numbers while they are running. I used one for 150k single rear wheel 1 ton pulling around a 36' enclosed gooseneck for over 150k until the 6.0l decided it wanted to start puking, 18k trailer fully loaded all the time.

Well, after church today, I'm going to measure everything up to see if I get the basic fit going on. Then tear into the thing a little to check out the internals. If it's good, I'm going to use it. Like you said, no real difference between it and the Dana 70 strength wise.
From what I have found out so far, the only problem was with an early (up to 93) version of the 10.25 Sterling which had short splines in the pinion gear to yoke end. I can determine if I have one of those by pulling the yoke and measuring it. (Good time to replace the front seal

Now if it is the short spline model, it is said to wobble in 4.10 or higher and with 40" tires. Since I have 33" tires and a mundane 3.54 ratio, it really should be fine anyway. However, the fix is simply to install a pinion gear with the next gen long splines. That fixes everything and makes Don and Shawn happy.

I'll box up that D70 rear disc brake kit and snappy and Purdy rear D60 cover and send them back your way.

The very first parts I order for this axle will be GLO stuff!

I'll buy (Buy) one of your rear covers. I've been working out so I'll be able to lift it! I'll need your rear leaf spring mounts and depending on what the brakes look like, your rear disc conversion. I have drums on this axle.
I think I'll just paint it up and install it like that, but cast an eye on getting a grizzly from Tate for it as soon as I come out of the D-Max SAS build.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:14:46 PM
Got into that Sterling rear axle today.
I checked it out and sure enough it says 3.55 on the tag.
I measured the WMS-WMS width. Stock is 66" This Sterling is 66" as well!
OK so far good to go
Then I tried to fit the driveshaft U-joint into the yoke.
That was a big no-go. The Dodge u-joint is larger than the Ford yoke. THe Dodge U-joint cap is the same diameter, however it is at least an inch wider than the saddle of the yoke. I'm thinking the Dodge is a series 1350, but not sure. No clue what the Ford yoke fits, Maybe a 1310 spicer...dunno

Anyway, here is the first glance at the crusty ford boat anchor in my trusty John Deere
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:16:05 PM
First I pressure washed it for maybe 30 minutes. Then I soaked it with the purple stuff and pulled down the shocks and sway bar. Then it was pressure washed again
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:17:12 PM
The brakes are 3" wide
The dodge has 12" X 2.5" brakes, so the Ford will be a noticeable braking improvement over what it was
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:18:04 PM
It cleaned up pretty well
It has the all important reluctor ring (Shiny thing) that I need to keep the Dodge anti lock brake system functioning.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:18:55 PM
This rear sway bar was a freebee and is a huge bonus that will significantly improve the trucks handling
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:20:10 PM
The diff is definitely an open unit which is not a good thing. There will be a Detroit locker or similar in there soon enough. A dodge with a thousand ft/lbs of torque, those small tires and one wheel getting all of that spells smoke screen for sure
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 09:21:06 PM
The fluid was old and discolored somewhat but much cleaner than what came out of the D70 rear axle. I'll clean the living daylights out of this thing and get it ready for one of Shawn's covers

I cleaned up the build tag which clearly indicates 3.55
I have to do some digging to decode everything else
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:04:05 PM
The sump looked like this cover...I think I'm good to go
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:06:42 PM
Posted by TJ:

Quote:
Originally Posted by flyin6 View Post
It cleaned up pretty well
It has the all important reluctor ring (Shiny thing) that I need to keep the Dodge anti lock brake system functioning.

Are you sure it'll just work as-is? Does the Ford reluctor have the same frequency as the stock Dodge?

I hate to be "that guy" but wouldn't rebuilding your D70 be the cheaper, "sure thing" route? Now that you cleaned it up nicely maybe you can even make a few bucks reselling the Sterling?

-TJ
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:07:49 PM
Posted by Ken:

I would personally ditch the rear antilock system. They sucked from the get-go and sucked up until they went 4 wheel abs. Take out the valve, put a couple fittings in and Big D is happy, and better stopping, no more spongy pedal, and no more wearing out the front brakes at 20k or less (especially since the dodge diesel doesn't use engine braking at idle without mods).
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:08:11 PM
Quote:
Originally Posted by KensAuto View Post
I would personally ditch the rear antilock system. They sucked from the getgo and sucked up until they went 4 wheel abs. Take out the valve, put a couple fittings in and Big D is happy, and better stopping, no more spongy pedal, and no more wearing out the front brakes at 20k or less (especially since the dodge diesel doesn't use engine braking at idle without mods).

I was surely thinking that same thought!

The truck came with a spongy pedal and the brake light was on, indicating some sort of problem, most likely with the anti-lock.
Good suggestion Ken, especially in light of the vehicle purpose, EMP and all that...
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:09:04 PM
From El Tate:

Quote:
Originally Posted by KensAuto View Post
I would personally ditch the rear antilock system. They sucked from the getgo and sucked up until they went 4 wheel abs. Take out the valve, put a couple fittings in and Big D is happy, and better stopping, no more spongy pedal, and no more wearing out the front brakes at 20k or less (especially since the dodge diesel doesn't use engine braking at idle without mods).

Just did some research; wiring might be right, but tooth count is not. ford's sensor controlled ABS and Speedo, and won't work with dodge's system. ditch it and run the housing sans ABS like Ken suggests and you'll be happier.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:09:55 PM
Quote:
Originally Posted by tjZ06 View Post
Are you sure it'll just work as-is? Does the Ford reluctor have the same frequency as the stock Dodge?

I hate to be "that guy" but wouldn't rebuilding your D70 be the cheaper, "sure thing" route? Now that you cleaned it up nicely maybe you can even make a few bucks reselling the Sterling?

-TJ

I hear ya, but I think I'll go with this out of the box adaptation.
With Tate solving the U-joint issue, and with Ken's suggestion of dumping the anti lock brakes which just makes sense to me, I can't come up with a good reason to spend a couple thousand building the D70 which would include a locker since I'd already be spending money on a teardown/reassemble.
De-tech it and it begins to make sense!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:11:24 PM
Let's do some reassembly
I worked down the "Hanging Jungle" some and got the front axle area a bit prettier.
First I really wanted to finally get one of Shawn's front covers mounted, so I did that first.
I glued the gasket to the cover but did not use any sealer at all on the axle face.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 21, 2014, 10:12:29 PM
Using the new frame bolts in 3/8" X 1.25" the cover was bolted up
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:04:08 AM
Oops, forgot the freshly painted differential tag...

I topped it up with 4 quarts of Valvoline synthetic gear oil, sorry Willie!

Shawn's unique design allows you to put any amount of oil you wish in there since it fills from the top and not the side.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:07:32 AM
I was determined to get some stuff installed and off the shelves and hanging jungle today, so that's where I focused

Next I installed the front shocks
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:09:57 AM
Next, the front driveshaft
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:12:13 AM
Hoping to get the steering somewhat installed, I pulled the steering column lower linkage and the gearbox.

