REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: Flyin6 on October 11, 2014, 10:46:23 AM

Title: SquareD Part 4: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 10:46:23 AM
During this part, we will pick up as the truck closes in on its OD Green paint job. It will start to take on uniquely military attributes.

At this point I am no longer thinking this truck is any back up sort of vehicle, but a primary go to truck should things turn horribly bad quickly. Knowing the vulnerability to the electronic Duramax truck, I could not really rely on it in all situations. A major EMP event would render it and all my efforts there useless, so this simple and old, yet modernized survival truck is now being given full attention.

Further as I am asked to demonstrate and teach on survival subjects, I have need of a "Technology Demonstrator," And SquareD will fill that role.

Not a high technology demonstrator, mind you, but rather a "Smart and Practical" technology demonstrator

Watch and enjoy in the pages to follow the coming departure from everything stock and a major transformation which will actually have the truck shedding many of it's former "repairs and fixes" in lieu of rock solid utterly reliability infused with some of the things I learned over 5+ years serving in combat theaters around the world.

Enjoy!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:08:34 AM
Some more areas needing attention:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:09:53 AM
More spots to fix:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:10:25 AM
And even more!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:11:25 AM
But then finally it was all done, and recoated in areas with the lacquer primer, then resanded yet again
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:12:50 AM
And F I N A L L Y after another sanding it is all done and ready for cleaning and paint!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:13:44 AM
The Tailgate finally got some attention, getting sanded and primed. I'll sand it in the morning
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:14:25 AM
And here it is at the end of build day 118, probably the last day before it gets the OD Green color top coat
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:17:28 AM
Gents, this was paint day. It is 2200 and I can say, it's still paint day!

The whole truck is now wearing a single coat of OD Green!!!!!!!!!!

Thing is, I have at least 2 more coats to shoot. Say 40 min between coats and 30 min to shoot, and I'll be into the wee hours of the morn before I see any shut eye.
I did a full court press today. 8-9 hours straight so far without a break. I just want to get this thing painted and give me that all important psychological boost as the truck takes the turn from coming apart toward starting to look like something!

Welp, time to get out there and get that second coat on...

My head is buzzing and I'm using a good respirator!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:17:57 AM
Quote:
Originally Posted by lutzjk913 View Post
Push forward man!

OK time now is 2243...
The second coat is on and only one small run on the back corner of the cab.

This whole coat really evened out the color...It looks pretty good

And I think I caught the first flying bug of the season in the bed right side. Something with wings is embedded in the paint...

Screw it, it will help break up the pattern some

one more coat...one more coat...one more coat....gotta maintain...one mo...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:18:39 AM
OK, 2329 and I'm going out to lay down the last coat...

Here goes nothing!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:19:01 AM
OK, 0009 and it's done

It was all shiny when I left it, but by tomorrow it should get all satin lookin'

I'm wasted...too tired to post up pics today, I'll get them up tomorrow morning, then get some pics of it during the daylight to show how it dried
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:20:33 AM
OK its 0910 (which is 9:10 AM for all you mustard seed, Kool-Aid pumping heart, jelly filled civies out there)

OK had a night to sleep off the thinner headache. Honestly, people actually inhale paint fumes because they want to? Heck, just employ them as laborers at a paint shop connected to a crematorium, so when they get enough, then just take their remains down a hall. Helps with unemployment, keeps them happy and helps two businesses, all the while increasing the national IQ!

Just call me the idea man!

OK, lots of purdy pics so lets get started.

Painting is a process, just like it was getting to this point.

One must clean, clean, and clean some more.

I started by cleaning the shop and blowing off the truck with compressed air
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:21:17 AM
It may be hard to detect, but with each progressive picture, the project is getting cleaner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:22:44 AM
Then as you clean out the cavities of dust, you have to vacuum that up, clean some more, tape up a section, wash the floor and so forth.

You are working toward getting a clean vehicle to paint and in a clean environment.

The masking begins. Remember this was a 10+ effort on paint day to get from body work complete all the way to painted!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:23:51 AM
Masking continues
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:24:23 AM
Just like the proverbial painter who paints himself into a corner and out of a floor, I am about to lose my work bench!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:25:14 AM
The masking and covering with drop cloths is endless...If you do this plan for how long you think it will take and double that. Fit that into your day and you'll be closer to realistic with respect to how much time all this takes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:26:22 AM
Most of that masking and covering is really not necessary because I will be removing the engine, transmission and transfer case in the near future, but I did it anyway to protect some of the newer parts I put on there.

Even though the entire truck is covered in black primer, it should be sealed before painting to prevent any funny business such as wrinkles or other paint on paint reaction.

OK I did that, using a high quality Omni epoxy two part primer to prime and seal the entire vehicle before any color.

This was the first coat of material being sprayed onto the body today
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:27:38 AM
This was done with a dedicated primer HVLP gun and a .018 nozzle with the material also thinned a bit with Acrylic enamel reducer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:28:18 AM
Coated!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:29:22 AM
Well, that turned out pretty good

I gave each coat 30-45 minutes to dry a bit before going on to the sugsequent coat

So

Finally

After all this time

It

is

Time

for

this color which is WW2 OD green. Again, I like it, but mostly I am using because it was the color of Dad's B-17G bomber that he flew as a 21 year old on 35 missions over Nazi Germany.

Dad I hope you like it

...He's in heaven...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:30:18 AM
And here's the first coat:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:31:29 AM
And about an hour later...Here's the second coat just having been sprayed.

The paint is semi gloss so it will not look like this (Shiny) when it's dry
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:32:22 AM
The body work is mostly invisible. Good enough for my work...I am no professional, just a seasoned amateur really.

There is a lot of detail painting that goes on. For areas on the firewall, you have to adjust the fan pattern to a tighter cone, then open it up on the big flat planes. That all takes time
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:33:26 AM
And an hour or so later, here is the third and final coat.

Remember, this paint is single stage old school stuff. It sprays on about 1/4" thick with each pass, so three coats is about equivalent of 8 normal modern Dodge truck paint jobs. I think at this point I am bullet resistant to at least .22LR based on paint alone
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:35:10 AM
And here it is after 8.5 hours of dry time, the following morning.

It is still not dry, so I think I'll keep the garage locked down the whole day, which just happens to be Saturday, the Sabbath, so that worked out nicely
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:36:54 AM
Some more.

Some sheen actually due to how well the paint flowed out and actually is continuing to flow out. Imagine what it would have looked like if I had added hardener, which glosses up things.
I might have lost the whole effect. I do like the semi gloss vs full on flat OD
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:59:04 AM
From the outside

I guess it turned out OK
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 11:59:56 AM
Quote:
Originally Posted by nmeyer414 View Post
Awesome color, that was a lot of work.


Nate,

You know, most people (Myself included) choose a vehicle color because we like the way it looks, agree?

But this color had depth and meaning to me. It connects me to my dad's plane, to him and in a way of millions of warriors past. That was the color of their uniforms...dirt and blood stained uniforms. And I wore a similar color as well. Yup a young lad I was but I wore an Army green before I wore a BDU, or a Nomex green or desert tan or any of the modern digital camos.

I don't know, hard to explain, but I definitely feel a kinship with that color and all that it means to me and those who have the eyes to see it...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:05:30 PM
Quote:
Originally Posted by FBJR View Post
Yep, don't want to totally derail this thing  Don is doing so well


Don Note: JR has a great old burb, 1/2 ton
He wants to convert itto a 3/4 ton diesel with a 6BT
He lives in the communist kalifornia collective...
Nuff said....


Still need a tranny/tcase and possibly another sub. If I can't upgrade mine to 3/4 legally I can't swap this motor in here. I could a 6.2 though as 1500s came with them then when exempt (98 under diesel) drop in the 6bt.

JR

You ought to read this stuff through my eyes sitting in Kentucky

You just said that if some idiot who has no clue, never had a girlfriend or had his first fight, gives you, a proper man, permission to change your suburban to a 3/4 ton

OK, some Don sense here. Screw them. It's not their truck, it's yours. It's no dammed business what so ever. If you want to change into the lunar rover , then by golly do it!

So that geek is with holding that piece of freedom from you! (Here's the part I don't understand...Why isn't the state capitol burning? Why is anything still functioning of that center of supreme stupidity? Well that's your problem, since you real men out there have been pacified to the point of allowing this silliness to exist)

Allow me to continue. So if this geek clerk gives you permission to change the truck into a 3/4 ton then you get his permission to install a motor that makes sense...And if this G-man who holds the power of regulation over a man who could crush his skinny neck with your pinky doesn't give his permission, then your recourse is to bolt in an absolutely awful problematic motor that makes no power just so you can start to get better mileage.

Does this sound crazy folks or what? People who are living in communist states left and right please do not comment, you have allowed this to happen.
This is absurd, the total stupidity of it is beyond comprehension. Now all the while a good man is asking geek boy for permission to live his life, Mexicans and gangs and drugs are flooding the streets. While we control water levels to save the life of some salamander tens of thousands, well, hundreds of thousands of acres of farmland lay fallow because farmers can't use the water since it will mess with the sexual mis-adventures of those fish/bug things.

Suggestion, flood all the streams with DDT, kill all life down to the viral level, flush them out to sea or pump the waste into mexico and since no life exists in the streams, maybe the farmers can use the water to grow, cabbage, corn, wheat, rice and the rest...crazy, but just an idea.

Man, I'm goin' off here, but reading of how S T U P I D California has become just gets me angry! I don't want people in charge out there to have any influence what so ever over what is left of free America. If I could I would, in the words of one of my earlier commanding generals, build a 15 foot tall fence around the whole place and put a good lock on it and check that lock once every 5 years.

JR...M O V E

In the mean time sell me the sub...

And the 6BT
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:06:52 PM
OK folks if I can borrow my thread just a moment

After drying all weekend, here is what it looks like with all the tape and paper removed:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:07:32 PM
I got a run!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:08:37 PM
Not much overspray in the door jambs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:09:22 PM
Firewall detail:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:10:07 PM
Quote:
Originally Posted by FBJR View Post
Couldn't have a run on the back or somewhere else. No, the one spot you will look at every time you go near or get into the SD.

Murphy,,,,,,,,,,,,,,,,,,,,,,,,,,but great work 

I'd give it a B to possibly a B+

But one thing is, it looks like someone did it themselves, pretty good but not as good as professional work.

Now from 10-15 feet it looks about as good as it gets.

I'll have to add it all up, but I should have somewhere less than $400 in that paint job!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:11:01 PM
I had to drive all over today, but I finally scored two, ten foot sections of 1/2" hydraulic line, so hopefully, I can have those mounted up tomorrow onto the back of the cab. The goal this week is to get the truck bed mounted back onto the frame and get it looking a bit more like a truck once more.

Hopefully I might even get the access door started on the bed floor. Once that is finished, the bed liner spray will start flying, and the roof will be prepped for the roof rack finish and install.

I ordered some Duplicolor spray can bed coating which I plan to use on the fuel access doors, the snorkel, and the roof rack. I have used it before and it gives the appropriate texture I am looking for on those parts.

I also ordered the weathertite 1,2,3,4,5, and 6 wire electrical connectors and a whole bunch of different dolor wire spools, since I will need to lay in some of the wiring for various things before closing off the roof.

Finally the new windshield installation is scheduled for next Wednesday

Forgot...that wasn't all. Today I started the conversation with Throughbred Diesel Not too awful far from Lexington, KY. I want to partner up with their considerable knowledge and vendor base for the engine and the transmission.

During the initial conversations, when we were talking about running multi fuels, being waste motor oil, Wade basically put the kabash on running the rotary pump.

He is a Cummins dealer and suggested we just go straight for the 7100 inline P-Pump and start at 600 HP. He thought that might be a bit difficult to handle, but at that level, he was good with keeping the bottom end stock, but in good condition.

That saves money for sure. His plan will be to convert the motor to the inline pump, play with the injectors, use the existing turbos, fire-ring and port the head and reinstall it with studs. That setup will be 100-150 HP and 300+ ft/lbs more than what I was considering, so he is bringing in a transmission expert to talk about what direction we need to go.

I/we will also be converting the alternator to a generator and basically, eliminating all electronics on the motor. THis thing is going tractor/stone age cool!

Actually we did talk about one other thing...sort of out there...But we started talking about converting my 2011 Duramax truck to a 12 valve Cummins as well, basically taking it backward a couple of decades so an EMP effect won't affect it either.

Thinking about it, with a 12 valve delivering 700HP/1500 torque and 20 MPG, that truck would have a max range of about 1,440 miles unrefueled!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:11:52 PM
Quote:
Originally Posted by rugbyman87 View Post
Glad i finally had time to catch up and.....you never fail to amaze me Don lol.
Great job on the paint, i know what a pain that is and it came out pretty darn good, besides that one pesky run. It happens, were not professionals, and even professionals have runs.
Also....wow on the drivetrain, your really going all out! I honestly didn't expect any less from you though. The next project you start you just need to go at it like you are doing a complete tear down and you will probably save some time!
I have made some progress on the boat finally, i'm about to update my build thread for the not so survival built boat.

Thanks

I'm just trying to do a good job showing what someone can do in their garage. I am pretty sure some folks can do better, I have done better, and worse.

The project has indeed evolved. So might as well rebuild everything. There is an advantage to doing it part by part over a lot of time, that being you get lots of eyes on. And lots of wisdom, and lots of good and some not so good recommendations.

From the conversation last night with Wade over at Thourghbred Diesel, I learned about changing out the internals of that alternator to make it self regulating. That's his great idea. Now I'll add to that Don's idea and add a second unit, but that unit will be a simple generator. THat will feed an isolated electrical system that could start the engine or only used to power accessories.

The interaction of smart people oftentimes spawns brilliance and advances in design. So far we don't actually have advances in design per see, just refinement. But what has been created is a novel change in concept. Go back through SEMA, auto shows and engineering conventions and show me vehicles designed to operate after civilization. Yup, big black hole, nada. The military has such things but they tend to be way over engineered and way too bulky and heavy. Hence the creation of Combat Max and Square D. In the end I believe Combat Max will see the most significant change when it too becomes a 12 valve tractor powered vehicle.

As for looking down the road at the next project, well, let's just say that if JR of this thread lived next door to me it would make things much easier. I see me building a square fender Chevy Suburban or Chevy V3500 and giving it the treatment.

Perhaps in the future I might build these things for customers, we'll have to see. I owned a hot rod shop in the past, and it did well, but there was one problem I could not surmount...People!

Customers all want everything for free, and labor is generally very poor. But given the right combination of some talented souls and by focusing the market toward serious people (read: No star mag folks) it could work, but that's another subject for another day
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:12:49 PM
Quote:
Originally Posted by rugbyman87 View Post
I agree with everything you said there Don. It has been a learning experience for me and i'm sure alot of us to watch you do this build and the dmax. When i do finally actually buy a house and have a garage of my own, it shall spawn some interesting builds as well. haha


There's a lot more to this and my other build thread
That being

Christ

TO me, these trucks matter but not to the extent that Jesus does. If they ever approach idol status, I hope they are removed from my life, because I do not need them. I hope that that simple message is loud and clear here on these pages to all who come.

In addition to showing what one can do in their garage, I hope to show that God loving and fearing men can do the things they like and fellowship at the same time here.

I want father God to be the eternal glue that holds this and all my threads together, and for Nate's Kookin Corner as well. This is for him. Think of it as a single light on a darkened desert plain that draws on in. The light of course is him, not me. I am simply a messenger who is thankfully being used at the moment to spread the word...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:14:02 PM
From a pesky DOT:

Was outta pocket for awhile- but thought of you all when I saw this; WE'RE EVERYWHERE DON!

Great progress, really like the color- immediately wanted to sneak over and paint a big white star on each door, three white vertical stripes on the bed and a pin-up girl on the front fenders! Your dad is truly honored!

Don Note: Sad discovery
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:15:57 PM
From Dustoff35:

Quote:
Originally Posted by BobbyB View Post
I think Harward performance should make a come back..

I found a couple of these in my toolbox, I think he will need to update the decals...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:16:55 PM
Quote:
Originally Posted by FBJR View Post
$400 in paint for a $4000 job is pretty good. Remember all the prep and detail no one else would have thought of or done.


Ohh, do I see spare 5.9 parts laying around!! Got mine unloaded last night and into a little LUV utility trailer I have. Now she gets a good cleaning while I look for the trannys.

I think I have a bunch of brand new VE pump parts I'm not going to use.

The boyz down at thoroughbred want me to do a P-Pump swap so they can easily dial in 600HP.
They don't think the rotary pump will eat waste oil as easily as a Bosch inline pump will. Plus the inline pump pushes 10 to 20 times the fuel of a rotary pump. All those VE pump goodies will either be going on Duane's truck or yours???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:17:31 PM
Got some more done today.

THe goal is to get the bed installed onto the truck frame this week. That means all the stuff hiding underneath needs to get done now. That was the goal for today. It is possible I might actually spray the bed liner tomorrow evening, but more likely, that will happen on Thursday and the big lift happen on Fritag.

I started with running the transmission cooler hard lines. I purchased hydraulic line, .500" O.D. with a .035 wall thickness to make up the lines.

I began the process by marking the first bend point
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:18:00 PM
The use of this simple device insures a nice uniform bend with no kinking
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:18:45 PM
And here is what it can do
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:19:31 PM
After taping the area up to prevent dings, I proceeded on one bend at a time. I made one tube, then duplicated it with the other pipe section on the floor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:20:06 PM
That all only took a few minutes, then I had the tubing bent properly
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:20:58 PM
Next up I cleaned it up and primed it with the acid etching U-Pol primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:21:32 PM
Then I broke out my favorite John Deere Blitz black to paint the lines
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:22:08 PM
Believe it or not, those lines were not easy to assemble. They kept wiggling all over and falling through and moving in all directions until I got a few of the clamps tightened
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:22:49 PM
I learned to temporarily hold everything in place with zip ties
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:23:20 PM
I used two layers of electrical shrink tubing at the T-Clamp points to totally eliminate any chafing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:24:07 PM
All the lines and clamps are now installed, and this part of the oil cooler relocation is in the bag
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:24:49 PM
Next up I needed to cut in an access from above for the new battery and auxiliary electrical compartment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:25:45 PM
It will go in here
The actual opening will be 8.5" X 21"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:26:39 PM
That new sheet metal saw proved to be a useless piece of junk, so I finished the job with a cut off wheel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:27:24 PM
The concept will be to have a flange with welded on nuts serving as a nut plate which will serve as the base mount for the top plate which is cut from 11 gage plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:28:38 PM
Here are the parts liberated with a plasma torch from that ugly plain old plate of steel!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:29:35 PM
This part fits!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:30:36 PM
Might have been useful to sneak in Mexicans, the skinny ones at least, had it not been for that battery and things under that hole! JR, don't get any ideas!