The latter was not easy. Long/big/fine thread bolts made for a second weight lifting session this afternoon!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:13:29 AM
This area in Dodge frames is prone to cracking. Here is more evidence I purchased a diamond in the rough. The frame is perfect! Not a hint of anything going bad here.

I cleaned it up, coated it with the rust converter, then a couple coats of Blitz paint
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:14:47 AM
If you're wondering, yes, I cut the lines to make removal easier. I have new ones for the reinstall.

I did the same treatment to the steering box mount plate, a simple but clever piece designed to spread the loads generated by steering over a larger area
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:15:35 AM
That got reattached to the new steering box
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:16:30 AM
The pitman arm will get cleaned and painted as well. I was surprised at how easily it came off the old box. I'm thinking it was working a little...Man, I bet the steering on that truck then was awful!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:17:17 AM
The hanging jungle is getting more space for future parts painting!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:17:56 AM
OK, Tate and I were exchanging emails. The subject is a traction diff for the Sterling.
I want to keep the cost low, since the parts for the Combat Max are scaring me!
Anyway I was thinking of a Lock-Rite mini locker to fit inside the stock diff case.
Tate suggested I look at a True-Track gear limited slip or another Grizzly like I have in my Duramax. I am definitely partial to the Grizzly's, but I'd be getting into a bunch of money.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:19:55 AM
This is what makes these projects an affliction.

I can't seem to leave anything alone

I start with changing the oil and buying new tires, but that eventually leads to a complete color change, SAS and an Allison turbine conversion.

I need to get the vehicle to my "Minimum" standard. Which means quite a bit more than just oil changed...

like I said, it's an affliction!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:42:07 AM
Quote:
Originally Posted by stlaser View Post
Do they make a mini spool for that Sterling yet? Remember this truck isn't going to see thousands of miles & may end up as the farm truck....

It is likely true that this Dodge will find itself sitting in the barn on a trickle charger, hooked up to a trailer, but later. For now, I would like to drive it enough for me to determine the truck is reliable and get it well into the "Survival truck realm.

With some things I am good with just getting it back to factory spec, Things like the brakes for example. But with winter approaching, a torque diesel and no traction device, or even mudding down on terra farm and getting stuck on wet grass is something I need to think about. Frankly producing something with 400+ ft lbs of torque and no limited slip is nuts, so in a way, I am making up for a poor decision from Dodge.
But I have this thing torn apart, Tate says it's not all that difficult to install a diff in the Sterling, so I am thinking this IS THE TIME to do that!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:42:56 AM
From Shawn:

Lets makes something really clear. Limited slips go in the back of 60's muscle cars not trucks. Don't waste your time on anything limited in a truck. It's either a Detroit style locker or spool / LL. I also like push button stuff. However, all limited slip will do is slip and leave you stranded. Trust me been there and done that trying to save wear on other parts. Spent a lot of money and still ended up with a real locker. That is all, you all may proceed forward now I have spoken! LOL
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:44:51 AM
You boyz are a bunch of chatter boxes when I'm away!

Back to the build...I was able to get more boxes in the trash and parts installed on the truck.

First I finished installing the steering box
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:45:46 AM
Then I cleaned up the pitman arm, coating and painting it to resto garage standards
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:47:12 AM
For some reason I got a little crazy on the rust removal and de-rusted the brake drums, treating them as well.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:48:15 AM
I'm going to have the drums turned so the slop all over the inside will be milled off with the pitted iron

Next I tackled the steering shaft. The factory design is junk. I removed it in favor of rebuilding something that would just wear out soon.
The borgensen shaft I ordered to fit the truck, did not!

My luck...

But I had a left over Toyota tundra steering joint, so I decided to cut the both of them apart and make something custom, which you see happening here.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 11:49:30 AM
The Toyotas steering joint was actually much larger than the Borgensen joint it replaced. And, the Toyotas joint bolted up to the Dodge steering wheel shaft with some simple elongation of the bolt holes.

In this series, the new shaft is being created
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:13:24 PM
I painted the new end black and installed it like that, after removing the 100mph tape I put on there to keep it from getting all banged up
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:14:36 PM
The installation went well, only taking a couple minutes
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:15:24 PM
Then the pitman arm
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:16:28 PM
Then the cross over steering linkage with two new tie rod ends
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:17:24 PM
I plan to scarf up some new fine threat grade 8 bolts and lock nuts for the tie rod clamps in a day or so. I just need to get some more of these parts onto that truck before I go crazy!

Next the drag link was bolted up
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:18:45 PM
Then I connected the Power steering lines, bolting up the new pressure line
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:19:40 PM
Steering works, and mo-better than ever. I still plan to move the steering stops in just a tad, but here is the left and right limits...It's all connected!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:20:32 PM
Then the new center rubber brake hose went in
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:21:24 PM
Then both caliper hoses, new Wagner parts, each!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:22:12 PM
Since the factory brake lines were rusty, I bent up my own new lines and started installing them. That takes some time, so I only got the left side done before running out of time for the day
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:22:57 PM
Those brake hubs are looking pretty good after several hours of curing in the sunlight!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:24:04 PM
Quote:
Originally Posted by duramaxdarren View Post
why no stainless steel braided brake hoses?

There is a reason and a secondary reason

First is the cost. The rubber lines are relatively inexpensive, although these wagners were not necessarily

Regarding the secondary reason(s) is actually a lot of considerations.
Stainless lines made their way into the automotive arena because they don't expand like a poorer quality rubber line. Standing on the brakes can generate 1100psi hydraulic pressure. Stainless lines can handle 1500 easily and the Teflon units over 3,000 working pressure.

But they kink! Did you know that? Stainless lines are used in aircraft where the movement is known and calculated against the known ability of the sheath to conform at max pressure.

Now let's talk a 4WD working suspension. The stainless lines are basically made the same length as the unit they replace. The rubber line they replace...The rubber line which does not kink and can take a lot more bending and shape shifting...See where I'm going with this?

On my street muscle cars, I would use the stainless lines but I'd make them myself with #3 or #4 fittings done properly. In some cases I'd do a loop so that a rapidly unwinding suspension wouldn't pull the line into a kink and destroy it or severely weaken it.

Nossir, I think high quality rubber lines are the proper choice, and Wagner lines have to be amongst the best.
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:26:07 PM
Pushing the ball downfield another foot at a time, inches on some days!

Today I finished the front brake line installation with new hard and rubber lines.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:27:21 PM
Then I felt an acute case of interior coming on. Knowing everything was about to get covered up, I applied a generous coat of seam sealer to all the seams than I might have compromised while wire brushing some time ago.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:28:10 PM
I even slopped it on the roof channel where it is welded to the windshield and side support metal. This is a common spot for these Dodges to rust out. This truck is protected for the next few decades now.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:29:22 PM
I cleaned up the factory HD rubber under layment, and re-glued the juke felt that had come loose in spots. After cleaning it still had some rust staining, but what the heck, that will be hidden from sight forever very soon.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:30:09 PM
After securing the wiring harness, I laid it out. If fit like it belonged there
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:31:07 PM
The next step was installing the new door seal, so I sanded the jamb and painted it semi-gloss black first
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:31:44 PM
Then installed both new gaskets
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:32:39 PM
That is definitely looking much better. I'll paint that jamb with the OD paint, but I plan to tape right up to the seal, so I wanted some paint down there first. The plan is to paint out the insides first, then the outside

Next, the rear window headliner trim, the seat belts, and the side quarter trims went in
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:33:32 PM
I still have to scrape out that ugly rear window trim, but I think I need to install a new rear window rubber seal, so I might as well just wait until I remove the glass.

Here's the state of finishedness at the moment
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:34:29 PM
This will be a picture free update tonight.
The faithful Fuji 5000 died an untimely death you all might remember.
Well, I had to dig through my old flight helmet bag to find my really ancient Fuji 3000. That intermittent at best camera has been dutifully posting pictures for a couple weeks so far, but lo, it is dying as well.
I'll spare everyone the details, but I am about to be camera free save for an old Sony I have with no battery (Dog chewed it up along with the charger and the case)
I'll be down to my cell phone and a piece of paper and a pencil pretty soon

Buy one you say...What, are you nuts? I can buy all 9/16" wheel studs, get the brakes turned and a couple of LED lamps for that, so guess where I'm going???

Anyhow, I'll try again in the morning before the workout to get the pics posted.
Today I went all the way to laying out the carpet with the interior install. It's almost all in.
I then removed the skid plate, drained the transfer fluid, and installed new transmission cross member rubber mounts (2 ea)
I traced a problem in the AC system to a little electronic control relay that is no longer available, and made friends with the orange and white cat. Seems that one has been more and more interested in the restoration of old Square D. Can't figure out how to put that cat to work, so maybe I'll just install it somewhere as a mouse deterrent
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:37:25 PM
Quote:
Originally Posted by BobbyB View Post
That charcoal will be blackerer after you get in and out a few times after getting dirty, or the pre rangers get in and out being dirty. But D2 is looking quite nice now that you've basically restored her back to her former glory. Now I've got a question. When you paint her in the OD green are you going to pull her apart and paint her that way or just tape it off and leave her whole ?

Good question.

I'd doing a paint as I go

I haven't gotten the paint in yet, or I would have already painted the jambs. I need to pull the fenders off to check out the cowl and firewall thoroughly for cracks, then recoat. I'll repaint all of that while it's apart.
I plan to pull the bed off for a couple days to redo the brake lines and treat the top of the frame that I couldn't get to...I'll repaint the underside and front then.
The hood is coming off as well to coat the underside with lizard skin to deaden the sound some and I'll just paint it then. Finally at some point the insides will be finished and it will just be a couple days to do the remaining body work, sand off and paint the exterior.
I'll also paint everything exterior like mirrors, grill, door handles and the like in that low gloss J.D. Blitz then as well
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on September 22, 2014, 07:38:04 PM
OK time to build it some more...

Today we will be all over the place, well, like most days. You see, the way I figure it, it all has to be finished, so who cares which part I work on. If I feel like working on the AC, that's where I go...Lights, ditto.

The thing started today with the 5-minute, turned forever install of the steering dampener. I bolted it on with the cylinder at 50% of it's travel, then I'd find some interference (With Shawn's cover)
Then I'd adjust it and find the interference again. No kidding I adjusted it six times before I got it to max out left or right just before or right at interference of max piston travel.

The pictures show the various changes as I get it toward it's sweet spot
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:12:42 PM
OK, cool, so let's build some more of this truck.

I am days ahead at this point, but I do some catching up...

So a few days ago, I reassembled the interior. In this installment we'll cover and install the seats along with some other stuff

First I dyed all the vinyl on the bench seat black, the sanded and repainted the frame in preparation for the seat cover
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:13:52 PM
That black vinyl dye/paint stuff did a great job on the other interior parts and on the seat as well.
I only coated the areas that might show from beneath the new cover
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:16:01 PM
It looked a little streaky in those shots past, but it was still drying when I snapped them

The seat bottom cover stretches over the top and is held on by both Velcro strips and a draw string that laces onto the frame. It's rather ingenious
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:17:04 PM
The top half was fairly simple but took some more work
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:18:07 PM
I made a couple of small X-cuts on top of the head rest plastic mounts, then tucked the material in and around the plastic piece
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:18:57 PM
Then after covering the headrests, I pushed them into their holes, remounted the plastic cover, and called the seat covering project done!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:19:53 PM
Next up, I cut the hole for the transfer case shifter, slid on and screwed down the boot, then back on with the factory shift knob.
Sorry, Bobby, no chrome skull, I'm saving that for your truck when you get it!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:20:47 PM
The holes were easy to place in the carpet. I simply laid it out, then from the underside, I sprayed some black paint through the holes, then cut those spots out from the carpet...easy
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:21:25 PM
In goes the seat belts
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:21:55 PM
Then I man handled the seat in there
How's it look?!?
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:22:48 PM
No, it wasn't bolted down in the last post, but here it is!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:23:37 PM
Some serious change has taken place here!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:24:13 PM
I am waiting on some paint to spray the doors before reinstalling the door panels and completing the interior restoration

Next, I threw the axle tag back onto the front D60
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:25:05 PM
I didn't show it before, but I was paint crazy that day, detailing all sorts of pieces parts
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:26:19 PM
Well, let's do some more catching up

Mr. Tate has been busy again...

Here is that Lock Rite he sent me that will be going into the Ford Sterling axle which will go into Square D

Looks OK, now if it only works OK!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:27:10 PM
I wanted to get some of the hanging jungle hung back on the truck, so I went to prepping the transfer case area, removing more rust, coating it (Again) and repainting to get even more rust off of it.

I hadn't wire brushed the transfer case or this part of the frame earlier because I couldn't get to it...Now it's all exposed
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:28:04 PM
So I wore out a cup brush on that big chunk of iron, the NP205 transfer case
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:29:14 PM
The rust converter does not work if you either don't scrape the scale away or if you remove all of the rust. So you want to get the part down to what you saw in the earlier posts.
Then you apply a liberal coat and it will turn bluish than black as it activates
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:30:04 PM
I did the same process on all of that expansive crossmember
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:30:50 PM
Then it got a top coat of the Blitz semi-gloss paint.

I am not going for a show car appearance, only to stop the rust and encapsulate it and then protect from further degeneration. Therefore wherever I found a good living layer of the original undercoating, I just cleaned it up then painted over it. That produces a crude looking finish, but it's very protective and that's what I am looking for here
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:31:56 PM
Here's how the skid plate turned out with the Nason paint with hardner. It is glossy, but is undercarriage so it will not really be seen.
Same Lycoming gray
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:32:37 PM
As you can see I redid the rear sway bar as well, prepping it for it's new home.

I wonder if a Chevy guy installs a Ford part on a Dodge if there is any spontaneous ignition, sparks, or instant corrosion or other malady?