You know what they say, if the bottom plate fits, then the top is sure to fit as well!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:31:49 PM
So that's it, the finish of another build day
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:33:41 PM
With the goal of being to drop that bed back on this week still in sight, I pushed ahead and got the access panel completed along with some other stuff.

I started off with spraying the snorkel and the gas port panels with the bed coating. Instead of using the usual Duplicolor stuff, I switched to a rustoleum product. It is OK but the duplicolor stuff is better I think

It looks like it had a run or two, but I top coated it later and most of that went away
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:34:38 PM

Duramax Forum Supporter
Supporting Member

 
flyin6's Avatar
 

Join Date: Oct 2011
Location: Northern Kentucky
Posts: 10,336  Starting with the underside flange clamped in place, one by one, I drilled 1/8" pilot holes

Not because I'm a pilot and I'm drilling holes you bonehead...But because they're called pilot holes...kids... 
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:35:16 PM
I like using the clecos because they hold everything together very tightly thereby ensuring the holes all line up and stay that way

So as I went along I snapped in another of those little gems until all the holes were in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:35:59 PM
Four of those holes will remain 1/8" and be used to pop rivet the nut plate into place to sort of hang it there. It will be held in place, of course through the clamping force of all those 5/16" screws

With the holes drilled, I transferred the nut plate onto the lid and using it as a template, drilled through the top plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:38:13 PM
Here's the access cleaned up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:39:22 PM
To make the thing a nut plate, I needed to add some nuts, don't you think? Best way to do that is to first add some bolts.

With the thing securely bolted together, the nuts were welded to the lower plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:40:51 PM
Then the almost completed nut plate was treated to acid etching primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:41:28 PM
Since I might be stepping around this thing, I decided to flush mount the hardware.

I'll be using these allen-headed stainless screws
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:42:46 PM
Counter sinking them was a simple matter of drilling out the bevel with a large drill bit, then setting the plunge depth and repeating over all the holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:43:56 PM
The various parts got a few coats of primers of varying types and a coat of bed liner for the bottom side of the access panel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:44:35 PM
The opening was primed as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:45:48 PM
Time to permanently rivet in the nut plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:47:02 PM
A quick check of the top for proper fit and I think this one is ready for sanding and bed liner!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:47:41 PM
It looks good from the underside as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:48:29 PM
The fuel filler plates are now finished and ready to install
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:49:23 PM
Quote:
Originally Posted by EL TATE View Post
^^x2. rubberized gasket material that forms to the bed possibly? could seal from the bottom but that would hold water against the metal...

But then again, I haven't seen "END OF BUILD DAY XXX" posted yet so maybe we're jumping the gun.


Yea, you're jumping the gun

The truck is getting a topper...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:50:45 PM
Man, getting this thing ready for the bed liner spray is a lot of work (Again)

I had a goal of setting the bed back onto the chassis tomorrow, but after an entire day of sanding, taping, and some other things I am almost completely taped up, but only about 40% sanded at the most.
It is easily going to span into tomorrow afternoon to get the areas sprayed with the bed liner.

I wanted to get some of the parts off the floor so I bolted on the snorkel

I used some good stainless hardware with a lock washer and a large fender washer to conform to the inside of the tube
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:51:30 PM
It fit up like it was made for the truck
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:52:35 PM
The brown truck finally delivered the hydro-boost brake fittings, so, before the dog got to them, I thought I'd stick them in the bores
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:53:18 PM
Those fittings will allow me to use aircraft lines or tractor hoses made up locally. That stuff will be far superior to factory pressure hoses and easy to replace, just find a tractor and harvest the line you need!

I messed with the fuel filler panels because I was not happy with how that crappy Rustoleum bead coating turned out. I'll stick them on in a couple days
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:54:47 PM
THe endless taping and sanding is mind numbing. Despite KLOVE playing in the background, I just pushed through...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 11, 2014, 12:56:13 PM
Never ending
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:00:04 PM
And sanding again...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:01:31 PM
Well, got the thing sprayed finally

The day started with more sanding and masking things up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:02:40 PM
I used a lot of paper and masking tape!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:03:28 PM
The gun used to spray something that thick splatters the stuff all over and with some force. That means the blobs of the liner that missed will easily travel some distance and hit things you care about. So covering everything is the order of the day with spraying bed liner type coatings.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:04:00 PM
The tailgate was flipped over and got sanded and prepped for some more primer and the bed liner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:04:54 PM
After washing everything with a good solvent cleaner, I shot a coat of primer/sealer over the bed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:05:44 PM
I tested the U-Pol Urethane two part bed liner on the tail gate first
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:06:28 PM
That turned out OK, so onward to the actual bed

I shot a flat area and part of the side to experiment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:07:01 PM
After a second coat on the tailgate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:08:05 PM
Next up is the door sill areas that is a high wear part of the cab to be sure
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:09:00 PM
All that was working out well, so on to the roof
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:10:17 PM
It definitely looks pretty rough up there, but I had some reasons for doing it that way.
First where you hook a foot under the roof rack when climbing up there it should provide some purchase.
Secondly, it will definitely not be reflective.
finally, a roof that coarse will hold onto dust which causing some good natural streaking and natural camouflage. All you have to do is drive it around and all the dust and pollen gets caught up and when hit with morning dew, starts to mute out everything.
Mostly, I really don't care much about how it looks, but over all I'll give the roof a:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:13:00 PM
Acceptable
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:13:59 PM
After it set up a little
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:16:29 PM
I used 7 liters of the urethane
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:17:06 PM
One left from that rather expensive case
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:17:43 PM
You may recall back at the beginning of the winter, I had sprayed the underside of the bed with a two part Epoxy bedliner.
THis application used a two part Urethane.

Hands down the Urethane is the better product. When I sanded up the Epoxy, it scratched easily. Sanding the Urethane is like pulling ticks from a coon dog...You only create vacancies for new ticks... What the Warrant Officer was trying to say is the Urethane is difficult to scratch as in scratch resistant!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:18:26 PM
And here it all is at the end of build day 123

I must have been using street pharmacueticals or eating mushrooms, or sucking down paint fumes or a combination of all of the above when earlier I stated "The end of build day 200"

Not 200

No where near

Build day 123

By the tie we hit Day 200, I'll be fitting a Mr. Fusion from back to the future fame or mounting that recoiless 90mm I've been eyeing down at the VFW
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:19:47 PM
Quote:
Originally Posted by nmeyer414 View Post
Most Soldiers wear a watch upside down like that to prevent the glare from giving their position away (designated marksmen or snipers). That caught on with a lot of Soldiers who are actual door kickers or marksmen. But yes wearing a watch face down will prevent the crystal from getting broken (when wearing a cheaper shock resistant watch).

I am liking that coating don.

I always did it because playing Armee tends to get stuff broken. However, I practiced keeping my bodie from getting broken. I failed miserably a few times, but most of the time, the inside working space was protected.

Another semi-funny story from Monday this week

So we all know Humpty Dumpty here took a great fall a couple weeks ago. Afterward, I got an appointment to see a chiropractor. He shot some X-rays of the spinal column. Afterward he wanted to talk to me. Monday, he set up the X-rays in the viewer and showed me the mess.

He said, looking at the two shots he had taken, I had lived a spirited and interesting life. He then said, while tracing lines all over twisted vertebra that I had broken my back three times.

I corrected him, saying that I had broken my back twice doing Armee stuff, and they had operated on me both times to correct it.
He smiled and said, Yes, those would be here, and here. Then he pointed at another vertebra that was about 1/4" shorter on one side than the other. He explained that a major crushing trauma did this one 20-30 years ago. Thinking back, I was in a helicopter crash then. We hit wires and spun in from maybe 50 feet onto a frozen river up near Socheu, Korea. I remember the Armee pulling a bunch of viles of blood out of me for drug testing, but no one paid much attention to the fact that I was sore like I had been dropped on my butt from, well, 50 feet.
Surprise, surprise, surprise....
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:21:08 PM
Quote:
Originally Posted by TexasRedNeck View Post
Don, good progress, sir.

How would you rate the U-Pol compared to line-x or high pressure Rhino Liner?


Different product

Allow me to explain.

Line-X and Rhino liner are professional products sprayed by high dollar equipment. Said equipment can spray on 1/4" thick product which U-Pol cannot.

I had my Tundra sprayed with Line-X coating in the bed, and it started to break down in 5 years. I had Rhino liner sprayed on the roof and sides of the truck which looked OK, I'd rate the application job a "C" at best which held up.

After those two experiences, I realized what you get is pot luck. Line-X sprayed on by a three tooth meth addicted loser is going to be crappy no matter what

It's the Armee Prime Rib syndrome... Sometimes the US Armee feeds something like prime rib to their soldiers. Thing is they boil the meat! So even though you started with the Mercedes Benz of beef cuts, boiling it would be like adding dubs on that lowered Merc which is adorned with jingle balls and a flame paint job.

So to me it all boils down to the fact that after many years dealing with boneheads, I'll just do it all myself. I may get a run in the paint, but at least I know the rust was dealt with, it was primed and painted properly with descent materials and no short cuts were taken.

So that's the real compare. If I had the $$$, I would use Rhino liner which I sprayed myself or found one of the few people in the business who could actually be trusted. But since I couldn't afford it, U-Pol was the best product which I could afford to spray myself, so for that reason, it's good enough.

Continued editorial comment: With the flooding of Chinese car parts into the parts market, we have come to accept mediocrity. I'll cite an example on this build. I ordered a rebuilt Cardone steering gearbox from PartsGeek.com.

I should have been concerned when I found dirt in some of the ports and cheap almost tar like black paint on the unit in the box. I cleaned it, prepped and painted it with a quality 2 part paint and installed it on the frame. Later when I was hooking up the steering column, I noticed it had about as much play in it as did the worn out unit I had just removed.

So I called PSC, the performance steering experts. They chuckled and asked if I still had the old core. They said CarDone doesn't rebuild many of the units they sell, other than to replace the seals, and tighten up the free play, which does nothing to address the core issue of overhauling real worn areas in the piston unit. They are all about just getting the junk back out on the street.

He asked me to please not send the "Rebuilt" Cardone unit to him, but send the original unit, which he felt was probably in better condition. I did not mention this before because I am going to do a write-up on the high performance steering mod I am doing which will feature a properly built gearbox.

THis is all part of the slow cancerous death of our once great nation. No longer great, I think we seem to be on drugs or something, since we are selling to accept this crap. And you did this! By buying cheap chinaman's junk over the more costly American or at least north American stuff, real American companies have had to move operations to other countries or outright contract out the manufacture of once great parts to people who grow their rice and fish in ponds of human feces.

Yup, that's true...I have seen it with my own eyeballs.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:23:03 PM
Quote:
Originally Posted by Dustoff 35 View Post
What? You don't remember the 90W gear oil that 14 bolt axle we picked up for you spewed all over my pristine trailer several years back?

PAYBACK BABY!!!!!


Yea, but that oil actually prevented that part of your trailer from rusting away.

Hey, here's a question:

How many times a year does Duane wash his vehicles?

A. Monthly

B. On his birthday

C. Twice a month

D. Weekly

If you answered with any of the above choices, post a demerit

Duane does not bother washing vehicles. It was washed at delivery, why waste any more time on it!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:24:48 PM
I pulled the tape off the truck parts just now

Here's what I saw

Oh and I forgot a pic of the panel all primered up yestertag prior to being mudded up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:26:15 PM
I don't think the roof is as ugly as I thought it was going to be. Also nice contrast in both color and texture. I think it works...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:27:21 PM
Different views
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:28:32 PM
I'll get a good comparison between the various bed coating products on this project. Eventually, I'll have 4 different brands on it.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:29:45 PM
Partial reason for the project success

Sled dog kept the red dog at bay!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:31:43 PM
Originally Posted by flyin6 View Post
Yea, but that oil actually prevented that part of your trailer from rusting away.

Hey, here's a question:

How many times a year does Duane wash his vehicles?

A. Monthly

B. On his birthday

C. Twice a month

D. Weekly

If you answered with any of the above choices, post a demerit

Duane does not bother washing vehicles. It was washed at delivery, why waste any more time on it!

The wife's Jeep Wrangler gets washed at least once per quarter.

The Sequoia, well... I honestly cannot remember the last time it was washed.



I think I'll go outside and pee on Don's trailer myself...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:32:39 PM
Well,, even with church today, I still got a few things done.

First let's play parts

Who wants to play parts?

OK, no one, well, I do

Here's the transmission oil cooler I will be mounting up on the roof rack in the very near future
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:33:34 PM
I'll be using some descent AN-8 hose. I believe this stuff is rated at 250 psi or there about. It will keep the line size about the same transitioning between hard line to rubber/braided hose to the cooler and back

Here, also, is some of the purdy fittings that will make all that happen
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:36:42 PM
I started on the bed. The goal remains getting that thing put back on to the chassis to free up work space and make the truck start to come back together.

First up was the fitting of the electrical access panel. I cleaned up the threads with a 5/16" tap
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:38:17 PM
Then fitted some foam weather strip to the underside
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:40:21 PM
It's important to use anti seize when screwing stainless hardware into regular steel threads. Failure to do so can easily strip the stainless bolt and snap it off in the threads
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:41:18 PM
With that done, I bolted that sucker into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:42:34 PM
Next came this task of enormous significance. Slipping the tail gate straps onto their mounts. You see, these things have been on that shelf forever, and now, finally, they are moving back onto the truck!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:43:41 PM
Whew, that was a monster!

Next, on to the fuel doors and caps

First I masked the area up a big because sure as the president is a foreigner, I'd drop something and scratch up that purdy not so shiny green stuff
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:44:21 PM
The hardware got a coat of shark hide to prevent corrosion.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:45:11 PM
Then assembly could start
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:46:49 PM
So far so good. Nothing fell apart.

Remember the slight curve of the bed sides vs the straight panel? Well the misalignment was maybe 1/16" to 1/8". Snugging the mount screws down made all that get along just fine! No gap, no muss, no fuss!

Next up the filler caps and rings.

Initially I used these socket screws, but you will soon see I preferred changing those to rusty bolts!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:47:36 PM
The lanyard is standard fare for aircraft of all sorts, so since this isn't an aircraft, I did it anyway! Make sense???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:49:08 PM
Next up, I decided to add the AN-8 ends to the 1/2" transmission cooler lines
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:50:48 PM
The factory actually used sloppy stainless clamps, the worm gear type. That's old school and works most of the time, but this aircraft stuff is way stronger and more reliable

The line itself will attach via one of these slick 90 degree fittings
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:51:55 PM
Then the other ends were built up in the same manner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:53:07 PM
Since I had the fittings out, I screwed in the 1/2" NPT to AN-8 fittings into the oil cooler.

That B&M unit is very stout, and that's why it got the nod
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:55:04 PM
This is the point I got to staring at those gaudy socket head screws sticking out just begging for a "wait-ah-minute" vine to snag. So I changed them out for the button head.

Watcha think, good move or not necessary?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:56:05 PM
Here's where it all sat at the end of build day 124

But there's more

Today I located and purchased a freshly rebuilt 12 valve P-Pump 1995 Cummins engine.

This beauty has moly coated marine pistons, new valves, head work, work to the injection pump and was completely gone through. In fact it is still being assembled. I anticipate a delivery this coming weekend. With the correct turbo, this motor will arrive on the doorstep making 600 HP and more than double that in torque.

I am actually going to take it to an engine dyno to have a diesel performance shop run it in to break in the rings, then give me a couple pulls before it ever sees the frame rails of square D.

Those boys, with me helping (Getting in the way) are going to build that antique A518 trans of mine to hold 1000 HP!

SO I will have one serious power plant going back into the truck with the correct pump to eat all sorts of nasty fuels and still possibly produce a 12 second quarter mile run if I really cared to do so.

600HP is actually a pretty conservative number for this motor. The guys up there were saying it will last forever at that low of a power point, and it could easily be turned up to make much, much more power if I wanted!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 09:59:11 PM
Quote:
Originally Posted by BobbyB View Post
Ok, so now I have 2 questions.

1. In the pic of the foam installed under the inspection plate does it, squish down into the lowlands in between the ribs? (and I almost referred to them as depressions and the military definition of 2 hilltops with lowland between them)

2. You just bought another 12V to grace D2's front end? So what's happening to the original D2 motor? Is that going into CMax in the long run or am I overthinking something that's glaringly obvious to everyone else but me?

OK in hindsight, I had more than 2 questions but I made it work with my original comment.

The foam squishes just fine and fills the voids

Yes, I purchased a 1995 in-line Bosch 7100 series pump engine. Those pumps produce many times the fuel that a VE pump does. Where the VE is limited to 350-400HP, a P-Pump can produce 1,000 horsepower. The P-pump cas easily produce 600 horsepower and eat motor oil as a fuel substitute, so that's why I purchased it. Plus the new motor has just been completely overhauled.

I'll just sell the VE motor on Craigslist.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:01:53 PM
Let's look at some square D progress, cause' there was some, sort of...

I picked up this cool Cat part meant for some earth moving piece of equipment. I ordered a rotating unit much different that this a few weeks ago, but it has never come in, so in the temporary mean time, I'll use this genuine Caterpillar part to fab in the rest of the rack.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:02:50 PM
"Target me" yellow will just not do, so some sanding was in order
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:04:00 PM
Followed by four coats of OD green paint

You can see it getting darker with each coat
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:04:56 PM
While I was waiting for the paint to dry, I hung the tailgate

I have always said to the boyz, "As long as you have a pick-up truck, you always have a place to sit."

Little pre-ranger saw the tailgate in the horizontal and asked if he could be the very first to sit on it!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:07:05 PM
I simply switched gears and started on the long range light enclosure, which should keep them intact whilst driving through things.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:08:26 PM
The idea is to make it in as few parts as possible, then fold everything together and then permanize with hot sparky stuff
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:09:48 PM
Starting to look like something...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:11:19 PM
Here's the outside, side, which is much thicker than the rest.

Worry not if it looks flimsy at the moment, it will get much beefier and able to take a lickin' in the morrow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:14:26 PM
Quote:
Originally Posted by Armalite View Post
I like the light box. Good idea. Paint it in the od green, and hide all that shiny chrome! Will there be another light box containing two more lights for the other side of the truck, or was the plan to mount that box in the center mass ?

No, the light box gets stuffed in on the far left side, then a LED bar in the middle somewhere, and the right belongs to the cooler and lines and a scoop for that.

Don't need symmetry...Just get the stuff on and make it work
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:15:35 PM
Got some things done today. With the rain and nasty weather it was slow, and I had to work around the glass folks, but There was some progress made.

First up I got the light box pretty much finished. It heeds some trimming, shaping (Possibly), body work and coating but it's mostly there.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:16:42 PM
They fit!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:18:10 PM
I purchased a new saftelite windshield, new gasket, and had it professionally installed right in my garage!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:19:35 PM
David, here, had 24 years experience and it showed. His son, Travis assisted. That man knew what to do to get that windshield to almost literally slide into place and Travis was very knowledgeable as well!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:20:29 PM
Next was the back window

At first they tried to slide the assembly into the rubber gasket which was already installed, however that technique did not work

Next, they decided to install the thing as one unit using a nylon chord. THat technique clinched the deal!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:21:59 PM
With all three of us pushing and pulling, the gasket pulled in true and the window was installed.

Note the proximity to the hydraulic tube mounts. Duane placed them perfectly!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:22:47 PM
The Red Dog was looking for some tasty tool to steal, but today, I bested her!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 12, 2014, 10:25:03 PM
Note: I had started on a roof rack earlier, but the design was garbage, so I canned it and started again with this one

This rack will be much, much stronger than the last one. The tubing I used was twice the size and nearly three times thicker.

The concept this time is to build a frame with the perimeter, then add in the various accessories, then create a separate composite floor plate which screws in and is removable. THis should lighten it up considerably while keeping it very strong.

It will not be symmetrical at all, but live with a shape dictated by the function and protection it needs to provide.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 11:59:07 AM
Just like before I will form most of the outside hoop from pre-bent angles fitted together as I go
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:00:52 PM
Here we go, first hoop going in:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:01:44 PM
This build benefits from the lessons learned from the first time. Notice that the front run is not straight, but more closely follows the curvature of the front of the cab
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:02:22 PM
I'm not as good as I need to be at the moment, but I am attempting to do a multi angle bend which extends outward to encircle and protect the snorkel pre cleaner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:03:36 PM
Seems to be working...

I will add a second, taller bar tomorrow and tie them both together. I think I'll make this part removable since if anything gets smashed up, this is very likely to be the chosen part!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:04:00 PM
And that's it for Build Day 126
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:17:32 PM
Quote:
Originally Posted by BobbyB View Post
Merely an observation.... But wouldn't it be a better idea to make the light box a bit more streamlined so branches slip off instead of grabbing hard on the 90s or the flat surface in front? Something like a teardrop shape? It'd also be a bit more aerodynamic (granted D2 is become aerodynamic as a brick with a parachute strapped to plywood) and cut down on wind noise, as well as cut your silhouette?

Just something I thought of while reading before racking out.

P.S. since you are building a new roof rack couldn't you include them into the structural design of the rack, so its a one piece unit instead of adding height and weight to the roof?

Streamlining for the sake of aerodynamics is lost with the factory silhouette, really.
However you are right with respect to the snagging on stuff comment.
OK, Bobby, I think I'll modify the box
Why not, everything else is modified
I talked about whacking off the top outside corner, so what I think I'll do is cut a generous angle into that corner and weld in a new plate all pretty like. That should make both you and some cedars down on the farm happier

Cool?

As for incorporating it into the rack. I thought about it and I agree, but as with the prebreather brush guard, I think I'll just make it a bolt in affair si if it gets torn up, or later on I want to replace it with something different it will be simplier. Never the less it will be sticking up some, but like a searchlight on top of that 105mm cannon on my old M60A1 MBT, although it might get catch a few branches from time to time, it sure was effective when you needed it.
That thing, BTW was 7.5 million candle power!
Here's something you didn't know...

Funny really

Did you know those searchlights work in the IR spectrum as well?

Know what that is good for?

Well when you infantry guyz are ah' sneakin up on us during some field exercise, we would flip the light to IR then focus the beam on you folks. That would expose you to like 2 hours of sunbathing in Miami every 10 minutes!

Ever get a sunburn during those exercises???
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:18:20 PM
I was thinking about, thinking just now, and this came to mind:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:18:48 PM
Makes one want to pray for rapid growth, doesn't it!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:19:22 PM
Well, messing around with the truck today, for a couple hours this late afternoon, I got the tailgate to close.
THis is a step forward, as when I purchased the truck, it would not stay closed and would only flop around in the open position

I finally remembered to get some linkage clips, which I ended up not using. I found some better all steel barrel clips that actually pinch the linkage rod in place making it as fool proof as one can I suppose
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:20:17 PM
Anyway all that went together and it worked...end of story
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:21:03 PM
it closes!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:21:52 PM
With Boby convicting me and with me already pondering the "Squareness" of the light box, I decided to apply some sparks to the semi-finished box
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:22:53 PM
Then through the pure magic that is fabrication all this happened:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:23:37 PM
That steel was much mo-better so things were well with the local universe for a time...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:24:04 PM
Ah, the steel nose thing

Got the idea from helicopters I have flown over the years. We have WSPS (Wire or something Protection System) Basically it's a hard edge that is the first thing that power lines that you, the pilot who just really screwed up badly, are in the process of bisecting. A real WSPS has saw teeth embedded in some hard rubber that literally saw the power lines in half thus saving you and the aircraft. My steel nose thing is not like that...It's just a piece of steel that stiffens up the front of Uni-light so it will kill branches and still sparkle like your brides diamond ring.
BTW, those WSPS things on Armee helicopters only get the problem of saving you for another day about 50% right
Ask me, I know
So, I'm the passenger in a Jet Ranger in Korea
Yea, the broken back story
ZThe first time I see the wires they are about 5 feet from my windshield
Before my heart stopped one millionth of a nano second later, that windshield was in my lap.
So I did the natural thing and threw out this really big hole in front of me.
The wire got cut all right while it was stretching, now being powered by Bell Helicopters in stead of Kung-Fool electric company, it couldn't take the argument it was having with several cowlings and those saw teeth and just like that it snapped.
And just like all good wires under a lot of helicopter inspired tension. it recoiled violently.
I guess the rotor blades didn't have wire strike protection because that recoiling wire ripped a chunk right out of one!
Yea, not cool. Blades keep your butt out of rice paddies, or in this case a frozen river right beside a rice paddy. So yea, we crashed, like right now spreading bell helicopter parts all over the place. The biggest parts of the helicopter still contained me and this lieutenant who just did all that, and that is an important fact because I am the guy writing all this and creating steel noses on things.
So, yea, what the heck was I talking about anyway...?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:25:15 PM
Ah, the nose thing

Here's some more pics of the manly creation!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:25:53 PM
Call that in the bank for right now

On to the developing roof rack system

I needed a second hoop so konstruktion started on that
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:27:07 PM
It needs to look a lot like this by golly!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:28:10 PM
We'll call it a reverse question mark for the time being until I can come up with some kool Armee soundin' acronym.

SO more bendin' and looky what happened:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:28:45 PM
I think that's a keeper!

So using my not so famous Cleco thing-ah-ma-bob, I fastened the lower bar and started to mentally cipher out how the rest of it is going to fit.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:29:26 PM
The upper run will fit somewhere near here:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:29:58 PM
Back to "Uni-Light w/nose device

It is going to go in somewhere around here
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:30:44 PM
As I started to look at it, I saw an opportunity to cut it right into the rack system.

If I cut the lower hoop right at the edge of the box, plus an eighth of an inch for some tabs, I could slide it down a few inches and tuck it in nicely and lower the profile.
That should keep bobby happy, and well, the rest of everybody's opinion doesn't matter anyway

Studying the position one could see how doing that would trick up this build even more
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:31:18 PM
That's all folks, another day, #127 now clearly in the bag...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:32:35 PM
From Dmaximus:
Quote:
Originally Posted by flyin6 View Post
Ah, the steel nose thing

Got the idea from helicopters I have flown over the years. We have WSPS (Wire or something Protection System) Basically it's a hard edge that is the first thing that power lines that you, the pilot who just really screwed up badly, are in the process of bisecting. A real WSPS has saw teeth embedded in some hard rubber that literally saw the power lines in half thus saving you and the aircraft. My steel nose thing is not like that...It's just a piece of steel that stiffens up the front of Uni-light so it will kill branches and still sparkle like your brides diamond ring.
BTW, those WSPS things on Armee helicopters only get the problem of saving you for another day about 50% right
Ask me, I know
So, I'm the passenger in a Jet Ranger in Korea
Yea, the broken back story
ZThe first time I see the wires they are about 5 feet from my windshield
Before my heart stopped one millionth of a nano second later, that windshield was in my lap.
So I did the natural thing and threw out this really big hole in front of me.
The wire got cut all right while it was stretching, now being powered by Bell Helicopters in stead of Kung-Fool electric company, it couldn't take the argument it was having with several cowlings and those saw teeth and just like that it snapped.
And just like all good wires under a lot of helicopter inspired tension. it recoiled violently.
I guess the rotor blades didn't have wire strike protection because that recoiling wire ripped a chunk right out of one!
Yea, not cool. Blades keep your butt out of rice paddies, or in this case a frozen river right beside a rice paddy. So yea, we crashed, like right now spreading bell helicopter parts all over the place. The biggest parts of the helicopter still contained me and this lieutenant who just did all that, and that is an important fact because I am the guy writing all this and creating steel noses on things.
So, yea, what the heck was I talking about anyway...?

I also have seen the WSPS (wire strike protection system) in action. The one on the Astar's as on the OH-58's are the same. I can't see it would cut anything larger than about 3/8". Any thing larger and your in a world of hurt. How about the tension on those wires. I was told it looked like 4th of July when the thing snapped. I was really surprise of the aftermath. Of course the wire took off the pitot tube and ran up the windshield. When it struck the WSPS it left some marks in the paint and that was it. The cabin is made of fiberglass and not a crack one surrounding the mount.

BTW: Liking the roof rack very much.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:33:14 PM
:
Originally Posted by Dmaximus View Post
I also have seen the WSPS (wire strike protection system) in action. The one on the Astar's as on the OH-58's are the same. I can't see it would cut anything larger than about 3/8". Any thing larger and your in a world of hurt. How about the tension on those wires. I was told it looked like 4th of July when the thing snapped. I was really surprise of the aftermath. Of course the wire took off the pitot tube and ran up the windshield. When it struck the WSPS it left some marks in the paint and that was it. The cabin is made of fiberglass and not a crack one surrounding the mount.

BTW: Liking the roof rack very much.

That OH-58 I was in was not so lucky. THe wire ripped off one of the trim tabs and about a hand sized piece of rotor blade

Big time instability and vibration
Know about "Pylon whirl" in the jet ranger? The transmission tore that stud off the bottom of the case and threw the cowling all over the place, some of it through the tail rotor.

I didn't tell this part. but we were just outside of the DMZ in Korea which requires position reports every 15 minutes I think. well after we had missed several, they launched search and rescue. Toward the end of the day a South Korean MD-500 comes ripping up the valley looking for us, and that's when I saw another wire. THis guy hits that wire, looses control and spins in right next to us. Yup, two crashed up helicopters!
Then the UH-60 crew that heard the ROK pilot radio in that he had found us made an approach and believe it or not was making an approach into the single remaining wire!!!!!!
I ran over to the wreckage, turned on the battery, flipped the VHF over to guard and started yelling, Black Hawk on approach to the crash site, go around, go around.
He did, and later that CW4 who was the commanding general's personal pilot said if I hadn't made that call, he would have flown right into that wire.

What a day!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:34:49 PM
From Dustoff35:
:
Originally Posted by BobbyB View Post
...I realize you haven't finalized the mounting position yet, but if you force a thick wire, steel cable or wait a minute vine down towards the bottom of the lightbox it could snag and if strong enough remove your lightbox from the roof rack...

Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:36:24 PM
From cudakidd53
Quote:
Originally Posted by Dustoff 35 View Post
Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me.


In case Don misses the shot here..........Whooooo, Whooooo, whoo asked ya....
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:36:53 PM
Quote:
Originally Posted by Dustoff 35 View Post
Might not be a bad thing...

Light box? Looks more like an oversized owl's head to me.

You named it, the owl's head it is!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:39:51 PM
Quote:
Originally Posted by FBJR View Post
Have you guys ever seen a WWII submarine? It had a wire from the bow up over the coning tower. With all the stuff on the truck, why not a simple wire up each side to the rack/future topper to do the same thing?
Run form the corner up on each side will keep your engine access clear as well as the air cleaner??

You're talking about limp risers, and yes the truck is getting them, but at some more distant point in the future. After I build the front end, and a part of the exo-skeleton, then I will add the 3/16" steel cable on a aircraft turnbuckle and a spring. That will attach to the highest point of all that business that is getting built in at the moment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:40:39 PM
Here's a bit more done on the truck.

First I remounted the lights in Duane's aptly named Owl's head
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:41:12 PM
All the interference is right here
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:41:41 PM
So I notched it

This simple clearance allowed the box to sit 2" lower into the protective frame
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:42:36 PM
Instead of cutting up that pretty lower bar, trough notching the "Nose" the box sat much lower. All that was required to get the Owl's Head to rest there was to build a shelf for it to sit onto.

Here is that simple but effective piece:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:43:17 PM
The 3" wide shelf piece has the 5/16" nuts welded to it, therefore mounting the box to it will be simpler.

That lip welds to the underside of the main support beam
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:43:52 PM
And here is the light box nestled lower in the roof rack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:44:54 PM
With that in about the right place, time to form up the two forward mounts I envisioned

The right mount was made from a curved and angled short section of steel tube and a home made flange that bolts to the Owl's Head
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:46:33 PM
Then with a couple of uprights tacked or really, semi-welded into place, I started to form the left/outside upper bar and owl's head mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:47:12 PM
It fits pretty well. The upper bar maintains the swept back angle to aid in shedding 2X4's, Kia parts and branches
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:47:59 PM
I've been learning a lot about that bender, which will help me do a better job with the exo skeleton. Instead of cutting that bar and welding another 90 to it, I carefully measured, marked, then set up the machine and bent this upper hoop. What do YOU think???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:48:49 PM
The OH right side mount was short, strong, simple, and gets the job done with no fuss
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:49:35 PM
Remember those 6-element lights?

Here's where they go, one on each side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:50:07 PM
At the conclusion of build day 128, here's what's going on:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:51:05 PM
Quote:
Originally Posted by KensAuto View Post
Nice bending! Now your thinking outside (of) the box! 

I finally had the sense to experiment and find the exact point on the die that the tube actually starts to bend. Then by marking and measuring from the starting point of the bend, I can get it pretty close.

I'll do the same for the 1.75" or 2" die I'll use for the exo-skeleton tubing.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:51:40 PM
Quote:
Originally Posted by TexasRedNeck View Post
Keep going Don!

Me thinks that in the time I've wired in a few accessories in my build thread, you've built an entire truck.....twice


Nope...

Neither is done, and Square D is far from operating

But it needs to get there.

I feel a certain push to get an EMP proof back up (Primary??) truck in place.

And no sooner that I get that done I'm starting on the tactical habitat thing or on the square fender, Cummins powered burb.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:52:18 PM
Quote:
Originally Posted by TexasRedNeck View Post
Keep going Don!

Me thinks that in the time I've wired in a few accessories in my build thread, you've built an entire truck.....twice


I am under strong pressure to open my own site...To possibly make the money to fund "Real Man"

I see a bunch of like minded people (You) doing builds on vehicles, homesteads, guns, cookin' planning finances, canning, I did mention building gunz, right? and a whole bunch of like minded subjects.

Cool thing is a lot of the "Guides" I think we'll have will be ex-military, special operations types, of the sort they have made movies about in recent times. We'll give it to you straight, not mix in all this civie "background noise" crap we are all subjected to. Nope those folks will simply serve as evening hunt training aids!

Sorry about the "Civie" term, but hey, I can't seem to stop using it. You guys can call me something as well...cool?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 12:53:25 PM
Quote:
Originally Posted by FBJR View Post
Oh no, it's popcorn time

Is it "BED TIME" yet ?????


Well, grass is coming in and that "Cuts" into my build time

Last week I was over at the Sherriffs office. In rolls an undercover unit...4 menses.
So I sez, "Hey you people finished eating out, drivin around and generally wastin' my tax money? I get a response out of two of them, both good menses. I sez, I need some strong backs and weak minds, you boyz look perfectly suited for the task! Then I sez, get your butts over to my place tomorrow and lift that bed back onto the truck frame for me so I don't twist an ankle or something..."

Well, I was kidding around, messing with them, man style. So the next day rolls around and I am sitting having lunch with my pastor. Me phone, she rings, well, beeps. One of those knuckleheads is on the other line. Turns out he and his buddies are in my driveway looking for me. You see, brave as they are, I find this funny, but they won't get out and check out around my house for me...They all think I'll shoot them or sick a killer dog on them, or they will step on a mine or fall into a pit or get caught in some Chinese man trap! Some of that is true unfortunately, one of them who I love like a son comes in my house one day sort of unannounced and the shepherd I had then takes him out in about three fifths of a micro second. It was a pitiful scene. Mikey has both arms up and is looking away like he doesn't want to see what's happing to this poor deputy. The dog has him, but hasn't clamped on and just waiting my command to start snacking. But I am laughing at the scene, watching one of our finest acting like a scared little school girl, so in the fashion of men, I just let the story spread, and all the officers look over truck and know my past so I let it all be...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:14:19 PM
OK, let's get on with the build. Even though we did Church, and the Sunday dinner, I got that roof rack a long way down the track

Here it is removed from the truckster
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:14:51 PM
First I bent this little piece to plug into the existing bottom hoop. I needed to get that formed in to build the top from
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:15:23 PM
And lookie here, it all connects
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:16:04 PM
With the outside perimeter connected, I added another stiffner to the main frame
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:18:28 PM
Then this brace went in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:21:14 PM
Followed by this upright

The back upper hoop bar is in place and if you look, already marked for the bend. Once bent, it will fall into the fish mouth and fit all purdy like
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:22:36 PM
With the tube bent and another upright added, the fit is working out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:23:05 PM
Now that upper hoop gets another bend
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:24:46 PM
Then that bar gets a fish-mouth cut in to mount to the next upright.