Guess we're gonna find out!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:33:27 PM
Here's the skid plate and cross member reinstalled
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:34:48 PM
Next up was the replacement of both motor mounts.

I have no idea of how long these have been in there, so it is really just cheap insurance to zero-time these parts. Working with the new transmission mounts, the motor mounts put the powertrain back in factory alignment.

Lifting that motor was a chore. I ended up blocking the oil pan and lifting with a jack...That chunk of Iron is HEAVY
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:36:33 PM
Well, I continued bear wrestling today (Installing an exhaust system)
I guess I won, it's on...

I started with this Diamond quiet replacement system for the square Dodges
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:37:05 PM
They don't mess around with the transition to the 4" pipe
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:37:58 PM
The system looks to be pretty good out of the box
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:38:40 PM
They went cheap on the clamps though!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:39:50 PM
Mr. Don will not be using any of that business.
Nope, we're going first class with Square D
At least with the clamps
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:41:06 PM
The down pipe went on with no fuss at all
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:42:08 PM
The next pipe was an S shaped affair to clear the cross members and the transfer case. It gave me some problems and I fitted it a half dozen times before finding that sweet spot
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:43:01 PM
This was the point where the easy ended and I had to get creative.

There were no hangars on this truck and it had used that ancient strap and rubber method of securing the exhaust. I'll have none of this for a truck that might find itself airborne and slamming down. I need this system anchored very solidly, and that's what it got
Starting with a U-bolt, First I cut it into a "J"
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:44:13 PM
Then cut threads onto the long end 1/2-13 and added some new hardware
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:45:19 PM
There was already a hole in the frame so I started there, but had to redrill another to better position the tailpipe
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:46:41 PM
In that last photo earlier, I'm adding a second hangar hanging from a stiffener in the truck bed underside
Here's the buildup
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:48:39 PM
You may have noticed that I moved from the front to the back and am now working forward.
That is because the muffler will be a custom fit requiring me to trim off sections of two different pipes. I am hanging it way up high and tucking it in the frame to be out of the way.

The muffler is pretty heavy and I planned to hang it as securely as I could

Since the threaded "L" or "J" was working I decided to just keep using it
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:49:48 PM
That is 1/2" solid steel rod.

I drilled two 1/2 inch holes in a cross member either side of the exhaust
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:51:08 PM
At this point the pipe is not trimmed, and held temporarily in place with another hangar. All that will be cut off before the muffler will fit though

Here' the approximate alignment and the other half of the hangar system I invented. A simple 4" clamp with two 1/2" studs welded to the flat side
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:54:00 PM
Here's the mount carrying the weight of that muffler and the pipe up stream
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:54:49 PM
I intentionally welded the studs on opposite sides of the clamp so that they would align facing slightly fore and aft

That should isolate and swing that develops, and the slight torque of the clamp makes it all more rigid

Here's another shot
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:56:06 PM
I added yet another hangar to the rear of the muffler.

That made for a total of 5 hangars and the turbo outlet carrying the weight.

I also wanted adjustability, and this system has it all over. I adjusted exactly where I wanted the pipes to hang, tucked up, but away from rattle points. A simple turn of a nut and the system moves either up or down
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:57:00 PM
Here it's adjusted into the final position
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 04, 2014, 11:58:59 PM
Next I focused on the tailpipe sticking way too far out

Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:00:11 AM
Bright aluminum color will never do, so I changed it up.

That duty fell to my always handy John Deere Blitz black paint
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:01:16 AM
Remember that everything rusty in the pics now is to be removed and replaced with upgraded parts.

I've meant to replace the fuel filter for some time now, so I finally did.

The old Mopar filter has been on there for some time!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:02:33 AM
The new one is a lot prettier. I put it in filled with fuel and with new O rings

It's barely visible in the pic behind the IC pipe
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:03:49 AM
This injection pump is all stock.
By adjusting the star wheel under the dome cap, the fuel screw under the cap in the back, and bumping the timing a little this 160 horse motor will add 100 + horsepower and raise torque from 400 to around 600! All by adjusting a few things!
I'll do that pretty soon
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:04:27 AM
Here's a look at the paint
It's a Gissepie (Texas) Synthetic enamel. The color is late WW2 through the Korean war for the US Army.
I'm not crazy about it, but my dad was a pilot of B17's who flew (Barely surviving) all 35 missions bombing Nazi Germany. I guess I feel a kinship by selecting the color from his time at war
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:05:05 AM
Well, I had a new can of paint, an old fender surface...There was no danger, so I took the shot!

Here's just one wet coat
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:05:53 AM
And a second coat
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:06:39 AM
And after a plate of spaghetti
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:07:16 AM
Shawn and GLO supplied the new spring hangars for the Sterling axle that is next up.
The factory plates will be cut off and these welded on in place of them
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:08:13 AM
Shawn also supplied one of his great axle covers. The Dana 60 one he sent earlier is going back to him, hopefully so he can use it on his bronco! Be a shame to waste the paint job...!

His covers are just the best. These things just scream overkill and precision!

This one will get the same paint job as the others have
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 12:09:53 AM
From CuddaKidd53:

Don-

Wow, a week goes by and lots happened! Like the "Don's Garage" website idea, with build stuff public and CIEMR stuff subscription; but maybe not- here's the thought process:

Gods made you the "change a few fluids" guy who rebuilds most of the truck! It's what draws people here and makes them hang around. Because of us DOTs, the site crash and the continual state of National Disarray, other discussions happen......

People speak of their experiences with God following your lead, others join in.......

Those who've been away for a variety of causes/reasons find themselves going back to the house of The Lord and share that fact with you/those here!

Buying a Diesel Chevy becomes an in road to all that is taking place all over your builds....

It's all born of your "listening" to his voice and putting it out there on a PUBLIC site.....going out into the world yet being more "not of" the world.

Were this a pay-only site, would those here, actually be here? Don't know, but I do know that God truly works in mysterious ways for/in all of us.

So I'm not sure constraining the public side to the build/educational material without the message is a solid "yes", but I'm just the DOT of Ed!

 AWESOME exhaust install, I really like those clamps- have never seen them before. Your heating, bending and threading of the solid rod reminds me of my father and grandfather's fabrication work- learned early in life not to grab shinny blue Curley Q's of metal!  If you wear a tool belt, I'm betting a can of Blitz is standard too.

God Bless you and your decisions as you make them-

Mike
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:30:59 AM
Man, you people have been busy in my absence!
I ate so much chocolate yesterday I think I actually O'D'd. Not as in the paint, but as in my blood sugar level!
Had to do an extra long workout this morning, but by noon I was feeling pretty good. Looking pretty good if I don't mind saying myself...Which isn't true, of course, but it's my thread, I can say anything I want!

OK, boneheads, pay attention, we have assemblage to get to!

As we know the priority is the rear axle...Right?

That's exactly why we are starting under the hood with stripping some stuff in preparation to do some painting!

Making sense so for?

Yea, I don't get it either...I just do this stuff!

I really wanted to get right on that axle, but I really wanted the truck to start turning a bit more green before I started.