This upright will be taller to raise the upper hoop about 2" to cover that precleaner better since it's also taller
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:31:17 PM
I cut a similar mouth into the hoop to fit that upright like a glove
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:32:08 PM
Then the two, taller uprights were tacked in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:32:45 PM
The pre-bent basketball hoop will be the last thing to go in, so back to the front. Another upright goes in here. Each time I make one of these things, it gets measured, cut on a drill press using a hole saw, then dressed up with a grinding wheel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:33:20 PM
Then the right one
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:34:09 PM
Then the section connecting the owl's eye box to the pre-cleaner cage was bent up, then tacked in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:34:59 PM
It will get some triangulation a little later

Now on to the protective cage

Here two more uprights go in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:36:01 PM
placing them at the apex of the bend to catch that pesky tree limb or disintegrating wall structure
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:37:04 PM
Then the previously bent top hoop is tacked on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:37:39 PM
Far from done, the structure is definitely getting in there
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:38:16 PM
The owl's eye mount is PDS (Pretty darned strong)
I don't think that metal box will be moving around all that much
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:39:12 PM
The particle separator device will rest inside this:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:39:48 PM
That was a good point to call it a day so I did.

Here's the DGS (Don's Garage Situation) at the end of Build Day 129
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:40:57 PM
Quote:
Originally Posted by Cudakidd53 View Post
Looking good- nice to see sparks a flying again!

Great googly-moolgy you weren't joking about green-up in Tucky; let it go a few more weeks and you can bale it and sell it for Hay- fill up the trailer and cart it out to near Nate. Texas is always hurting for hay it would seem!

I was only down for a single day, Saturday, Man... the impatience around here!

I surprised myself with the amount of fab I was able to turn out yestertag, with it being Sunday and all. Spousal unit had to cipher all her expenses so's eye could finish summin the tax disinformation.

Anyone with me on this convoluted tax system?

I try my darnest to do it correctly. I oftentimes run it on turbo-tax, then get professional help. Yet every year the IRS sends me a bill for owed taxes!. THis year I get a bill from them for 2010 taxes for $1,800, then another for last year's for fifty something. Does it ever end?

They just have you over a barrel. At any time they come back and say, you know Mr. Harward, we noted that you claimed jelly beans as a business expense for your 1974 taxes. We just can't see that and are disallowing that deduction. You owe $3.21 for the jelly beans, $100 (per year) fine for filing that, and accrued interest, then when the fine amount exceeds your annual income you are subject to alternative minimum taxes which have also been unpaid, according to our calculations for a number of decades, so it is our determination that in addition to the $643,871 you owe in back taxes and fines, you have also been tried and sentenced in tax court and are to report to your local sheriff to be arrested to begin serving your 63 year sentence!

And what's the alternative minimum tax anyway. It's as if someone is saying, hey, this tax code thing is beyond comprehension, it's to the point where no one can figure it out and smart people actually use it to get out of paying any taxes at all, so let's just start again and throw out a couple rules. We can make it anything we'd like so let's fix it up to where after a week of sorting through all these rules we don't understand they will find this rule which simply says to surrender 75% of all your money! Yea, let's do that!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:41:34 PM
OK, time for everyone's evening fix

I know this silly thread is an addiction for a lot of people out there!

Work continues on the roof rack build. It is nearing completion of the fab stage. After that it will get painted or coated, then the accessories will be installed, the wiring harness installed and the whole kit and ka-boodle will get bolted down for keeps

The 20" light bar showed up. I know this part is not EMP proof, but it is not a primary lighting system, but part of the "Scene illumination" feature I'm building into this truck. I want big light and low amp pull, so LED was the way to go. Primary lighting on this truck will remain old school incandescence

Here's that cool light bar:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:42:10 PM
It will go into the front of the rack just to the right (Vehicle right) of the owl's eye
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:43:04 PM
The mount is a simple 1 X 1 section of square tubing set on two stations with 2ea 1/4" bolt/studs that the light fixture slides down over
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:43:49 PM
It welded on in three places and is pretty strong and secure
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:44:28 PM
The light bar simply slides onto the studs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:45:27 PM
While I was working up front, I finished installing the triangulating brace onto the light box mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:46:01 PM
So far, so good
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:46:51 PM
Here, the final 1.25" square tube brace is welded in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:47:41 PM
Then the rear uprights were installed, completing the hoop assembly in the back
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:48:15 PM
Then I added one more upright onto the left side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:48:57 PM
I think that pretty much finishes out the structure
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:49:25 PM
Now for the oil cooler. It will occupy this space:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:49:56 PM
About here:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:50:45 PM
The rear mount is a simple piece of angle with 2 ea 1/4" bolt studs welded in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:51:32 PM
The cooler is so lightweight, that just the two tack welds supports the cooler for now
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:52:56 PM
The front mount is a bit more robust. 3" plate .125" thick with two more studs welded in place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:53:53 PM
That piece is bolted to the cooler and then was welded to two legs made of 1/2" square steel tubing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:54:53 PM
Air flow is going to be from the bottom, then up through the cooler, then exit out the top. That is why it is tilted and why I will make a cowling to direct the air flow where it needs to go.

The cowling is first made from cardboard, then the adjusted cardboard is traced onto metal, then cut out. I am thinking this needs to be made from sheet aircraft aluminum, say .025 or .032...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:55:38 PM
Quote:
Originally Posted by flyin6 View Post
Air flow is going to be from the bottom, then up through the cooler, then exit out the top. That is why it is tilted and why I will make a cowling to direct the air flow where it needs to go.

The cowling is first made from cardboard, then the adjusted cardboard is traced onto metal, then cut out. I am thinking this needs to be made from sheet aircraft aluminum, say .025 or .032...


Hey Big D-

Are you considering any louvres in front to deflect debree from striking the cooler? We used a homemade grill of them running horizontally to block dirt and rocks racing dirt track- air bent the corners, hard stuff did not. Easy to spray mud off of flat surfaces, not radiators! Side view of them had a high horizontal plane, ramp up 45 degrees, down 45 degrees but past first plane down to a second horizontal plane. All of these viewed from the front prevented seeing all but a thin line of radiator, with each louvre about 1-2" apart.

Let me know if it interests you and I can draw a picture incase verbal description isn't making translation from Obummer Land to Bluegrass Ville.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:56:12 PM
Quote:
Originally Posted by Cudakidd53 View Post
Hey Big D-

Are you considering any louvres in front to deflect debree from striking the cooler? We used a homemade grill of them running horizontally to block dirt and rocks racing dirt track- air bent the corners, hard stuff did not. Easy to spray mud off of flat surfaces, not radiators! Side view of them had a high horizontal plane, ramp up 45 degrees, down 45 degrees but past first plane down to a second horizontal plane. All of these viewed from the front prevented seeing all but a thin line of radiator, with each louvre about 1-2" apart.


Let me know if it interests you and I can draw a picture incase verbal description isn't making translation from Obummer Land to Bluegrass Ville.

Yea, Mike I did give it some thought, but decided not to do anything. First this is not a dedicated off road machine, just one that is hardened up a little. When I have gone off roading in the past, not all that much mud was blown onto the roof, let alone any that would get "Sucked" into the opening. This thing has no suction as it were.

Mud would more likely fall onto the top as in descending after being splashed. The cooler is between 4-5 times the size of the stocker, so a lot of it could be covered and still do at least the job of that stocker. Finally, the stock cooler sat in the path of mudville. Nothing but a grill opening to impede the entry of debris, and the W250 was designed to be an on/off road work truck. So, no, me thinks louvers would be overkill in this application.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:57:41 PM
Quote:
Originally Posted by BobbyB View Post
How heavy it the rack? What do you think the finalized weight will be? Pre load out and post loadout? Just asking, since I don't want to see it go down the road of TacTopper. But I'm liking the design so far.


It's getting heavier. I'd guess from having to move it around, that it is currently in the 95-100 range. It only gets a laminate lightweight floor, a couple lights, some tabs, and paint to finish it, so it is more or less there in the current configuration.

As far as additional loading. Well, I always throw the lightest stuff up on top just because I don't want it falling on my knoggin when I finally need it, so maybe 50 pounds more and call it a day...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:58:45 PM
Speaking of cooler, that's all I had time to mess with today.

I had to spend hours on this, but now Mr. Cheetah is ready to destroy some serious vegetation.
This machine is serious. 34 HP and a top speed of 16MPH, but that's on level ground. GO down hill and I'll bet it can hit 25...It's a screamer. It will wheelie just by taking off too fast. I need (Want) to put some Harley shorty mufflers on it!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 01:59:31 PM
Then no sooner I get started on the rack, and Jake the psycho dog from down the street shows up. He eats, and drinks at my place, plays with my mutts, tears up something then leaves fast as he came...Weird dog
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:00:06 PM
So today, I picked up the floor material and wanted to build in the air ducting for the cooler.
Using aircraft .025 aluminum I marked out the pieces
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:21:10 PM
Then cut them out with the big shear
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:54:00 PM
That went pretty quickly
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:57:04 PM
Before the ducting is added:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:57:38 PM
The top piece goes in first
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:58:37 PM
Hole by hole the piece is drilled and cleco'd into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 02:59:51 PM
Then the right side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:11:41 PM
Then the left side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:12:41 PM
I may add an extension to the left side, should I decide to retask that 20" light bar to the rear of the truck and add in an eight light, 8" lamp to open up that space in front of the cooler intake.
I guess, I'm pretty much deciding on doing that...

But here is the thing prior to removing the plastic and riveting it together. I plan to build the duct as a one piece affair which screws to the structure with some 10-24 sheet metal screws. That way I can remove it for maintenance and cleaning of if it gets buggered up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:13:20 PM
And this is how the whole thing sits tonight, the end of a very short build day 131
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:15:21 PM
OK, let's finish up this oil cooler cowling.

Here is the progression of that thing through riveting and the acid etching primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:16:05 PM
I gave it four coats of the Vietnam and later OD Green, same as the prefilter top
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:16:56 PM
The goal today is to get the fab work completed and the composite floor built, and hopefully completed, although I didn't quite get it there

Next, I welded in a bunch of mounts for the soon to come floor which might carry some weight like my posterior, so I want that sucker bolted down well!

Here are some of the mounts constructed from simple angle iron
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:17:57 PM
Then I mocked up the oil cooler fittings, lines, and t-clamp to help me see how things were going to fit for when I made up the floor piece
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:18:51 PM
next in queue was the area illumination lights. Here is how the right side one mounted up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:20:19 PM
And the left one

IO tried something new this time...bending square tube in a circular die...

I think it turned out OK
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:21:20 PM
I think I figured out how to create cheap grab handles as well!

With the paint dry on the cooler cowling, I checked that for fit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:22:37 PM
I think the design could be improved with some sealing foam, so two strips were glued in to keep everything snug and the air channeled
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:23:50 PM
That will work, that one's in the bag

Next, the floor.

I said composite because I will be using a wood core surrounded by multiple layers of fiberglass cloth and resin and over coated with bed liner. I feel this will be both strong and light weight

I laid it up and thought it was close enough, so this is done as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:24:52 PM
OK, well a little trimming was needed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:26:27 PM
Some additions, and some more trimmings
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:29:28 PM
I laid out a single piece of 12 oz cloth and applied the resin.

It will get a layer on the underside, and another on this side at a minimum
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:30:30 PM
The rack is awaiting final welding, and tapping of the numerous #10 X 24 holes for the air cowling
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:31:33 PM
And that, my eager lads, is the end of build day 132
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:34:07 PM
OK enough Buck Rogers...

Anyone even know who Buck Rogers is?

Admittedly well before my time, but sort of iconic...

OK, tonight's update is boring. Just a lot of worky labor. I nearly got the platform thing done and finished up the welding along with modding the LED light mount and adding a spiffier light unit.

So first up was grinding and sanding to get the platform ready for the next couple layers of fiberglass and resin
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:35:00 PM
That hand grinder with a #40 grit wheel made quick work of the excess glass cloth and high spots

With that done, I laid up a layer on the opposite side completely encasing the wood inside the glass
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:36:25 PM
After some sanding to roughen up the surface again, I laid on 3 more layers of glass cloth to the bottom side.
This lumpy looking mess will sand smooth as a baby's butt and be ready for primer in the morrow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:37:10 PM
And here it is a few hours later having hardened up, but still a tiny bit tacky in a few spots. I'm giving it the evening to set up completely. I am using long drying time polyester resin this time to give me plenty of working time with the cloth
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:37:42 PM
As I discussed earlier, I decided to go to a different design light to unshroud the opening for the transmission cooler. Here it is just sitting about where I want it to be
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:38:48 PM
I trimmed down the mount as well and welded up a 1/8" X 3" wide backing plate. The light bar mounts on welded in studs like before, so all in all, it should be about bullet proof as I could ask for
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:40:03 PM
Then for the next couple hours I welded every joint and connection. Now all there is left to do is drill the holes for the floor panel, do some grinding to clean it up, wire brush it then start the painting.

This rack will get primer, then either John Deere Blitz paint, or bed liner. I still haven't decided. The bed liner would hide mistakes and match the roof, but having it painted semi-flat black would be a pleasing contrast to the roof, and match the hood.

Yes, the hood is going to be semi-flat black, not OD green to reduce the glare, especially from those roof mounted lights.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:40:44 PM
And here is where it all sits tonight, the end of build day 133
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:43:59 PM
RIB

(Racks I built)

The Yota rack was sprayed with rhino liner. It failed in about 5 years. Whitened, cracked and started peeling off

The H2 roof and deck racks were sprayed with the duplicolor bed coating and for the time I owned that vehicle, it remained G-T-G
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:45:05 PM
Quote:
Originally Posted by BobbyB View Post
Now a question.

When you finally install the rack and the lights are mounted are you:

A. Going to run individual wire harnesses for each light?

B. Going to run only one wire harness and have all the lights tied into it, but with different switches?

Just wondering since, I will be adding some extra lights to my XJ, since I didn't sell it.

A. I plan to wire the owl's eye to the high beams of the headlights. I switch the HB on the OE comes on as well

The LED's will be wired to a switch labeled "Scene" meaning Scene illumination. That switch will activate the light bank on the front and both sides of the rack as well as the 20" light bar in the back which will serve as a super back-up light. It will also function independently with the back up light circuit through a diode which will prevent the power from powering the rest of the LED's if power came from the back-ups

I guess I'm answering all this in "A"...

After the thing is all painted up pretty like, I will mount everything and build a plug in harness. I purchased weather-pak connectors for every accessory up there and a couple extra for future growth. I plan to build a harness which will secure on top, then plug into a panel that will fit where the original bed illumination light lens was. I make up a steel patch for that, run the pigtails out of that, then you simply push weather tight wire connectors together and voila' you're, as they say in the movies, "All hooked up!"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:46:58 PM
Last night's update, which turns out to this morning's update is one that will look a lot like the one from yesterday

I finished laying in glass, adding 2-3 more layers of glass sheet onto each side of the floorboard part.

All it needs now is some smoothing then it gets sprayed with bed liner.

Mike, you were thinking it might slide around, but with it being bolted down in 10 places, I'm not thinking so
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:48:04 PM
The piece with the first and second layers set up before smoothing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:48:48 PM
Last pic, previous entry, was the other side which gets more layers as well

Here it is fully layered up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:49:32 PM
Last pic, previous entry, was the other side which gets more layers as well

Here it is fully layered up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:50:13 PM
Then I quit for the night...

Yep, no consideration for you needs to see useless pics what so ever...

Ya know, time for you people to develop your own lives

Make some of your own pictures of twisted metal.

Granted my favorite variety is the kind caused by 105mm high explosives, but this is presently working for me.

Git yer semi worthless collective butz out there and make somethin' And please make it quality. No more threads "Guys, should I paint my chevy badge black?" of getting into major mods, LED back up bulbs on order!

My wife says I need to work on my empathy for people...I'm trying...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:51:32 PM
On the way out of the door, just before I dropped the willie pete grenade, here's what state the mess had developed into:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:53:43 PM
Big work day even with it being Samstag!

Here's the situation I started with

Everything hardened and cured just like advertised
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:54:48 PM
The floor plate got a super-duper sanding with 40 grit on both sides to prep for the primer and bed liner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:56:15 PM
Then the never ending cleaning started. I had to use the wire brush with a 2.5" cup all over the whole thing. That led to some more grinding and yet more wire brushing. I went on until my back was sore enough to start to complain about...I don't like to complain, so that point was good enough!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:57:14 PM
Then I washed the steel several times with solvent and liqueur thinner to get all the oil off
THis pile of rags was from just the front!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 03:58:58 PM
Then I drilled holes into the mount angles, and clamped the floor into place, then drilled those holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:00:21 PM
Flipped over it looks like this:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:01:17 PM
Then after constructing an "A" frame I hung everything up in position to paint
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:03:18 PM
Here's the first of two coats of the yellow acid etching primer. I feel this is an essential step to prevent rust and add longevity to the final coating. Layering of quality products is what you get when you 1. Do it yourself or 2. Pay a really lot of money, then watch them to make sure they actually use the stuff!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:31:03 PM
Next I shot a total of three coats of epoxy two part black primer.

It all by itself could serve as a top coat, but I am just looking for a good foundation for the bed liner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:33:57 PM
Yellow disappearin'

Black coverin'
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:34:39 PM
The floor got some epoxy as well, although it really did not need any...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:35:27 PM
Primer complete
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:36:28 PM
Then one can of U-Pol Urethane bed liner from the "Shutz Gun"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:37:58 PM
That's a keeper!

Especially considering you'll never see it. I suspect that panel will do it's job well into the future without much fuss or complaint

Next, I chose this epoxy bed liner product from Duplicolor to finish the actual rack.

It was easy to work with and to my surprise, no matter how thick I sprayed it, the material flowed out pretty smooth
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:38:43 PM
Here's the floor after some drying time...although not completely set up at the time of the photos
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:39:47 PM
Same-Same with the steel rack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:42:47 PM
Here's some pics of the morning after:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:44:20 PM
The Bed Liner used on the rack is a Duplicolor premium water based Epoxy

Yea...

Got some tree hugger half-man stuff on there

Didn't notice that until I read the can...after having sprayed it

So, even though it turned our fairly uniform and smooth, the jury is out with respect to it's toughness.

It might me tough in the same sense as the halo 3 rangers...they think they are tough, but in reality the average fat girl can take them out with one arm (And that is a major concern because I don't know if Kintucky is unique in this respect, but there are a LOT of fat girls here...!!!) (Get it...LOTs of fat girls)

The urethane stuff is fairly tough whereas I have found the epoxies are tough to a point where their surface integrity is exceeded, then they fail miserably.

Well one added bonus is that if the rack scratches all up and rusts, then the resulting rust streaks will help cammo up the truck!

Have to rename it, hmmm, thinking, "Junkyard warrior"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:45:50 PM
OK lots to post up tonight so let's get busy

I started by getting the rack onto the benches so I could work on it

The plan will be to build it up while it is off the truck, then hoist the finished assembly up and set it in place all permanent like
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:46:54 PM
Next, drill out the mounting holes for the floor piece, to get that temporarily bolted up so I can run everything else
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:48:07 PM
Then all the holes were tapped for the cooler shroud to 10-24 machine screw thread
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:48:55 PM
Then Oil cooler gets installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:50:01 PM
Then it's cowling. I ordered some stainless screws which haven't showed just yet, so I'll revisit this step later on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:51:03 PM
Then Duane's Owl's eye housing was installed with stainless, button head screws
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:52:22 PM
It will be important to make sure everything is grounded well, so I fashioned up this ground cable that goes from the common ground stud to one of the roof mounting bolts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:53:38 PM
Then I mounted the spot lights and started on the wiring harness
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:54:36 PM
Those plug in connectors were then removed in favor of my weather protected harness ends
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:55:35 PM
They build up fairly easily
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:56:15 PM
Those steel pins are inserted into the plastic connector making the world, one with goodness

Next the front LED light was bolted in place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:57:23 PM
Then one of those weather-pak ends installed onto the LED harness

The idea is to make everything so that it can be easily removed for service and plug into a central wiring harness that I am about to build.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:58:01 PM
Then the side illumination LED lamps were bolted in place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:58:42 PM
As soon as I bolted in the right lamp assembly I noticed a problem
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 04:59:28 PM
Yup, that oil cooler line wants to go straight into the lamp, so either the line has to change or the lamp needs to move.

I found a #8, 45 degree fitting that solved the problem
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:00:03 PM
Back to wiring

The spots got their connectors and that plugged into the growing wiring harness
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:00:35 PM
Wiring harness build out so far
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:01:21 PM
The ends that came on the LED's were cut off so that the weather-pak connectors could be attached
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:02:48 PM
Fast forwarding some, those ends were created, the harness connected, then convoluted tubing placed over the wires. That was zip-tied to the inside of the upper tube
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:03:42 PM
The harness ended in a 4 hole pigtail utilizing 2 holes for now that will allow for future growth. THe single line/plug is for the aft 20" LED lamp
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:04:15 PM
Still have a bunch left over!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 13, 2014, 05:05:09 PM
Some views of the build out so far
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:03:13 PM
Next, I'm going to find a place for these:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:06:01 PM
This a typical load with a Rubbermaid action packer and a couple water cans.

In all actuality, I doubt the H20 cans will get up there because they tend to move the CG north a bit too far for my liking. But I wanted some sort of a pattern to use to place the tie down rings where they might be useful
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:07:13 PM
Those items resulted in the rings being positioned here:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:08:34 PM
Drilled in and bolted in place, a couple bolts were left out because they penetrated the frame, and I will need to remove the floor to install the rack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:10:23 PM
And here's the mess at the end of build day 136
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:11:09 PM
From streetrodchev:

Don, why not run the wire harness on the bottom side of the rack? It would be better protected there
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:11:57 PM
From FBJR:
Quote:
Originally Posted by streetrodchev View Post
Don, why not run the wire harness on the bottom side of the rack? It would be better protected there.

First thing I thought of too. Not exposed=less likely to damage.

Run the cooler lines straight back under the deck too. looks like a natural.

Will your tractor lift that thing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:13:21 PM
OK, here's today's progress

First acting on that great suggestion yesterday, I moved the wiring harness to the inside/underside of the rack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:14:07 PM
That was a great idea. it's much neater looking and everything is now well protected
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:15:15 PM
Next was prep for the big lift.

I pushed some heavy weights in the gym today, so I decided to just lift the thing myself, and it worked

I prepped the area first. THe floor was placed to be in a good spot to catch me if I took another fall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:16:03 PM
I prepped the cab with some heavy thick blankets, some plywood and a couple 2 X 4's
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:16:44 PM
Then with a single clean and jerk style lift it was sitting on the roof!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:17:15 PM
Then little by little I screwed in the bolts and pulled away the blankets and plywood
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:18:07 PM
I used stainless steel washer head 3/8" bolts to secure the rack to the roof hard points
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:19:05 PM
All the welding had tweaked the rack a little, but after bolting down the fit is pretty good
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:19:59 PM
I still don't have the button head screws to hold the floor down, so I temporarily bolted it with three fasteners to keep everything honest
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:20:56 PM
It almost looks like it was custom built just for this truck!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:42:43 PM
I think the proportions look about right. I thought it might get a bit too tall, but now that I see it up there, it's just fine

OK, next up, let's connect the oil cooler lines
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:43:39 PM
Following the same excellent advice as burying the harness, I followed suit and ran the oil cooler lines below the rack floor.

I have to admit it turned out much better than the way I had envisioned

I was working with a selection of AN#8 fittings
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:44:24 PM
The best way I have found to cut this hose is to first wrap it with electrical tape, then cut it with a chop saw
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:45:02 PM
Then after a short visit to the vise, hose #1 was assembled
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:45:32 PM
Then installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:46:06 PM
Then the second hose...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:47:02 PM
I used those plastic T-Clamps to isolate the hoses and prevent chaffing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:47:42 PM
I'm pleased with the sanitary installation. Techy looking but not over the top
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:48:42 PM
Quote:
Originally Posted by lutzjk913 View Post
coming along nicely.

whats next on the list?

Today, probably window seals, windshield wipers, rust proof spray and some chorsey stuff

Need to get the bed back on so I can free up some floor space.

After that, the engine comes out, since the new P-Pump 12 valve motor is nearly finished. I was lucky enough to find it being rebuilt, so I got to pick certain things and modifications to build it right the first time.

When the engine comes out, well so does the trans and transfer case. I'll overhaul the transfer and now, since I found someone within 100 miles that specializes in these old A518's I'm likely to drive the carcass up to him and allow that to be farmed out...Not sure though as I'd like to learn how to do that meself.

Of course while the trans is out and being altered, I plan to detail out the motor and rebuild the alternator, add a generator, rebuild the starter, and paint the Cummins.

I'll also start the next big project, the front suspension and steering conversion. That is a biggie...

Tate and I are discussing changing the thing over to 4.10 gears, adding a front locker, 35 spline axles and those super duper hubs he sells.

Seems I am doing some (Most??) things twice. Should have said at day one, "Mission statement: Build the most rad, low tech militarized/survival/expedition square dodge truck in the world."

If I would have admitted that simple truth to myself, I wouldn't be reopening things already closed up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:51:24 PM
Quote:
Originally Posted by FBJR View Post
You sure about that 518 Don? I am leaning towards the 618 (47rh) after doing a little more research.

My 91 setup is nice with the 205 and all. But the 7100 motor with a 618 lockup sounds so much better.

JR,
Doesn't that 47RH have some electronic circuitry for the lock-up part of the converter? I know the 47RE is an electronic transmission so it is definitely a NO-GO, but although I am not sure, somehow I'm thinking there is a transistor, resistor, diode or do-dad livin in side that 47 trans.

Secondly the torque converter for the lockup design is more complicated and anywhere from 2-3 times the cost of the A518 unit?

Finally, the A518 can be made as strong as the strongest 47RH, so all one is really sacrificing is a little gas mileage and having to deal with some more heat production from the older A518. I added that big trans cooler and will add a 55 gallon deep pan just to deal with the extra heat.

I own a 518. I would have to buy a 47RH. People think the latter trans is gold plated whereas they treat the 518 like scrap cardboard with respect to price. The 518 accepts many of the 48 transmission parts so it can be modernized easily and do all that without needing electricity...

So, that's my argument for staying simple. That and the concept works harmoniously with how my brain works
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:53:15 PM
Here's some pics of the 12 valve motor going together

It is a 1995 P-Pump 6BT
Overhauled to zero time
Modified with Marine pistons
Dowel pin corrected
60 pound valve springs
Comp valve job
Head shaved (A little)
ARP head studs
4000 RPM governor springs
Cut delivery valves
Modified fuel plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:54:47 PM
Pistons are nice!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:57:00 PM
Can you believe I'm 60 today!!!!!

Should have bought the farm in Korea in 1987 when we flew through wires and crashed
Should have been killed in Just cause when a .50 gunner lined up on me and opened up
Should have been killed 45 minutes into the start of Desert Storm when three surface to air missiles all missed, but we crashed anyway getting away from the last one
Should have been killed in Baghdad when I was dumb enough to get into an IED explosion on the ground with my helicopter which was W A Y too close to the fun and games
Should have died maybe a thousand times in Afghanistan when the snaps of bullets passing by all missed their mark
Maybe I could have died on the operating table a few times when Armee surgeons fixed stuff that got broke
Or up at the Swangunks when I held the rope that was tied to my brother who took a big fall and pulled me over the edge as well (Glad that little pine tree I was tied to held!)
Could have died when I rolled over my Merc Cougar, or when my buddy rolled over his GTO with no seat belts, or when I parachuted into the bay near flordia during water survival training...Got tangled in the parachute chords and my life raft didn't inflate.
There were a couple gunfights, a couple bar fights, and of course my wife who could dispatch me in an instant for doing any of ten million things punishable by death...like not screwing the lid onto the toothpaste...stuff like that

But look at me, I made it
6 decades
Fully twice the age of more than half the readership here, bless your little star mag hearts!
I made it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 12:58:49 PM
OK, let's get a bit more done on this truck

The engine assembly continues. I will be placing it on a Harbor Freight 2K engine stand and dressing it all purdy like, then reinstalling it.

I am continuing on the JMVI (Jap Maple viewing initiative) which is associated closely with the PDI (Parts reduction initiative)

Basically that all means bolting on parts that have been blocking my view and cluttering the benches

With the truck painted, time to bolt back on the door stuff

First up: Mirrors

But with them being all shiny, I first had to make them black
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:00:02 PM
Before going on, lets play parts and tools a bit

I didn't like setting my gloves on fire (With my hands inside) any longer so the spark maker extraordinaire, the chop saw is being retired

This evolution cold metal 14" saw is the newest thing. It uses neon light and radioactive matter to bisect steel!

Well, actually it just cuts through steel with a tungsten carbide saw blade that lasts several thousand years when cawing jap kars apart of a couple days on a chevy!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:14:28 PM
And I got another shipment of kool stainless hardware from "The Nutty Company" a great place to buy small amounts of this sort of thing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:15:24 PM
That allowed me to bolt down the roof rack floor for good
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:23:04 PM
Back to the doors

While the bed liner substrate matrix composite compound was hardening up, I went to work on the window felts and seals.

The door glass gets a total of four seals. an inner and an outer felt at the bottom. A felt channel forward and a wrap around rubber gasket/felt covering the other tow sides

Here is that big stuff going in:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:24:14 PM
The forward felt folds into the channel making the door glass all warm and fuzzy
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:25:00 PM
Great fit eh? (that was for all you frozen Canadians)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:25:32 PM
Then after a fine adjustment:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:26:12 PM
Der felts:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:27:10 PM
That last pic shows the outside felt sticking up, but it isn't on the truck

Photo must have been shopped by the CIA or something

Time to use up some of that dynamat sound deadener
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 01:28:09 PM
The stuff is easy to install
Cut
Peel
Stick
Roll

or

CPSR for short
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 02:59:23 PM
Next up, why not reinstall the door panel

By doing so, I re-exposed a pic of the old Tundy that was thought to have disappeared!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 04:52:56 PM
I can't find the door handles!

I put a call into the university of Kentucky, archeology department. They will send out a team to sift through layers of dust and parts on the benches and possibly uncover the missing parts along with some bones from a pterodactyl!

Next I bolted on those mirrors.

I'm not so keen on them at this point

If new ones in black do not exist, then they are safe. If parts are available, you might not want to buy stock in these parts just yet...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 04:55:13 PM
It is looking like I can get some help on Thursday to get the bed lifted back onto the chassis.

I fear for JR's blood pressure should this take much longer...

Got some more work done, but not a lot.

I probably should have done this earlier, having pulled the door glass, but, better late than never.

I polished the glass bring it back to a new like appearance from the pitted, over sprayed cloudy thing it was.

Looking better...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 04:56:29 PM
And, yes the window rubber/felt is a bit warped, but that's the way it was sent to me, so I'm trusting with exposure to the elements (Sun) it will straighten out

I finished up the passenger door as well. It got the same treatment as the drivers door
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 04:57:22 PM
With that dynamat on there, all you get is a dull thud when tapping it now. No tinny resonance sound at all...

Then I sez to meself, me sez, "Hey how's come these old trucks only have a single rubber seal on the door while the newer trucks have a double or even triple weather-strip seal??"

I didn't answer myself right away, cause I was wonderin' where that all came from??

Anyhow, there is this neat self adhesive rubber weather-strip I found at O'Rileys so I ran a strip of it up the inside of the door frame where it would rest against the inside of the door

It fit well!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 04:58:35 PM
Well if it fit there that well, maybe it would fit around the rest of the door as well!

So I stuck it in there about where the vertical rise on the door frame ended, continuing around to the front of the door
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:00:11 PM
Nice fit, eh??

And now the door shuts with a thump instead of that cheapo Dodge sounding tin can closin'
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:01:02 PM
Well, if it fit well there and stopped the cheapo rattlin' dodge sound, maybe it would work on the tailgate as well...

It did!!!!!!!!!!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:01:43 PM
Next up, I finally took possession of the Donaldson top spin precleaner for the snorkel.

This gem features a spinning air stream driven impeller which sweeps the dust particulate out the aft facing vent. It is something like 96%-99% effective in removing dust from the air travelling through it!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:03:15 PM
Lets look inside

We can see the impeller and the simplicity of the design
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:04:21 PM
So I mounted it up and called it done
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:09:42 PM
I also had the silicone "Hump" hose and some new clamps taking up space on the bench, so I threw them on as well

All I need now is that fender with the Duane named, "Franken Snorkel" and it will be an assembly

And yes it fits with the door open as you can see
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 05:12:06 PM
OK, movin' on. Next I rejoined the door speakers to their harness. Earlier I had cut the harness to simplify removing the door, now it was time to make that all better. I wired in one of those neato electrical connectors on each side just in the event I ever have to unbolt the door again.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:00:20 PM
Seems to work either open or closed...And no sparks!!!!!!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:01:24 PM
Since I was in to connecting things, I decided to connect the hydraulic lines on the back of the cab to the transmission.

TO do that I selected a good place to cut the lines. Here's the spot:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:02:01 PM
When I was pulling off the cooler line, I twisted the fitting in half

Hmmm, don't know my own strength...

No biggie, that trans is coming out to be rebuilt, I'll fix it when I rebuild it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:03:03 PM
After cutting one of the lines, it yielded a nice little elbow, which I will clean up and use to build my new live from. First for the compression AN#8 fitting
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:03:43 PM
And of course the rust converter and the John Deere paint
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:04:42 PM
The lines will no longer run forward, cluttering up the front end, so I removed and discarded them. I pulled the oil cooler as well. It is good and of great quality, so I will retask it as a power steering fluid cooler
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:05:26 PM
What was removed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:06:05 PM
That cooler is way smaller than the B&M unit which replaced it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:07:02 PM
Then the other line was built up with an AN-8 end
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:07:42 PM
Raiding the hose end drawer in the hardware bins produced everything I was going to need
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:08:41 PM
Using a measured length of AN-8 hose, I made up one of the lines and loosely screwed it into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:09:44 PM
Here's the other new line recycling part of the old steel line
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:10:14 PM
And here, both lines are setting where they will live a long useful life
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:11:04 PM
Those lines will get a bracket that will rise from the adjacent small hole in the frame to keep them from actually touching anything and chaffing

I added some juice to the electrical system and fired up the lights.

THe Owl's eye assembly melted a hole in my garage wall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:11:45 PM
You can definitely NOT look directly into the front LED light bar. Those little bulb thing-ah-ma-jigs are pretty liberal with the lumens.

Oddly though the side LED's did not fire up!!!!!!!!!!

Heck with it, I'll cipher on it tomorrow after I get back from lifting...Gotta be some snafu in the wiring somewhere.

I left the trickle charger on the interstate battery for the night and went in and finished up my pot of Don's spaghetti. The pre-Rangers made short work of that stuff!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:13:04 PM
Quote:
Originally Posted by FBJR View Post
Gotta love those "weatherpack" connectors, good work.

I can't believe that cooler would do any good at all for that 518. That one picture reminded me I need the inspection plate for mine!

What goodies do you have in mind for it. I have a read up on a few rebuilds and there are a couple shops with easy driving that work on them here. I figure a good TC and HD build with shift kit at minimum.


I'm going to have to go full tilt on the A518
Triple disc converter, best (and extra) clutches...strongest bands, valve body rework, billet parts everywhere, 55 gal pan.
I'm figuring 3K-4K in parts with me possibly doing all the labor, just to learn it.
I think I'll build it to something like a 1000HP standard, if there is such a thing, then know that it will be able to withstand a sudden stoppage event with 600HP applied.
I just want it not to break when I, or someone I care about, might need it the most.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:13:49 PM
Quote:
Originally Posted by Cudakidd53 View Post
I stopped to mentally review all that you've done to Square-D so far; WOW! I REALLY cannot imagine how Duane's gonna top you on his Double-D build........maybe more direct in his approach (not calling it a fluid change), but more thorough?


It really is starting to look awesome! Plan ahead to the day when you actually fire that motor up resting in its new home- we'll want a video clip with sound!

Thanks for the daily fix!

Duane and I are not in competition
He will not try to "One Up" me...What's the purpose??Bragging rights?
Hell, I surrender those right now. That's kids stuff, adolescent thinking.

I suspect he will produce a well thought out clean conversion that tends toward the conservative side and closer to stock in appearance. That's what I would do with such a classic. I'd probably even leave those ugly colors on there.
The beauty is in the detail. Not in the macro. That is why a late Chevy with a lift kit and star mags is a rolling billboard stating to all the world something about the length of a falace. But if you dig and see flipped shackles, long travel this or that, tricked out and crafted things everywhere, then you're onto something real. And those builds are like pearls...one in many thousands.
Not much imagination nor creativity in today's hot rodding/car crafting crowd.