So I started by taking off stuff
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:33:35 AM
Earlier in the deconstruction/build I was wire brushing and caught a piece of that chrome grill, essentially, killing it. Well that is all solved now, that the grill will actually be getting the paint treatment.

Color you ask?

Who knows... Could be J.Deere black, flat silver, OD Green, or here's one...How's about the base color of the truck as it sits now??? You see that's a silver, and I just happened to own a quart of that color...???

Anyway, the front area of the truck is getting uglier
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:36:14 AM
How did this all start you ask?

Well, see that roll of rugger belt? Well, that was going into the front and top of the radiator to replace the factory piece that the red dog chewed up. So I sez to myself, "Self, we need to paint the stuff beneath that before we mount it, I sez."

So that's how it all started. First I was just going to paint one small area, but we know how the various bones are all connected to the other bones, so the work area spread like poison Ivy on a patch of sunburn! The grill was all up in the way, so with the removal of six thousand screws, it was out of there!

I never did put that rubber thing on there, but I did spray some of that ugly paint!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:39:52 AM
Comment:  At this point I believe I was a bit sloppy. Painting the top and not removing things to do a proper job.. .

Somehow around here I am no longer just making things serviceable, but actually phasing into a restoration.

As things got prettier, I always knew that way down inside the belly of the beast so to speak, that it was still a turd, and that bothered me.

You'll see upgrades happening shortly that are definitely above and beyond the restoration process, but it was a couple month long slide into that way of thinking.

Shortly we will stop with Part 3 and move into Part 4 which was the beginning of that change of mind.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:41:07 AM
Here's some pictures of rust:
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:42:02 AM
Lookey here! The wheels fit!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:42:40 AM
, first the axles get pulled...Same-same as our D-max's

Notice the cool O-Ring sealed axle flange. I don't think the chebby axle is made like that...Good idea Ford!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:43:31 AM
A quick check of the lock-rite confirmed that it will fit!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:45:03 AM
Next the hubs came off

The bearings were excellent and will not be replaced
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:45:48 AM
So, let's tear down drum brakes for you numb-skulls who are afraid of getting your pinkeys dirty...I'll learn you all proper like how to do it...Step, but painful step

First, pull the emergency brake cable. Just yank the living snot out of it until you figure that won't work, then go get a set of diagonal needle nose and fish the thing out of it's hole. Kind of like snake hunting in a rabbit borough, only different!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:46:47 AM
Then the spring on the self adjusting star wheel, then that rusty Iceland looking thing
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:47:45 AM
The the cylinder screw thing ah-ma-jig
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:48:38 AM
Clean your wounds, tape them up, check up on the tetanus shot currency and continue

The least covered shoe is next. Remove the spring that keeps it in there one millimeter from total annihilation!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:49:11 AM
Then fish the bent nail out the back side
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:50:13 AM
Now, using a 3 pound hammer and a 12" prybar pound the dog snot out of the shoe, or just look at it for a minute or so until it falls out on it's own accord!

Actually, there's still one spring that is holding it loosely from falling onto your foot
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:51:15 AM
Next go after the spring(s) holding the remaining shoe in place
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:52:59 AM
Now we pull that shoe off

No, bonehead, not your shoe, the brake shoe...kids!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:53:57 AM
Next pull the Australian part off (the boom-a-rang) and throw it as hard as you can at the first jap car you see. If it all works out it will skip off the hood, totaling the piece of non American junk and keep on going!

You really didn't think it would come back did you?

If you have kids, select one and send them after it
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:54:34 AM
Then the wheel hydraulic cylinder comes off
Not too much to this thing
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:55:08 AM
Here's about what you'll have left unless you are dissembling a Korean kar. Then there will be some dried rice and fish scales stuck about here and there!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:55:56 AM
The backing plates were laid out in the driveway where I soaked them down with degreaser and as bait. I kept the small ball peen hammer close by. I was waiting on the red dog to come ah-sheakin. I figure I'd hit her with the hammer, teaching her she needs to stop stealing all my stuff!

So here's the axle so far
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:57:02 AM
In the second shot, I had removed the lines and wiring harness

Now it's time to grind welds to remove the shock mounts, which I will not be using
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 08:59:46 AM
As we near the end of Part 3, I am removing the shock mounts, simply because they do not line up with the factory upper mounts, but this change is more aggressive that a simple "Fix" and starts to get into the "Fab" thing which is characteristic of what happens to the whole truck in the months and parts to come

Some foreshadowing perhaps???
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:00:20 AM
Then the spring pads get the same treatment
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:01:12 AM
These backing plates and Australian part got cleaned up. Tomorrow, they will get the rust grinding treatment and get all purdy
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:01:43 AM
And the axle is now torn down and ready for a super cleaning, wire cup grinding and rust control and paint
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:02:47 AM
Quote:
Originally Posted by dkami712 View Post
Those drums sure looked nasty before you took them apart. They're nasty on a good day, must have been fun with 15+ years of rust! Sounds like you'll have that sterling in new looking conditions 'morrow. Excited to see the converter do its magic again!

Yessir, I'm gettin' on em' right after the workout!

Have a problem with the grinder though...
Seems as though the red dog has been busy...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:03:41 AM
So, let's get some more done with the square Dodge

Today was all about making rust go away and prepping parts to become a viable axle ready to go back in the truck.

But to work, one must first have to work, to be able to work.

Grinder had to be repaired first...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:04:44 AM
Only cost me one old extension cord.

So with the grinder back in action I went to work on all that rust. Suffice it to say, I was in an orange cloud for hours!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:05:48 AM
Then I coated those parts with the rust converter
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:06:52 AM
That's when I saw these two catching a cat nap...I had dark killing thoughts, but before I could carry through, they passed and I started getting hungry!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:07:28 AM
The red pure bred German Shepherd ate up a can of Blitz spray paint today along with a roll of paper towels and a cross tip screwdriver!

Anyway, once those parts dried I started in with various primers. The copper colored stuff, is, copper primer! I thought on possible highly corrosive areas like inside the brake drums it might serve well
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:08:13 AM
The backing plates dried all nice and black, so I covered all that up with a layer of zinc based primer
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:09:17 AM
Next came the rear axle itself. After forever and two hours worth of grinding it started to look like metal and not a signal buoy in the Indian ocean
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:10:20 AM
To keep everything sequenced in the painting/ drying, repainting production line, I sanded down Shawn's axle cover and painted it with the copper rich stuff
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:10:59 AM
I am never short of amazement over the quality of these axle covers he makes!

So, back to the axle, I cleaned the inside out pretty well then the housing itself with cans of brake cleaner. I like the stuff because it dries leaving no residue
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:11:48 AM
With the housing and inside cleaned up, I coated the thing with the rust converter

Here it is in sequence doing it's thing
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:12:28 AM
Does a pretty good job doesn't it!