Duane, on the other hand is a master at the detail, much better than I am. I could be the same, but I am not going to perplex an entire season over the chemical composition of a vat of copper sulfide used to do the first step of plating on a single screw on his dash. He on the other hand will also know the name and have obtained the high school transcripts on the boy who mixed that chemical bath.

Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:14:58 PM
Quote:
Originally Posted by KensAuto View Post
Just for you. Now I've got to go back to work!
http://www.duramaxforum.com/forum/2748810-post7043.html


Thanks Ken, that's perfect!

Here it is for the rest of you common rabble..

Duane, my friend:

For those of you who don't know Mr. Duane and that's everyone, well allow me to splain a few things.
Duane looks at everything as he is examining a new ailen life form. He is detailed oriented to the point I feel like beating him after discussing how to tighten a bolt.
You see, I just tighten it. Duane reads and studies the metallurgy. Was it Brazilian iron or melted down jap kars?? He learns about the company that zinc washed the thing, and finds the unit price the manufacturer paid for it, adjusted for cost of living of course. He then calls a few people, posts up in some bolt forum, and builds a folder with all the information he can on the thing. Me, well, by now I'm glassy eyed and thinking of a second way of killing myself!
Now satisified that he knows enough about this bolt and how it might be viewed by changing EPA and OSHA standards, he selects a torque wrench.
His are sterlized in an autoclave and calibrated by NASA. They are manufactured using a secreative process by captured German scientists and prayed over by tibetan Buddist monks.
After consulting his Almanac for the exact time of the day when the solar system is at the greatest point of balance and the air quality is optomized, he selects his operating room attire and enters the temperature controlled environment of his garage where nary a single microbe that he doesn't know about survives. The item to be bolted together is placed on a dead flat New Zealand granite plate and aligned to true north. The wrench approach angle is calculated and he brings the torque wrench to with 1.565432345" of the bolt. After controlling his breathing and checking the room temp to be an even 68.385 degrees he places the wrench onto the bolt head. About this time I open the door, trip, spilling my sweet tea all over the floor, and Duane passes out due to a heart stoppage. I walk slowly over to the defibulator hanging on the wall and examine it. Thinking Duane's still pretty young, I make a call or two, then finally walk over to his corpse, forgetting all about the defib thing and kick him in the chest. He wakes up with a sore chest and a bruise and I feel much better. We then forget all about that bolt and take off to a nearby gun shop. His wife calls us seventy three times and we do guy stuff the rest of the afternoon.
No sir, you don't want to see any of his tools, garage or anything else. Except for his vehicles, which for some reason to my knowledge he has never ever washed...Really!
Black hawk pilots...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:15:49 PM
Anyone ready to put the bed back onto the frame? (JR??)

Well I started by covering the thing with moving blankets so that the paint job would have a chance of staying intact
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:16:30 PM
To help with the bed alignment, I made up two 3/8" X 4.5" studs. One screwed into the bed mount itself, and it would make aligning the bed a simple matter of dropping the studs into their associated holes.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:17:08 PM
Duane and Dan came over and the three of us lifted it and carried it the short distance to the truck, where we set it onto the frame

That's when we discovered the bed and that cool water/methanol tank cannot occupy the same truck at the same time!

I removed the tank and that cool frame I had built and then noticed that the bed just touches the auxiliary electrical compartment I installed earlier.

I have a choice
1. Notch the frame of the bed right where it doesn't need to be notched
or
2. Add a 1" body spacer to the bed and to the cab as well to make things line back up

I'm opting for Door #2

The bed in all the pics will look crooked because it is sitting 1.5" higher in the rear due to it sitting on some 2 X 4 blocks for the moment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:17:41 PM
Here's those blocks
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:18:14 PM
Since I lost my rear water alchy tank, Dan who just happens to be an aluminum fabricator, is going to create a 1/4" thick tank to sit in between the frame rails and be strong enough to ride over a big rock
Cool
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:18:50 PM
The green tape indicates where the studs were supposed to fit to visually aid in the placement of that heavy thing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:19:58 PM
Quote:
Originally Posted by TexasRedNeck View Post
Now it's looking like a truck Don!

Cudakidd, check your PMs

And that's a good thing, because now the radiator support and all that's there comes out followed by the engine, trans and transfer case...

But when all that goes back in, it will be for keeps
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:22:43 PM
From Dustoff35:

I just had to point out a few similarities between some random items I noticed around your garage yesterday and some things I found in my shop:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:24:45 PM
From Dustoff35
Quote:
Originally Posted by FBJR View Post
Don, Just get a 3 inch dia. or so piece of poly off ebay and cut to depth. Drill your hole and you are done. Weather won't kill em, get it in about any color and easier to drill than rubber.


The trick to drilling rubber is to use a forstner bit on a low speed in a press. Forstner bits are common in wooodworking and leave the sides of the bore clean and with a nice, flat bottom, great for counter-sinking. I used these bits for drilling hockey pucks when I fabricated anti-vibration feet for my compressors. The feet prevent the compressors from moving around on concrete and dampens the noise a little.

The cost to make my own out of hockey pucks was a lot less than purchasing anti-vib feet from McMaster or Grainger.

Don, should you decide to go the hockey puck route, I have a full set of Forstner bits, from 1/4" up to 2-1/8".
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:26:23 PM

Quote:
Originally Posted by Yellow is Good View Post
Don, did you find the hockey pucks you wanted? Got lots up here is the great white north.

Yup!
I purchased 20 of them yesterday
and
A set of forstner drill bits over at HF
All I needed is to drill some rubber. If I need something better, Duane is always a short drive away

Didn't work on Square D yestertag. had 14 yards of mulch to get through. In 6 hours and several slipped vertebra and a couple hundred sore muscles, we made it through about 5 scoops of it.
You'll have to go back ten thousand or so pages in this at "My build Thread" to read about my theory on mulch piles.
Summing up, the stuff multiplies.
You might have say 11 yards delivered
You can spread say 6, killing yourself in the process
The next morning you start out with a pile of about 8.5 yards
If you allow sufficient time for the stuff to multiply itself, you can stretch it to 20 yards and beyond!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:27:25 PM
OK, got the body spacers installed.

I started with this bag of hockey pucks priced @ $1.59 ea.

And this seven piece Fostner drill master bit pack. They cost me $12.99 so this was definitely a low cost mod!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:28:25 PM
I drilled a sufficient number of them to slide over the 3/8 bed mount bolts and 7/16" cab mount bolts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:32:32 PM
Hardware stack up is simple. 3/8" bolt, lock washer, SAE washer and you're done. THe bolts I selected weren't much longer than the bolts the factory used
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:35:18 PM
Installation was straight forward and quick
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:36:31 PM
Here the bed has been bolted down. You can see the misalignment between it and the cab
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:37:13 PM
When I took the body bolts out, one of the nut plates in the cab stripped out
EEOUCHHHE!
So it took some time to cut that out, and weld in a new nut plate.
Otherwise raising the cab would have been a 20 min operation instead of a 2 hour ordeal.

Here the body has been raised as well, and the alignment is back in the green!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:38:01 PM
And the underside of the cab showing the pucks bolted in place and lookin' good!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:38:40 PM
Looking aft, everything is clearing nicely. I sort of wish I was not sitting as high, but that's the way this truck will have to remain to clear everything.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:39:21 PM
With the bed permanently attached, reassembly of all it's parts comes next

I had accumulated a host of LED light bulbs chosen because of their very low amp draw to replace the incandesce bulbs.
If we have an EMP event. I don't care if the taillights never work again, as the dawn of civilization would have passed anyway.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:39:58 PM
The wiring harness was fished into the tail light openings
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:41:00 PM
Then the standard bulbs were replaced with the LED units
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:41:39 PM
The LED tower is the very bright back up bulbs which will be augmented with the 18 element LED strip light yet to be mounted
Next up the bulbs were installed into the new tail light lenses
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:42:36 PM
The old rubber gasket was ka-put, so I sealed up everything with a bed of RTV silicone, then installed the lens
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:43:34 PM
The gas filler neck would not bolt up, so I had to cut it apart and start anew.

Using the old plastic spacer/mount. I decided to fab up a plate and use it to drop the filler neck a tad, allowing it to fit the opening
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:44:06 PM
Here's the piece I need to create
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:45:27 PM
To create that center hole, I first had to drill a 1/2" hole through which I could set a hydraulic hole punch
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:46:13 PM
A few quick pumps on the bright yellow handle, and the second hole was created
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:47:08 PM
The larger hole is required to clear the mandrel for the full size hole punch which will create the finished hole.

Here's how that happened:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:47:52 PM
Finished panel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:48:59 PM
This part will connect to the fuel cap panel on one end and to the filler pipe on the other
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:49:56 PM
I wanted to create a pliable gasket seal, so I applied a bead of silicone to the opposite mating surfaces and left the parts to dry overnight. Tomorrow they will become one and all that will get properly attached to the filler panel and finally get connected to the filler line and tank.
When that is done, I could add fuel to the tank if I wanted to
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:51:58 PM
Purchased the topper yesterday from Bill at MMM sales

I drove about a hundred miles north to near Lima, Ohio and met this mighty man of God. Funny but we talked about 10 minutes about the topper, I purchased it, then spent the next 5-6 hours talking about the bible, God, Jesus, our nation and related subjects. It was GREAT!
He would speak in bible verses sometimes. It was like a graduate course in interpersonal relationships with the creator, and I couldn't take notes fast enough.

Any way, I settled on a high rise unit he had in stock. He stock hundreds of used toppers for everything imaginable, even had a dog house looking one designed for the BlackHawk
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:52:36 PM
The beast of burden
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:53:12 PM
Brother Bill M.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:53:50 PM
Made it home, but only after the turbo discharge pipe popped off, and later on a rock hit my windshield
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:54:49 PM
It has some clear coat peeling, but after I roll on some latex house paint, it will be ah-ight
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:55:25 PM
It was local having come from nearby MMM toppers
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:56:06 PM
Not sure whose feet those were...

The thing still had the protective cover on the handle protecting the lock
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:56:44 PM
And it came off a green 1990 Dodge!

That's significant

You see 99% of all toppers sold in the day to Dodge truck owners were actually Ford toppers. Thing is, the ford topper hangs over just a bit and way back in the 90's, no one was as discerning as folks are today, so they got away with it.
You could however, order a Dodge-correct topper which gave a perfect fit and this is one of those!
I handed over $425 for it, but feel good about the purchase!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:57:24 PM
Here's the worse part of it:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 08:58:26 PM
The chebby is ah' lookin good!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:00:54 PM
Here's the topper getting pressure washed using a powerful detergent and 3200 psi
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:01:40 PM
The inside cleaned up like new. No need to do anything further, just leave it as is!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:02:19 PM
Inside the shop it will get the lights, an antenna, some pioneer equipment and maybe something on the top...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:03:20 PM
It won't stay this particular hue of green very much longer.

First up the rear LED light was installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:04:10 PM
And it clears the rear glass when it is fully open
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:05:11 PM
Before proceeding to the next fab job, I decided to get some paint on the axe and shovel I purchased for this truck. Off road and utility vehicles ought to have basic tools permanently carried by the vehicle in preparation for when they will be needed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:06:01 PM
That was just a base coat...I'll go back over the metal parts later on with some OD green

So, this truck is going to get a powerful CB radio. I think I'll opt for around 150watts. I plan to push that through a long antenna.

Here is what I will be using:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:06:48 PM
The coax cable is 18 feet long, a favorite length for long range communications on the CB frequencies.

I plan to fab up a dual position mount. Although the antenna has some flexibility, I want to be able to store it in a "Travel" position, then stand it straight up at times to be able to talk greater distances

Here is the antenna base stud mount I'll be building around
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:07:56 PM
TO do the dual position thing, I'll mount a steel tube inside another tube and drill some holes in different positions.

The inner tube will capture the antenna stud.

Here's what that looks like:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:09:04 PM
Through the magic of electricity and the rabid accumulation of sparks, this happened:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:09:38 PM
Then with one set of holes drilled through everything, I rotated the inner piece to the desired angle and then drilled through the same outside cylinder holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:10:18 PM
Producing this, the rotational mount part:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:11:20 PM
That 1/4" bolt will be replaced with a catch pin and clip that can be pulled and replaced as desired

Next I developed the base plate and positioned it on the left forward side of the topper
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 14, 2014, 09:11:53 PM
Then I tacked up the antenna stud mount cylinder to the base plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 12:55:22 PM
And checked the two antenna positions
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 12:56:24 PM
That looked OK, so I added the second support to the rotating cylinder

I also added a guard that will keep things from snagging the delicate antenna base
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:40:36 PM
Back to the pioneer gear for a second...The paint dried and with the 5/8" holes drilled these parts are ready to be fitted as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:41:58 PM
The antenna needs a place to store while in travel mode...that looks like this:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:42:42 PM
The antenna needs a place to store while in travel mode...that looks like this:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:43:17 PM
Other things that happened:

I shipped the power steering gearbox off to Performance Steering (PSC) to be rebuilt as a high performance unit complete with fittings to power a steering assist cylinder

The engine was finished finally
I'll be picking it up this weekend and getting it on the stand for build up and painting

And, I'm not through the process yet, but I just purchased (I think) another 12 valve P-Pump engine along with a 47RH 2WD drive transmission.

I'll have to see if that can be converted to a 4WD unit...If so, I'll have the option to go to a lock-up converter and reduce heat production...

That concludes build day 143!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:44:53 PM
OK, let's get busy on Square D once again.

Still doing a bit everytime to reduce the pile of parts on the bench, and I think I'm making a dent in that mess over there.

Today that initiative involved the wheel well moldings.

Time to get the back ones repaired and on.

As always, cleaning first, then sanding
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:45:24 PM
Then some paint:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:46:00 PM
 let those sit out in the sun for a few hours while I powered away on a zillion little tasks aimed at getting the pioneer equipment mounted.

Once all the ancillary items are mounted to the topper, I can strip it, sand it, then paint it. That is necessary before mounting it, and mounting it will yield floor space for the Cummins engine that is showing up tomorrow!

First on that front today, I finished the antenna hook to capture it while in travel mode
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:47:16 PM
Then came the axe head mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:48:09 PM
The backside of the bolt is welded to the mount to make it simple to just loosen the wingnut to get to the tool

I drill the bolts to fit a simple spring clip to keep everything where it is supposed to be
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:48:52 PM
And the aft Axe mount goes here:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:50:10 PM
The front mount is a simple 1/2" stud fitted through the side of the topper, and a hockey puck. I countersunk a hole in the puck to place a washer and the bolt below the surface level
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:51:19 PM
Pretty simple and uber strong mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:51:50 PM
I'd say that task is in the bag, time to move on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:52:42 PM
Next up: The shovel

Front mount first

The blade will face forward and inward, to ward off branches and poor quality jap car wiring harnesses
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:53:25 PM
Rear mount is same as we used on the Axe handle

What is now becoming standard as the hockey puck mount system

Think I'll use those pucks for the roof rack as well!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:54:01 PM
And with that, the shovel is all secured and time to leave that for greener pastures!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:55:11 PM
Those clips come from just about anywhere, but I like the John Deere variety. They don't seem to rust as badly as those cheapo jap tractor parts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:56:10 PM
Nearing the evening, the wheel well moldings were dry and time to mount

They came with hard nylon studs that had seen better days. I used one that was in good condition, but replaced the rest with more modern nylon units
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:57:44 PM
Then I scraped off the old tape and applied a new layer of 3M double sided molding tape. This stuff cost me $37 for the roll!!!!!!!!!!!!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 04:58:28 PM
Last look at the naked wheel well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:00:52 PM
And properly healed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:02:38 PM
The muted colors are working for me!

Now on to the udder side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:07:40 PM
And that folks, is a wrap

Build Day 144 in the bag!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:09:16 PM
Let's get started

On each paint job from start to completion in one installment

Here's the start, I stripped all the "Stuff" off the topper in preparation for sanding
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:09:53 PM
The top had a lot of the clear coating weathered away, so a through sanding was in order.
I feathered the whole thing with the orbital and #120 grit. One pad did nearly the whole top!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:11:00 PM
After the affected areas were feathered, the whole top was sanded a second time with #240 grit to get it smooth enough for the sealer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:11:53 PM
Next I cleaned the top completely
First by blowing it off with compressed air
Next wiping with a clean cloth and using a blow gun.
Then I washed it twice with prep-all, a solvent designed to remove stuff the paint doesn't need.
(Dam shame it doesn't work on politicians!)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:13:04 PM
Clean enough!
Next came the taping up of everything
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:14:10 PM
...and more taping, then I had to cover Square D with all our fine linen!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:15:07 PM
After a final cleaning, next came the epoxy primer/sealer
Last time I used black.
The paint company suggested red oxide, so I selected gray!
Makes sense, eh?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:15:53 PM
That came out fine. I sprayed the one coat the manufacturer called for and let it dry for awhile.

Then I mixed up some OD green 2 parts paint to one part reducer, and sprayed on the first of three coats
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:16:36 PM
Same GCI paint, synthetic enamel I used on the truck
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:17:14 PM
Then an hour later came the second coat
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:18:26 PM
The color was coming in pretty good with the second coat, but the third one iced the cake for sure!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:18:52 PM
Well, that was a complete day. a complete paint job with only about a forth of the top sanded before I started, and I even got in church, and a sunday dinner out!

But right now, I'm cooked

Time for my beauty sleep and the end of build day 145
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:20:17 PM
I think I finally figured out how to spray that paint.

This time I had no runs or sags. Not even a bug to commemorate the event!

Here's the pics from this morning @ about 11 hours drying time:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:20:55 PM
Next up, I'll have to paint up the fixtures that were created to hold the various things on it, then I might even paint up the aluminum...Maybe

After that, I want to create a 2 X 3 box steel frame to fit on top of the bed that this thing would bolt to. Reason is I will later be tying in the spare tire mount to it, and something like a ladder up the side in the back somewhere. Instead of always drilling into the fiberglass, and hoping it would carry the load, it would be nice to have something a bit more solid. Plus, it will give the growing pre-rangers a bit more headroom for when dad gets a little wild-cat with his off road drivin'
(Get it, Wild, cat...as in KY wild cats...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:21:39 PM
Originally Posted by sl2racer View Post
No one sees the top anyways..

I'm actually thinking of putting bed liner or no-slip paint on there. I might be crawling around up there, and was half way thinking of adding one of the Ashley supplied solar panels to the top and building a partial rack up there.