With that drying and a cross country invitational fast approaching. I scuffed down a bunch of parts and plussed up the hanging jungle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:13:16 AM
Then with a fresh batch of Lycoming gray Dupont Nason mixed up, I sprayed the jungle yet again
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:14:03 AM
Hard to even remember just how rusty those parts were just a day ago, now they look new.

I left the emergency brake pawl copper since it got several coats and that should give it all the protection it needs without getting some paint hardening in between parts that used to move freely
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:14:41 AM
Here is two fresh gallons of Gillespie WW2 OD Green paint just waiting to get all atomized and collect on some of Square D's ruggedly handsome shoulders!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:16:47 AM
Well, it's morning...

Time to make good my promise

Here's a pic of that diff after the rust converter stuff fully cured
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:17:25 AM
Everywhere there was rust that I mostly removed the metal turned dark black, whereas the mostly rust free areas show a translucent color varying from black to brownish.

I beat on it with a hammer some, it's durable!

The radiator top mounts did not turn out well yesterday, so I stripped them all the way to bare metal. I found that the factory had galvanized or zinc washed them and I wanted to keep that appearance, but some of the metal was surface pitted from corrosion so I just sprayed them with that copper primer
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:19:17 AM
Next on to installing the spring pads onto the Ford axle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:20:29 AM
Those beauties are another product of Shawn's at GLO. He makes good stuff (Obviously!) Look at the fit on the radius cut to the axle tube.

This is one of those things you measure again, and again, and a third time.

I was pretty nervous setting this all up, but in the end, it came out to within 1/16" of where I wanted it to be.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:22:15 AM
With that out of the way, it was on to installing the locker
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:24:07 AM
Since the spider gear cross pin could slide out without removing the ring gear, I was hoping to get this done without removing the carrier.

First you pull the cross pin bolt and shaft
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:25:14 AM
Then the spider gears almost fall out
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:26:12 AM
You have to reach way inside, but the last side gear pulls straight out
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:27:46 AM
So far so good, so I slipped in the new side gears
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:29:19 AM
But...
I forgot something
The thrust washers that go behind those side gears
Those washers take up some space...

Yea

So without knowing at that moment, what I later discovered and know so painfully well now, I continued...

The center, locking part of the lock rite goes together with some simple pins, then slides in.

This sequence is a test
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:34:32 AM
I continued loading the parts

not knowing about the thrust washers and forgetting all about the steel pins

Yup

SO for some goofy reason. I think...

Did I just finish this thing?
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:35:15 AM
Continuing in my ignorant bliss, I said to me self

"Well, self, heck you're done! Let's glue on the gasket and button this sucker up!"

So I did...

Yep
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:36:11 AM
So that's what I started to do

You might recall seeing the parts that came out of the diff sitting in the diff cover...?

Well, my plan is to paint and install the axle with the old diff cover in place, then bolt on Shawn's pretty piece so all that shiney paint doesn't get to looking like Normandy on D-Day.

Well, inside that cover, I immediately noticed tow really big washers

Hmmm

Then I sat down as I realized what I almost did. That momentary pause caused me to take inventory of things, and that's when I noticed the steel pins still in the lock-Rite box.

OK, no biggie, I'll just pull the thing out and stick it back in with ALL OF ITS PARTS

So I did that, and guess what...

It no longer fits

Those two silly washers caused the rest of the story...

So this is what happened next:
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:36:51 AM
Then this:
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:37:36 AM
And finally this:

Or so I thought at the moment
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:38:10 AM
The grease just holds everything together while you're slipping it all together again.

I reinstalled the diff, tightened the caps down then started to remove all the 5/16" bolts that helped align the gasket.

Then one bolt slipped out of my hand

As I reached in to it, I bumped it down into the inner recesses of the case

I could no longer see it

Hmmm

Out comes the magnet and for the next 30 minutes I fish around and can't find anything

Did this really just happen?

Did I imagine that just happened?

Nope, I didn't

So after tapping on the case, rotating it upside down and tapping, blessing it, and everything else I could thing about, no bolt

So I had no choice but to pull the diff back out once again, so I did

Guess what, no bolt in sight

But

There is a passage leading up to the pinion bearing

Could it have gone all the way up there?
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:39:07 AM
Well, I searched, prodded, tapped some more

Now the axle housing finish is starting to look like a roadside bomb went off nearby, but I continue

How in the name of all that's good and right is this happening to me?

With no place else to go, I got a really big socket and removed the pinion nut, and the pinion gear

It fell right out of the case, along with a little 5/16" bolt!

Can you believe that?

You just don't bolt a set of gears back together...Oh NO!

A little too much of this or not enough of that and the thing is all wacked out

SO I tightened, and loosened and tightened, put the carrier in, took it out, put it back in and so forth into the far reaches of the night, until at one magical moment, the preload, turning force, and runout all fell into place.

I quickly bolted on the cover and left the area.

That is why there were no pictures last night. I was set to finish around 1800, but I finally drug my defeated butt into the shower around 2130.

I took this picture from a distance, hoping not to offend anything!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:40:16 AM
Quote:
Originally Posted by KensAuto View Post
I hate to question the Grand Master of suspension geometry and canine training, but do you think you should have waited on welding up the spring perches until you got the new springs in and diff located, so you could adjust the pinion angle?

Special K

I am certainly no grand master of anything, except maybe my chilli!

(I once won a contest where four other folks and I were judged...Impressive don't you think?)

Here's my thoughts:
The old Dana 70 axle had the perches welded at zero degrees (Level) relative to the pinion angle.
The new springs have a wedge attached to the bottom of the lower leaf that will rotate the pinion up what looks like 4 degrees.

You don't really want the pinion to be aligned exactly with the drive shaft center with a suspended axle subject to any wrap.
Why you ask?
Another good question BK (Brother Ken)
When torque is applied, the pinion climbs upward, so if it was slightly below perfect alignment, it would then climb to the point where it is nearly aligned.

I plan to add a torque bar to the design here, but even that will allow (the way I build em') to rotate just a little, maybe 1/2 of a degree.

Anyway, since super lift designed those springs, I assume (Big dangerous word there) that they know their business and have positioned that pinion angle where it needs to be.

That and I want to paint up the axle and install it and not have to keep putting it in and taking it out
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:42:48 AM
didn't get everything I wanted to get done, with running around getting things...
I did get the rear drums turned, Finally!

They came out fine with a minimum of a cut

I got a set of Bosch front powder coated rotors on the line (Headed this way). These things are 12.87" in diameter so I feel that is a pretty good place to start from.

The final plan is to install GM hydro brakes onto this truck and make the vacuum stuff go bye-bye.

I got the wood collected for the unique rear jack stand system I am about to invent. I figure I need to suspend the truck and support it from some place other than the rear axle, since it is about to come out.

Jack stands that I have located will not get 30+ inches tall so I'm going to do something else.

Good old 6 X 6's and 2 X 6's

Again, going old school and hillbilly for at least a part of this adventure.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:43:33 AM
I had planned to paint up the diff, axle hubs and since I'd be spraying the JD Blitz paint, the front radiator area as well.

Remember my radiator bone is connected to the rear axle bone theory?

Well with today's accomplishments, that theory lives once again!

I had previously used some acid etching primer on the new parts of the axle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:44:29 AM
One backing plate had been previously installed while I mocked up something. When I reinstall a backing plate I layer on a bead of RTV to make it a tad more waterproof. That was the case here.

I then removed the lower grill valence panel to gain good access to that front sheet metal
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:45:09 AM
Then it all got sanded and scuffed up with a combination of papers, wire brushes and the abrasive pad
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:46:16 AM
The rear hubs were next. Getting degreased, wire brushed, then coated with that rust converter
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:46:52 AM
Next things got taped off and washed down with the prep-sol
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:47:28 AM
Then came paint time.

Here's a fresh quart of the Blitz stuff

I mix it with a little reducer and the Valspar hardener

Valspar is the company that makes paints for John Deere
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:48:12 AM
The front end with one, still wet, coat
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:48:52 AM
Then the Sterling axle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:49:51 AM
Then the hubs.

Here is showing after two coats
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:50:29 AM
Then the third and final coat
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:51:36 AM
Pushed that ball downfield another foot or so today.

First I collected the 3" wide brake drums which cleaned up great and are now true and round. That only cost $30! What a deal!

Next I reassembled some stuff in the engine bay. Those radiator mounts went back in first. I just left them in primer since it is a pretty durable surface.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:52:13 AM
Pics are a bit fuzzy...this camera is giving me fits!

Next the hood catch/release went back in
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:52:59 AM
All that stuff was removed so that I could repaint that radiator support before replacing the upper radiator rubber air seal

I chose some ag belt cut to size. I used this slick tool to punch the holes to line up with the factory design
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:53:48 AM
Then some of these plastic expand tabs that locked it all back in place
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:54:30 AM
That is done enough for now.
I have decided to pull the factory intercooler and put a late model power stroke intercooler in its place. The ford unit is approximately twice the size.

Why you ask?

Well, seems I am pushing the boundary of the fluid change project a bit more. I decided to just go through the motor all at once elevating it ftom it's 160HP/400TQ up to 400HP/800ish TQ.

With these motors it's not all that hard or expensive and you get a mile per gallon more to boot!

More than that I need to go through just about everything on this truck before I'll declare it ready and serviceable.

Here's the axle after the Blitz paint dried and hardened
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:55:35 AM
And some innocent bystanders
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:56:42 AM
The sled dog is wintering up again. That cat is skittish. Guess he never forgave me for knocking him out a year ago...Long story.

Well, today was H-hour for the rear axle removal.

Since it has supported the truck by way of two jack stands, and needs to go bye-bye, I had to come up with something else.

Here's what I did:
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:57:50 AM
It's sturdy an about as immovable as a fat woman in a candy aisle!

Here's the axle losing the jack stands and some parts
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:58:39 AM
My buddy, Mr. Hypertherm helped make quick work of that rusty steel
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 09:59:45 AM
The springs were not so easy

The bolts had rusted to the sleeves and the rubber dry rotted. It was a bear getting those bolts out but after pulling pounding, and cutting, they yielded
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:00:47 AM
Springs...things that have been, and things to come
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:01:24 AM
These are factory and will get reused
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:01:47 AM
I will not be reusing the factory spring plates. Just like I did with the Chebby, I am flipping the U-Bolts with some cool Ruff-Stuff plates.

I will also be adding a traction/axle wrap bar from them, due in in a few days
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:02:32 AM
Quote:
Originally Posted by FBJR View Post
Those blocks look rough. WIll that pin clean up OK, er while the RC dries on the mounts 

Yep, they do

Luckily they are not a precision part or they would be going bye-bye.

Today. I'll grind off the rust and see what I have left to work with.

I have a couple days, since it was just yesterday that I decided to build the rear suspension instead of just putting it back near stock. I just don't want to do it a second time, later on...

Plus, I will be pulling the bed off any time now so it's a great time to have full access to everything under there.

While the bed is off, I plan to

drop and Re-plumb the fuel tank with bigger lines, a sump, renew all the defective stuff and make it all pretty.
Grind off the frame (Again) to really get it back to near new.
I am just not happy with the amount of dirt and rust I am still getting off parts of it. I guess I just can't stand that it's a pig with a paint job...Better just to be a new pig!
I can easily drop the anti-lock valve and run all new steel brake lines. No sense in keeping any of that rusty, problematic stuff in there
I can stand the bed up on end and take the underside down to metal, then properly recoat it and paint it and all the recesses olive drab.
I want this truck to look like it was produced by Dodge in OD, so there is some work to be done.
I can more easily install that anti wrap/traction bar thing. This will be a first run, as the Chevy will be getting the same treatment.
I'll more easily be able to fab in whatever mounts are necessary to mount that new rear sway bar.
Finally I can get a good look at things and renew/repair everything I find that is questionable.

I know this project is growing daily in breath and scope. But I guess I just can't stand to drive something that is half a$$ed and if I have something apart, why not just jump ahead in the interest of saving money to where I intend this build to be.
The way I see it, the Chebby is vastly capable right now with no backup. If I took the chebby down for the SAS and relied on my band aided square dodge...And then the bottom fell out of everything, well, all I'd have left would be this patched up truck.
The more I thought about it, the more it made sense to dive into the Dodge and get it mostly right and able to go it on it's own for many years before tearing down my best vehicle.
When I say mostly there, I'm refereeing to things like the front suspension and the motor and trans.
For now the suspension is freshened up and brought back to near new specification. The leaf spring front suspension is known to ride harshly so I will definitely be replacing it with a radius arm/coil over or coil spring suspension in the future.
The engine will someday live in the 500+ HP range sporting a couple of turbos, but for now a good tune and upgrade to the near 400HP range is great.
The trans needs to be a much more capable unit, however for now a cleaned and tuned stocker will do.
That's the one over the world picture of the square D project for now...
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:03:58 AM
Originally Posted by nmeyer414 View Post
I can bet that your mechs probably didnt like you at first because they probably didnt like to do things right the first time.

When I owned my business, I had a buck sergeant, Apache crew chief working for me. He never knew whether to call me sir or Big Don...He settled on Big D.

He did do things right the first time, but did them too right!
Whenever he did anything the manual was out and open, there were torque wrenches about and notes on everything. He took twice as long on everything, but nothing he did ever failed.

We did things so well, business started coming in from all over, and I mean all over. I was in Clarksville TN, and one day a police officer from Atlanta brings his mustang in for a new engine! Another time I get this call from a sergeant major. He says he wants all this stuff done to his car. I ask him how he heard about me. He said one of the cars we built was terrorizing the drag strip. I knew we pretty much owned the local track with the mustangs we were turning out in droves. So I said, yep, we're all over the local and Nashville tracks. HE said he hadn't ever been there?
Well, he said he heard about us at the track and so forth. Then he said he was racing at a track in Hawaii!!!!!!!!!!
We had built a car for a soldier who got transferred to the big island, and when he started winning, he talked about my shop!
It is a small world...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:04:46 AM
Quote:
Originally Posted by FBJR View Post
Since you mentioned dropping the tank, have you thought about a skid plate?