I kicked around the idea of adding a roof top tent to the topper...just toyed with the idea. The total survival package with respect to this vehicle is to build the trailer. If I make that thing right, it will have slide outs and a lot of ground clearance so that it could be a good bivouac spot along with having a decent supply of water and other essentials.

So if I proceed with that build, the roof tent would only be department of redundancy department stuff...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:22:27 PM
Quote:
Originally Posted by whatelsebutadmax View Post
Don, great work, I have been following your thread for a while and I saw this and thought it was interesting. Conqueror Australia | Conqueror Australia?s Urban Escape Vehicles are the ultimate Aussie off-road camper trailer built to travel anywhere
.

I was all over that about a year ago.
I went as far as to contact them about availability. THe trailers are actually manufactured in South Africa for the Aussies. They had plans to bring them to our left coast but with ridiculous DOT and EPA regulations, they basically said no thanks!

Americans probably have no idea just how much DOT and EPA hurts us as a country. Remember the excellent Land Rover Defenders? They are no longer sold, but guess what, they are still manufactured. LR pulled the plug because DOT mandated the vehicle turn in to the soft-core crop of 4WD junk we currently have and LR said, no, screw you, we'll just sell to the rest of the world...and they do!

There is so much that we can't do anymore because of safety Nazis and lawyers who drive the legislators through big law suits. If Jeep tried to build a CJ today, ala 1979 like my first CJ, it would be outlawed. It would have to be lowered have a myriad of electronic systems overlaying it, tripling the cost and glove leather so the seats didn't offend our fat American tushes...

Yup, no real man conqueror coming here anytime soon!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:23:24 PM
Quote:
Originally Posted by OVERWATCH_09 View Post
IMO, the tipping has already been reached, we're just along for the ride at this point.

Concur!

Symptoms: Kenyan born foreign illegal alien married to another male person (Check that out for yourself...) elected and reelected for a second time
Media silent, awaiting the messiah to make it all good
Debt that cannot ever be paid off, currently 400K for every man woman and child in the US
Constitutional rights violated almost routinely
Christians shut down at every turn
Abortions selling like M&M's
Military on board and endorsing gay lifestyles
Normal military leaders currently being purged
in favor of Kool-Aid drinkers
Government direction closely resembling 1935 Germany
Moral fabric of the nation makes us look like Sodom and Gomorrah
2nd amendment abolished by Maryland and New York, and coming elsewhere
And that is largely unchallenged!
Legal Americans forced into buying insurance, and still can't get it
Whereas
Illegal aliens, criminal mostly get free healthcare
Descent Americans under attack by freaks everywhere
Normal is now in the minority
Federal law enforcement in Nevada suspended 1st amendment rights!
Illegal land grabs
The few and powerful and corrupt of government, now openly using their authority to stifle law abiding citizens
MRAPs taken from the Armed forces and given to Homeland security
Police everywhere are militarizing
Our rights under attack at every level
Socialists have obviously gained or been appointed to key positions of power
We have abandoned the British and Israel
We host Muslims as if they were our long lost cousin when they are nothing more than a huge cult with major money
Our kids have to pray outside of their schools, but learn about Islam inside
and the coup-de-gras
China is buying 145 tons of gold a month!
Why?
To back up their currency and make it the world base currency replacing the dollar
which
overnight will completely destroy our economy
Ruin the dollar
Cause martial law to be called
Probably cause OB and the boys to ask China or NATO for help
which
Will get us occupied by foreign troops and destroy our republic permanently
That will precipitate the greatest revolutionary war the planet has ever seen and
if I'm right leave us in a couple years with 1/6th to 1/10th of our population remaining and have us subjugated to our new rulers until the second coming.
That's how I see it,
But, hey
I'm just an old soldier
What would I know?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:24:20 PM
Menses,
I've been busy as a one armed paper hanger!
Have family visiting, mulching, had to cut back all my rose bushes...The winter nearly killed them.
Did I mention I'm spreading mulch again??
I have made headway with the bed top frame. It's maybe 80% complete...Could go into paint tomorrow

Engine is finished
Plastic pin broke during final timing and fuel pump installation.
That is repaired
Just got the 2K engine stand. Hope to take delivery of that beast Tuesday
Pics coming
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:25:03 PM
OK, for the weak amongst you
Most/all of you
Who couldn't wait another day without exhibiting anxiety symptoms
Here's a bit

The project at hand in this Bed bone is connected to the topper bone is connected to the light harness bone is somehow connected to the front suspension bone...I am trying to get the topper mounted
It cannot simple mount onto the bed
Reason is that the bed sheet metal is not made of strong stuff like my quoffee this very morn.
As an experiment, I stuck a 50" long section of the "C" channel steel I am using to fab up the stake pocket anchors, into the center pocket. Then I flexed the steel in and out.
WHOA...lots of movement.
Sort of like that big crack in the world in Kalifornia. Everything looks pretty strong there, right? Lots of rock, big stuff all jammed up and immovable looking...
Truck beds same thing. All strong looking, but when that fault is stomped on east of LA, a few buildings full of LGT people and heroine addicts in san fran fall over.
Yup, that bed is not as strong as one would wish, so I needed to strengthen it.
To accomplish that, I chose this .125" wall 1.5" X 3" rectangle tubing to bolt down along the top of said bed making it ninja turtle strong.
So that's the plan, and this is the stuff:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:25:41 PM
The plan to anchor this rail is to bolt it into the stake pockets using one bolt through the bottom, and one through the side
Dodge conveniently provided the necessary holes, so the bolt locations were predetermined since the creation of the universe.

The stack pocket anchor will consist of a nut plate on the bottom, welded to a section of "C" channel, with a nut plate cap tidying up the top and making me all fuzzy happy.

Here is the start of the creation of the nut plate process:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:26:09 PM
Mark the centers
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:28:01 PM
Drill the holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:28:31 PM
Clean them up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:29:09 PM
Weld on the 3/8" nuts
and there are your nut plates
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 05:30:32 PM
Next cut your sections of "C" channel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:25:36 PM
Weld on the bottom plates
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:26:09 PM
Then the top plates
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:27:06 PM
You can see the factory installed hole
You can see I didn't cut twice and they are still too short
or anything like that going on
The darned things fit!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:27:56 PM
I spotted some paint on them through the hole, nicely locating the location for the next set of holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:28:27 PM
Those holes were drilled
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:29:10 PM
And the nuts welded into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:29:57 PM
Stake pocket anchors all fabbed up
Kool
And looky here
they all fit!
That's one in a row
or JPL (Just plain luck)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:30:29 PM
Next the top rails were set in place, one at a time, and marked to locate the holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:31:37 PM
And here you can see just how the whole thing is anchored:

Note that the top bolt will eventually go through the topper mounting flange as well.
In fact the three bolts on each side will probably be replaced by studs protruding up from the stake pocket anchors, that will make mounting the topper mo-better and provide a threaded something for me to use to bolt stuff to later
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:32:27 PM
You will note the gap between the rail and the top of the bed.

I measured the gap precisely
It is a variable strip ranging from .12645" to .9746" with a fairly consistent width. The gap needs to be sealed, so I modeled up program for my neighbors 5-axis machine, where I plan to bill some billet steel to the exact dimensions to fill the gap!

Either that or I'll slide in a foam strip...

DOT's...

The other side worked out as well:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:33:05 PM
Since I have a nice battleship-strong area now, my mind is racing with all sorts of ideas of things to bolt to it.

Right off the bat I came up with a ladder mounted up to the left rear to get up to whatever ends up on the lofty roof.

So I predrilled some holes where I'll weld up some nutz on the backside to make that all happen
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:34:29 PM
The other side I already planned to serve as the upper mount for the swing away tire carrier which is coming along with the bumper

Here's themses holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:35:14 PM
Then I cut the front section to fit snugly

It does!

It will bolt to the side pieces just to make it easier to install/service/modify/remove/scrap
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:35:59 PM
This is creepy

SO I'm working throughout the day

I turn around, and there's the red dog

I flip up the welding mask, and there's the red dog

I turn around unexpectantly, and you...Red dog

And she's lookin at me...starin' at me. Like she's thinking..."I'm gonna steal your soul!" "I'm gonna get it...Just when you least expect it, you'll be thinking I'm coming for a screwdriver or a tasty set of pliers, but you'll be wrong...It's your soul this time..."

Like I said...Creepy!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:36:36 PM
Sorry, a little PTPD coming out there
(Post Traumatic Project Disorder)

OK, back to stuff

Let's play tools!

Anyone want to play tools?

This HF 2K engine stand which I intend to modify should be supporting 985 lbs of 600HP P-Pumped freshly build Cummins engine this coming week early...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:37:18 PM
Quote:
Originally Posted by nvrgasagn View Post
Looking forward to this as I'm in the process of looking for engine stands for a 5.9. Can't wait to see the progress!

That motor is obviously heavy

So I plan to make up two side mounts that tie into the engine mounts, and have those legs pinned for easy removal. Figure, I purchased another 12 valve P-pump engine already for the Chevy, and there is the VE pump motor coming out of Square D...That means I'll have three Cummins engines sitting on the floor at one time!!!!!

Probably tilt the earth a little in the direction of northern Kentucky.

The new built 12 valve will be living on that stand for awhile while I detail it. I'd like to have all the injectors, turbos, and the like installed, and have rebuilt the starter and alternator and have already added a generator into the loop prior to doing the swap...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:37:43 PM
Quote:
Originally Posted by FBJR View Post
So is the shell going on top of the frame you built, or inside?

The topper fits on top of the steel frame

If on top won't it mess up the front alignment?

Who cares about front alignment?

Yep, the that new coal burner should be sweet.

Does red dog like the plasma cutter, hope he doesn't get to chewing on it.

Hmmm...Didn't think about that...Considering what that light saber thing did to my finger, I should be able to set that red dog ablaze if it gets too close

Oh, its fun to watch all those idiots when that happens, I just hate when I have to go there on that gay new bridge.

Protect and defend, right???:cookoo[1]:

Don, guess what papers I filed this week? It has a date on it


So you movin after retirement?
Kali: you buy land by the square foot.
In Kintucky your property line runs from an old tree, to a pile of rocks, to a bend in a stream and is 92 acres more or less...!
 

See above^^^^
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:39:36 PM
Quote:
Originally Posted by TexasRedNeck View Post
223 Ammo for Sale - Bulk 223/5.56 Ammo Ships Free

$390/1000 delivered to your door including shipping

Lets talk ballistics of the 5.56 for moment

the 55 gn FMJ was designed to be shot out of a 20 inch barrel. IIRC it tumbles and fragments effectly down to about 2600fps, below that velocity it becomes an ice pick, most modern 5.56 platforms are 14 or 16 inch which cuts the 3100 fps velocity down about 300-400 fps meaning the rounds drop below the lethality velocity at very short distance

The M855 is good against 10ga metal at 400M, but I don't recall its lethality against flesh.

62gn has become the round of choice since the barrels have shortened to 16, 14 or 12 on a lot of weapons but it is expensive.

Hornady TAP in the red box seems to be the best (maybe the Black Hills 62 gn)

What do you guys think about the mil surp 55gn/SS109 and M855?

I was talking to a Russian Naval infantryman (Marine) who goes by "Russian Joe" google him, interesting guy

Because of him and my way too big mouth at the moment, I ended up owning my AK, and Duane his 556...long funny story.

He and I were into it, me siding on the M4, he for the AK. Now, having been on the receiving end of the AK, and seeing what it was doing to some helicopters and unfortunately, some of our guys, there is NOOO doubt in my military brain about the effectiveness of that cartridge, bullet, and weapon.

It's a good, hardy gun...nuff said

In fact, if you just purchased a AK or two and never thought again about a M4, AR, Car-15, M-16 you'd be better off

Cheaper ammo, cheaper gun, like half the price on both, and I'd have to side with the AK for durability over the M-16 series. AK's always work. M-16 types mostly work.

Now getting to the bullet. the 55, 52,53 grain cartridges are squirrel and pest killers. The maximum effective killing range against man sized targets is a Russian military tested 95 meters. Yup, inside a football field.

Now can you get luckier outside of that...yup, but it isn't very likely.

Step up to the 62 grain. I shoot the M855 stuff. Now you have good base power, and a bullet that doesn't run out of snap in 35 feet. It likes less twist in the barrel so the 1:7 in the 14.5" mil spec barrels on all of my guns eats it up and produces good infantry assault rifle groups.

Mostly I just shoot it front post, snap two quick shots, pause, aim and shoot again. I'm happy if I hit the thing I'm shooting at...like a Toyota truck on the run for example.

I've heard that round will work out to 200 meters and a bit beyond. I have also debriefed with a certain medic who entered a room, shot a guy twice with the green tip. The bad guy went down then started to get up again, so he got shot twice more! This medic cleared the house and on the way out the shot guy was going for his gun, so he got shot two more times. There was some confusion and the bad guy ended up getting shot a seventh time which turned off the lights. Interested in what had happened the body was examined and sure enough there were six exit wounds from the chest area. Now we assume this guy was amped up on something as they often were, which might account for the superhuman survival ability, but he was shot 6 times inside 10 feet and was still alive. The exit holes were maybe 4mm, almost like thick needle injection sites. Just not big enough a hole and the bullet spinning so fast and moving so fast and being so skinny, just drilled clean holes through him.

So, then came the hollow point M___ whatever it is 77 gr latest stuff. I hear this bullet has descent range, but when firing it from 500 feet from the door of my helicopter, I couldn't ever pick up the dust splash and walk my successive rounds onto the target. That's how we pilots shoot! We just fill the air up with bullets and noise, try to hit something and act like Tom Cruise in an F14 and get out of Dodge.

The 123 grain standard ball cartridge from the AK is a wrecking ball by comparison! It's big, makes big holes, and holds up well at 250 meters. THe standard site on the AK is adjustable. If you yank it backward (Where mine lives) the weapon is zeroed at both 25 and 250 meters! Now if you're shooting at anything beyond 250 meters, I'm thinking you are looking at a Korean conflict style wave of screamin' chinamen who are about to overrun ya. Then, what the heck, start shooting arty style and get as many as you can before things turn into the "Batter-up" phase which is never any fun.

If you're 250 meters away, then you can run away...something I highly recommend with respect to a gun fight.

M4: Debate it on and on
Meanwhile get an AK and as the new yerkers say, "Forget about it"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:40:03 PM
I had to check to see if this was actually my 12 valve build thread!

I fab up a new engine made from glass and used cooking utensils, then all you people do is start talking about the weather, cooking, politics and gunz!

What does one have to do to get you boneheads to stay just a wee little bit on subject?

Hey, that Texas hillbilly guy postin' out here on this thread (And we appreciate his posts) doesn't want anyone junking up his thread...wants to keep it focused!
Sorry, had to laugh...
I'm wonderin' "now how does one do that exactly????"
Why don't you guyz go junk up his thread for a few pages. Then by that time I will have created a new transmission from scrap oak and rebar...Then you can come back, look at the pictures, then talk about barbeque sauce!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:40:58 PM
I've been busy with a bunch of other things, hence project time has been limited.
So today, after doing the dishes, cleaning the house, cultivating the garden, planting the potatoes, running to the bank, doing laundry, doing the dishes, feeding the dogs, pulling weeds, and hunting down pepper seedlings, I finally got to Square D.
I think I am getting the motor tomorrow, tonight fell apart again. so first up I put that 2000LB HB HD engine stand together

It's a good buy for $125 me thinks
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:41:31 PM
It has six road wheels just like my old M60A1 and a bunch of hardware
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:42:15 PM
The legs are held on with steel pull pins for folding later on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:42:53 PM
Each wheel is bolted on with 4ea 5/16" bolts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:43:22 PM
The single upright is tilted aft a degree or two
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:43:51 PM
And is supported by two additional legs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:44:43 PM
The head unit is constructed of some righteous steel. Made from two Hyundai's, I'll bet it approaches 1" thick, as do the arms
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:45:56 PM
I think when I get that big-ole Cummins on there, I'll probably apply some sparks and hot steel and build a couple arms to support the engine mounts

So with that done, I went after the pioneer gear mounts, first coating the cleaned steel with acid etch primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:47:06 PM
Then when dried, I shot them with truck bed liner for a good sturdy, durable finish
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:47:44 PM
Then I made up some nut plates to weld into that front section of the steel bed rail system
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:48:37 PM
Then I welded those into the front tube section

I wasn't messin' around, that is a 1/2" bolt
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:49:07 PM
Then I marked and drilled the holes in the side rails
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:49:40 PM
And bolted that sucker on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:50:20 PM
I inserted some 3/8" bolts into the holes for the ladder and spare tire rack mount. I'll weld those nuts onto the inside of that steel tube when I pull it all down for cleaning and painting tomorrow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:50:55 PM
And with the precious little time I had left that's all I got done today.

Here's the state of the mess at the moment:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:51:57 PM
Got the motor
Here's Josh, the guy who built it and Carter his really cool son

Notice the size of that engine...That is a F150 Ford it is sitting in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:52:47 PM
The tractor had no problem lifting it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:53:24 PM
But can the engine stand hold the weight???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:54:03 PM
This motor is big
975 dressed, so it is probably 875 hanging there like that

I have to say, the stand didn't even give a creak or issue a moan!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:55:05 PM
I got a complete data sheet on this motor

It's going to be a monster!

Josh cautioned me about using it in the "Light" square dodge. He said that motor is going to move that little truck around like it isn't there. He cautioned me from turning it up too far since it is so powerful already

The motor came out of a full sixed 95 truck. It moved that truck around very well. He said that truck was fast on the stock injectors!

The Square Dodge trucks like mine only weigh a bit over 6,000 lbs. I'll add a thousand I think, so 7,000 lb truck. My D-Max truck is 8700 with around 1100 ft lbs and it is pretty quick for a truck. I can only imagine 1600 ft lbs in a truck weighing a ton less...

So we discussed running that motor in this lighter truck with a 37" tire and 3.55 gears. Josh thought it ought to be about right taking off from a stop, but at 65MPH when it got into it's torque curve he thought it would just be spinning the tires all the time...