Would be terrible to have some korean kar put a hole in that plastic as you slide over it.

I am adding the composite plate to my titan. Then time for my manifolds and downpipe with faked egr pipe (blocked anyway and pvc justs dumps out)

JR

Yes I am considering that. But I am also considering another tank, as well as a couple of tanks.

This one is 30 gallons. THis truck routinely gets 20-22 MPG I was told by the previous owner. That means the truck gets 20 on the highway and 18 around town and country driving. So I have a range of something less than 600 miles.

My minimum requirement would be around 1000 miles, but possibly much farther.

I could keep the factory tank, then fab up a box to fit where the spare used to reside, then add in another tank in the side or front of the bed somewhere.

Since this is a slice and dice truck, no telling what I might do, so expect anything. I am subject to cut all over to get room to stick, store, and mount things.

I talked to a guy today about the Power-stroke intercooler I want which is double the size of the stocker. He has some F250's parted out with all sorts of fuel tanks. Let me see what I can come up with...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:05:10 AM
Today, which is not over yet, was/is a parts sourcing day.
So far I have accumulated $145 worth of fender, frame, and other plated, stainless, and anodized bolts and nuts.

I picked up new parking brake cables to complete the Sterling rear axle build up.

I picked up a cool Harbor freight media blast cabinet at Duane's suggestion to blast the myriad of parts coming off that square truck.

In a moment I am calling the guy who sells all the performance parts for that engine. Plan to just jump in the deep end and get it straight to where it will lunch the transmission while parallel parking or idling over a kia with an Obama/Biden sticker that missed a green light because the driver was texting and not paying attention.
That will force me to upgrade the transmission straight away as well.

I was holding right under 10K, but this episode will surely push me over the top.
__________________
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:06:11 AM
Quote:
Originally Posted by Cudakidd53 View Post
With the OD Green paint, have you toyed with the idea of a canvas cover similar to a transport style? Light easy on/off and well within your theme; also remember your purchase of serious amounts of material for the original Tacticle Topper


Duane and I were over at Harbor freight checking out the 12K winch when the blast cabinet caught our attention and turned into the "Quest for the day"

The reason for the 12K winch lookin, is the fact that that gaudy front fat lower lip "bubba" lookin bumper and seat thing is coming off. I mentioned that I am upgrading to a much bigger intercooler, so that fat lip bumper thing (FLBT) is now going to get in the way. A shame really, since it makes for a great bench and welding table. All my wood and cardboard welding tables have mysteriously disappeared after, well, welding...

So since that bubba gump lookin FLBT is going the way of the great scrap heaps of the kintucky dynasty, I need to build up another bumper, wichins I's plan to do ricky tick!

Now I plan to make it more than a bumper, but include a wrap around feature. That would match up with the rear bumper hack apart project (RBHAP) where I apply excited electrons through the nozzle of Mr.' Hypertherm to make large sections of that go to the same scrap heaps. Then applying a friendly high energy flow of better and less angry electrons to a nice flat piece of 3/16" kintucky steal in various trapezoidal shapes which will become one with each other in some aggressive, yet, oddly pleasing shape on the back end of that square dinosaur.

Where am I going with all this??? Well, those bumper forms would then become the base for an exo-skeleton which would use the cab roof as the upper plane to extend aft all the way back.
Add in a couple ribs and you can both roll over successfully, and cover with a canvas shroud to get all Armee lookin for my more sentimental moments and Sunday church of course!
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:07:14 AM
Got some more cool parts headed this way.

That means I need a full court press on the BRI (Box Reduction Initiative)

Inbound is a tach, pillar mount with a Pyrometer and boost gage, fuel pin, 3800RPM gov spring, really cool mechanical lift pump, fuel tank sump and something else... I think

Anywho, Eric who owns a diesel performance operation and owns one of these square Dodges making significant HP and torque, is teaming up with me to get Square D right with all things performance
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:08:16 AM
Ok picture time

I did a bunch of things today, here's a pic of how it all started
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:08:56 AM
I used this
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:09:44 AM
After maybe 40 minutes of wasting my time, this was the result
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:10:16 AM
This is what I think about this cheap Chinaman POJ
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:10:46 AM
Same part
5 minutes
Horsepower and elbow
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:11:35 AM
15 minutes later both spacer blocks are finished and the rust converter is cooking away
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:12:11 AM
Next up the brake drum gets the treatment

They did a good job with cleaning the surface on the lathe. Cost of milling both was $30
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:13:00 AM
These are American made drums, circa 1991. I had to choose to either recondition them or buy the problematic chinaman junk...I thought about that 2.6 micro seconds...Old American part won!

I taped it up and sprayed the living snot out of it on the inside with that super duper primer. I certainly don't want any nasty rust dirtying up the works in what is to become the operating room clean drum assembly.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:13:43 AM
Then I wire brushed down the axles themselves, and coated them with the rust converter stuff
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:14:40 AM
Then everything moved over to the hanging jungle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:15:25 AM
like those axles will never see the light of day, but they will never rust either. Rust can and will accelerate wear on seals and bearings as well as gear teeth.

I had this quart of the Chrysler dark silver, which was the base color of the truck which was going to go to waste, so I decided to use it

Am I ever happy I did

That color is gorgeous! I mean just right of really, really pretty!

After spraying these parts, I was tempted to spray my hands and legs to see if it made me look any better, but the wife yelled at me about something and I forgot what I was doing...
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:16:29 AM
Look what it did:
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 10:17:10 AM
how nasty these looked?

So guess what I'm using that paint on next???
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 03:08:43 PM
Got some more stuff done today and set a personal best record today!

It was spring hanging time. I used new 9/16" fine thread hardware with nylock nuts. Reason is, I tighten the nut to where the surfaces just touch then back it off about an eighth of a turn. That prevents any binding and sometimes gets some more travel out of the suspension.

It's loose as a goose eating 4 day old pumpkin pie, but no rocking type play at all.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 03:10:07 PM
I'm having custom U-bolts bent up tomorrow so I stacked the reconditioned block and new spring onto Shawn's spring pad and took some measurements.

I will need a 13" tall U-bolt measured from the bottom of the axle tube.
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 03:13:00 PM
Next I installed both springs with the brand new shackles and new bolts
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 03:13:51 PM
Sky-Jacker has added some wedges onto the spring pack to correct for the repositioned axle
Title: Re: SquareD Build Thread Part 3: The build gets more serious...
Post by: Flyin6 on October 05, 2014, 03:15:27 PM
And now for my personal best:

I got my first shipment in today from Ruff Stuff, a double shear shock bracket(s). The box only sat idle a couple hours before the parts were used!

Not for one second did that box block my view of the Jap maple tree!

Here's the new shock bracket:
Title: Re: SquareD Build Thread, Part 1: The beginning
Post by: KensAuto on May 03, 2016, 03:03:13 PM
test
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