I have to think that one through, as I don't want to build a dangerous vehicle

The Bosch pump is rebuilt and hot-rodded. IT has cut delivery valves and a fuel plate that flows much more fuel than stock
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:56:47 PM
That turbo will not be staying!
It will either be sold or used on Duane's power wagon truck as this is a good upgrade for the VE rotary pump engines
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:57:27 PM
Actually, the manifold will be going bye-bye as well to make way for that great three piece pulse manifold I purchased last winter

And here is a cast in number that means something to someone!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:58:27 PM
It has ARP head studs and the rocker pedestals were milled so that the washer remains (Which means you can attain actual torque!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 06:59:51 PM
Despite me pouring some fresh mulch and dirt on it from the bucket, the thing is looking pretty spiffy
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:01:56 PM
I got a bunch of parts with it as well to include the accessories and brackets which I might not be using but will serve as great spares, an intercooler, a giant cross flow radiator which weighs half what the brass one does, a manual clutch flywheel and a huge AC condensor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:02:34 PM
And here's the same mess as yesterday, but with additional clutter!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:03:43 PM
Quote:
Originally Posted by BobbyB View Post
True, however, you have a motor in D2, as it sits, will fullfill the requirements set forth by you correct? I know you march to the sound of your own drummer, or rotor beat, but

If the builder cautioned you against using the new 12V in a light truck:
"Josh cautioned me about using it in the "Light" square dodge. He said that motor is going to move that little truck around like it isn't there. He cautioned me from turning it up too far since it is so powerful already"


And you yourself :
"I have to think that one through, as I don't want to build a dangerous vehicle"

In my opinion, as an impartial observer, it'd be a smarter move to learn what you can/need/want on what you already have in D2, and use the newly gained smarts to work the Harward Performance magic on the new one when it's time to SAS and 12V the CMax. Especially considering the "new" 12V came out of a fullsized truck and seems that it'd probably be the better choice for the Chevy.


Copy all that

But I'm not running the VE pump, because you can't turn them up to the base power levels I want, 2, because it is a 171K motor that I'd feel better about if it was rebuilt, which this new motor is, and I really just want to standardize powerplants across the board. Learn and invest in one then one spare part serves two vehicles, and for reasons like that...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:05:16 PM
Got some work done today, but with all the lawn care/winter cleanup, visiting families, tsunamis, and the like, I'm not getting big chunks of time spent on the projects

I started with soaking all those miscellaneous parts with purple stuff

You won't believe how nice this seemingly trashed parts turned out to look like
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:06:18 PM
Before Josh departed yestertag, I got him to answer a passel of questions about the desert tan motor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:07:15 PM
While the parts soaked in the degreaser, I bolted the dried parts back onto the topper.
Here's the antenna mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:07:53 PM
The axe mount, and antenna parts seem to blend into the paint scheme rather well me thinks
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:08:32 PM
...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:09:12 PM
The opposite side got the shovel, which just got sprayed with bed liner coating to make it a tad more rust resistant.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:09:49 PM
The 3/4" long 1/4" stainless bolts do not protrude very far into the interior spaces
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:10:19 PM
Remember that grungy starter
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:10:56 PM
And radiator???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:11:43 PM
nd intercooler???

All are looking much better
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:19:55 PM
The starter and alternator are off to the rebuilder to get refurbed and the rest of this stuff will get blasted, sanded or something, then painted before reinstallation
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:20:41 PM
And that is a wrap for tonight's efforts in inching the ball down field
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:22:00 PM
From Armalite:
Since you already have the knowledge, and the tools, would it really be that hard, years down the road of course, to pull the motor out of square d, and put it into combat max ?

Just thinking, get this motor in now, and have square d ready to roll. You have a motor built and ready to go to work. Apply it now, and don't leave it sitting on a bench, for years of dust collecting. If SHTF sooner than later, you will be glad you have a motor in square d, instead of collecting dust...

Years from now, when/if you put a cummins in combat max, drive it, assert the power, then decide if you want to swap motors, leave em like they are, or rebuild the factory motor that is in square d at that time, then make an educated decision...

Use what you have available, make do with what you've got. You can always adjust years from now, when you have not one, but two up and running trucks capable of getting you into no mans land if SHTF....

Get the motor installed asap, is my opinion...


Not to put down Bobby, or Cuda, but c'mon guys. When is the last time you saw a senior citizen doing 65mph, much less the speed limit???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:22:58 PM
Holy smokes...

What a reaction

But for the wrong reason

Allow me to explain

I am a bit of a study in human communications

Pilots have to develop precise communications to prevent bad things from happening, agree?

Example: Non flying pilot says, "See that?"
So what is he asking?
Did you see the oil pressure gage just flicker, did you see the power setting 2% too high? Or did you see the other aircraft that crossed overhead and disappear into that cloud over there?

It's vague, and leaves to no reaction, or usually, as is the case here in this thread, an incorrect response.

The flying pilot was actually thinking the non flying pilot was refereeing to the wasp climbing on the windshield on his side just below the glare shield!

When I said I was going to put the VE motor and the new engine on Craigslist, the assumption our Airborne warrior made was probably that I was selling the motor already in the truck, and 2, selling the pretty motor. all painted up and ready to install.

Close but not exactly. The VE motor is off to a new home soon.
The pretty motor all painted up and ready stays on the stand where it will be dressed, then installed

The "New" motor is a 250K P-Pump motor I just picked up yesterday morning out of a wrecked 1994 truck that I stumbled across and purchased for a very good price. That one is the one I will try to flip quickly and return the monies into a plethora of things coming up for SquareD

OK, all good?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:24:35 PM
Well, let's get some stuff done on Square D

First, Dan brought over the aluminum tank he built for the rear of the truck, the one that will hold the water/methanol

It is made from 1/4" wall aluminum because it will be located in an area that might see some rock or 2 X 4 action
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:25:35 PM
The two straps will weld to the bottom of the tank, and are 1/2" thick. That should make this thing next to bulletproof. The tank sits flush with the bottom of the frame rails completely wrapped with steel on the sides and top. It fits with maybe 1.5" clearance. The two straps will attach to the bottom of the frame through existing holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:26:44 PM
Oh, it will get a 1/8" NPT bung for the outlet and a filler neck coming in from the top

Here's that latest 12 valve P-Pump engine I just picked up. It has some impact damage as does the radiator, but I should not be using the rad so it matters little
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:27:34 PM
Starting with the bed rail pieces, I welded in a spacer in the front piece and the nuts on the sides
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:28:10 PM
Then the parts were wire brush cleaned using a cup grinder
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:28:54 PM
Same-same for the anchors. Next I applied the rust converter to the anchor pieces and let them sun dry along with my tomatoes!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:29:33 PM
While that business was drying and hardening, I sprayed two wet coats of epoxy primer sealer onto the steel rails
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:30:04 PM
Then after the rust converter dried, the stake pocket anchors got the same treatment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:30:47 PM
That stuff takes a couple hours to set up and dry, so on to the next project.

The topper will be going onto the bed, hopefully, this week sometime, so it was time to remount the front seat into it's new location, in the bed

$ nuts and it was out. The bed area was cleaned up before I made a new mess by drilling the four holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:31:39 PM
I put tape down, positioned the seat, marked the position of the 4 studs, drilled some holes, then slid it home and bolted it down
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:32:25 PM
Before you ask, yes, something will be going under the seat and on the drivers side...

So, now the stake pocket anchors were dry. Since they are interior/hidden parts, I coated them with a premium rubberized undercoating.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:33:04 PM
The bed rails were coated with the same bed coating product I used on the roof rack assembly
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:34:03 PM
With the seat out, and waiting on coatings to dry, off to chores again.

It was a good time to get some sound deadener rolled onto the back panel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:34:56 PM
Coatings were still drying, so time for another chore

This time we'll put the fuel tank filler neck in

You may remember that last time we looked at it, I had to fab up a plate to fit the angle adapter. I squeezed out two opposing beads of silicone gasket sealer and allowed them to dry and harden. They effectively form two "O" rings which seal against each other
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:35:34 PM
Some quick screwdriver and wrench work and those parts became as one
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:36:22 PM
I applied another 1/4" bead of RTV to this surface, then screwed that into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:37:17 PM
I'll have to find a 1.5" 90 degree hose, probably a heater hose, and cut it to connect the parts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:38:08 PM
Stake pocket anchors were now dry enough to work with
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:38:59 PM
I purchased a 30" piece of high strength 3/8" threaded rod, and turned it into a bunch of studs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:40:02 PM
Those got threaded into the anchors and nutted on the inside so I could adjust for proper length.

The two center anchors got a bottom stud as well because the space was insufficient for a bolt
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:41:16 PM
The hardware will be nylon lock nuts and fender washers which are extra biggins
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:42:24 PM
I left most of the bolts/nuts fairly loose for now, until I get the topper positioned.

I plan to set it directly on top of the studs, mark the positions, drill the holes then drop it home for good, then snug everything up.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:43:49 PM
Update:

Got the bed rails mounted, waiting on D&D (Duane and Dan) to do the lift to place the topper onto the bed.

Ordered a grant steering wheel because the stock one is just so ugly.

Trying to sort through the front suspension thing which is coming right up.

Lots of questions there and one PDB (Pretty darn big) project getting that concocted.

Mean while lots of other bones in the air:

Sorting the engine turbo/injectors
Figuring out what to do with the transmission
selection of front seats
removal of old engine
Redoing the radiator core support to hold more up to date components
Did I mention the front suspension?
Crossover steering
New steering gearbox/lines/stuff
Have to figure out what to do with that front suspension
and finally
The front suspension!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:45:05 PM
So...front suspension...

We are nearly standing at the gate

Start the thing or get off the fence.

I had procured the radius arms and things to make it a coil spring suspension.

Well, kiddies, that is not as easy as I was hoping. There are things in the way like a steering column on one side and a turbocharger or air cleaner on the other side.

The Dodge D60 housing doesn't give one much of an axle tube to work with on the right side...the very place everything including the rear bumper anchors to!

So in the middle of all this I run across this Ramcharger Central guy, a one Jungle Jim...
Hey I didn't pick the name...
He is a talented builder of great parts. In fact I will be using his kit to reinforce the weak frame area where the steering gear box is about to be installed. Those parts have already been ordered.

The problem with the stock Dodge front end is two fold
1. It rides rough
2. the short springs provide only marginal travel.

My plan was to eliminate all of that and go to coils which routinely travel all over the place.
But
That requires half a summer of fab and sparks
So I approached him with the prospect of using longer leaf springs in there. Stockers are 48". The next step would be to go to 52" Chevy springs and there is a possibility of going up to 56" springs as well!

Than, my dear, would make a H U G E difference in both numbered items...

So we're standing on the ramp. Next step is a 12,000 foot fall until the chute pops on this HALO jump.
I'd like for the chute to actually open!

Opinions???
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:46:13 PM
Quote:
Originally Posted by Tedram View Post
To me the right thing for Square D is to build the strongest most reliable front suspension you can. Just ask yourself which is more bullet proof, the coil over or the larger leafs..... then move out smartly.

That's what got me to this place in the first place.

Coil-overs got a down vote. One bullet strike and you're toast.

Coils got the not because they are more or less bullet proof and get me a cushy ride plus scads of travel.

But the price in doing that is real estate up there in the fender wells for the big spring pockets, and a lot of fab and build time.
That is OK in the long run

But fast forward to leaf springs
They are old school and ride poorly.
But the reason they ride poorly is that they are too short and poorly R&D'd
Install a much longer leaf and you pretty much fix all that
Plus, what's stronger than a couple of leaf spring packs?
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:48:02 PM
time to post up some more progress

In preparation to install the topper, I moved the studs all the way out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:48:46 PM
Then put down a couple layers of the closed cell foam used to seal these toppers to the bed rails
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:49:20 PM
The steel rail got a layer as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:50:24 PM
Then the whole thing was loosely bolted together. It REALLY stiffened up the bed/body structure
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:51:44 PM
I had to create a fork lift, so I ratchet strapped two 2 X 6 spruce boards to the underside of the bucket and made a forklift for a day.

Heck if I can use wood and cardboard welding tables, then why not a wooden forklift
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:52:52 PM
There was creaking and groaning and some gnashing (of my) teeth, but in the end my contraption lifted the topper
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:53:42 PM
I carefully drilled the holes and the thing set right down where it was supposed to!

Then I started to lift it back off 6" or so to stick on another layer of foam sealer tape when this happened:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:54:15 PM
No damage, and I saw that as an omen so I just let it be and bolted it all down like it is supposed to be

I had to make up some special hardware from fender washers, and used them with nylon lock nuts to seal the deal
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:55:18 PM
And that produced the results I was looking for
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:56:02 PM
It all buttoned up and sealed nicely
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 15, 2014, 07:56:52 PM
I also found time to cut "Franken-Snorkel off the badly deformed fender. It will get some attention and painting, then fitted to it's new home.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:46:32 AM
Well, that's it, end of build day 150.

Would have gotten more done, but had 3 yards of mulch to deal with as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:49:13 AM
The steering gearbox is almost here
as is the frame stiffening kit I picked up from Jungle over at Ramcharger central

With that in mind, it's time to prep the battlefield so to speak

First up, remove the new/old car-done sorta-rebuilt box.

The steering shaft was the first victim
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:49:52 AM
Then the bump-steer prone aft facing drag link which will not be reused
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:50:40 AM
Then the steering box
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:51:16 AM
Next this arm will be replaced with a cap to delete it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:51:53 AM
These are the parts of the crossover steering conversion minus the linkage

You might also note the addition of upper bronze bushings for the king pin which will eliminate that funky spring apparatus thing that wears with time. These bushings also eliminate or help to at least the dreaded death wobble associated with this type axle
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:52:24 AM
The quality of these WFO Concept parts is obvious.
Here's the new steering arm which will fit to the far knuckle
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:53:14 AM
And off it comes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:54:05 AM
Old/New

Sort of like me and all of you
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:54:48 AM
Nylon bushing out, bronze bushing, in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:55:52 AM
There it is in all that pretty grease snug as a bug in a rug
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:57:24 AM
The studs come out and bolts replace them
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:58:27 AM
Then the big chunky thing gets bolted on with 7,000,000 ft/tons of torque
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 08:59:45 AM
This large stud pushes down on a steel disc which applies pressure to the bronze bushing and keeps everything happy in there
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:00:16 AM
A grease zerk finishes this side off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:00:52 AM
Left over stuff
Only the shaft will be reused
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:01:24 AM
And there she is done, done, done
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:02:09 AM
On to the right side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:03:01 AM
After popping the old stuff out, 4 super strong studs get installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:03:42 AM
The arm gets loaded up with the steel disc and some cool grease that does not match my shoes!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:05:26 AM
And that gets bolted on with some lug nut taper lookin' nuts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:06:34 AM
Then the cool stuff gets installed.

Next up is project core.

You see the radiator core mount is connected to the steering box bone. That is, it is in the way for guden-weldin' so it's as good a time as any to yank it out.
I have to reconfigure it for the larger radiator and intercooler anyway, so here we go
First up: Get the freshly cleaned floor dirty again!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:08:20 AM
I know, I know, several EPA guyz in kalifornia just suffered strokes, but not to worry, I had the stray neighbor dogs slurpin' all that up fast as it came out

Well in the next few shots all that stuff gets gone, bit by bit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:09:07 AM
That intercooler is maybe half the size of the one going back in!

These two bolts are all that holds that core support in place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:09:44 AM
And after a day of sweatin like OB in a real Christian church, here is the SOB
(Status of the build) at the end of build day 151
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:11:34 AM
Let's get the day started with playing parts

Who likes to play parts?

Today the PSC steering box showed up

This is the very box I removed from the truck some time ago

It's looking a bit better wouldn't you say
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:12:20 AM
You can see that it is plumbed for pressure takeoff for a future steering ram.

I also picked up a new 2WD steering arm that will index the steering properly for the upcoming crossover swap
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:13:07 AM
Jungle Jim over at Ramcharger Central makes this cool frame stiffening kit to box in the frame at the steering gearbox. Unboxed frames often crack. My frame was crack free and I intend to keep it that way
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:13:54 AM
Time to make some werkin' room

Out with the radiator support!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:14:50 AM
I pressure washed the thing before setting it on the new welding table to see if I can fit some new stuff to it

The 1995 Radiator is almost twice the size of the one that came out of the truck and is aluminum with plastic end tanks making it lighter aw well.

I believe I am going to make a run at fitting it along with the 95 Intercooler

I want it to turn out looking like it came from the factory like that...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:18:06 AM
Here is the steering box stiffening plate we will be installing today
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:19:48 AM
The fit is approximate, and I had to do some trimming to get it to fit well. But once I did it fit perfectly.

The plate bolts to the outside of the frame through two existing holes in the factory frame.
It is then used as a drill guide to use a 1" hole saw to cut exactly positioned holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:20:49 AM
These DOM sleeves fit between the two frame halves once the plate is fitted to the inside
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:21:28 AM
Here are some rough marks of "About where" I needed to trim.

With the magic of sparking really hot liquid metal filling in gaps, I wasn't worried about getting a precision fit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:22:02 AM
The results of the drilling
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:23:04 AM
Here's a test fitting

As you can see things are fitting quite well

Good work Jim with this neat little invention
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:24:14 AM
I removed the air pump and power steering pump stack to get a bit of free space
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:25:22 AM
Next the area was cleaned up with a #80 grit flap wheel to prep for welding
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:26:21 AM
Then the 4-DOM bushings were bolted to the "Old" steering gearbox
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:27:07 AM
Then that assembly was fitted to the frame and plate for welding
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:28:57 AM
With the box resting in the 2WD position it is recessed into the frame somewhat and held on with 4 bolts. In the old 4WD position it bolted to a plate which bolted to the frame with 3 bolts, albeit larger diameter. I like this fit much better

Next up I welded everything except for one area on the inside which I will weld after I pull the engine
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:30:57 AM
And that's a wrap for build day #152
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:31:49 AM
Not a great day in the shop

First I started with removing the air conditioner to gain some room to fit the passenger side plate.

I snapped a bolt head off pretty quick...hmmm...

Then the body was completely corroded to the bolts and wouldn't budge. So I rested a 2 X 4 on it and tapped with a hammer. That cracked the aluminum destroying it.

OK, no big deal I was going to rebuild or replace it anyway, but there went my core charge.

The plate needed trimming again. I managed to get it in there, then when I was welding it, I ran out of wire!

OK, no biggie, I'll get on the intercooler. I figure a complete cleaning and painting with the epoxy was a good starting point. 30 minutes into the wire brushing I flipped it over to discover one tube with all sorts of holes in it!

The tube and that area of the I/C was heavily corroded and pitted and is unserviceable.

So after that I threw in the towel and gave up for the day!
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:33:06 AM
Quote:
Originally Posted by EL TATE View Post
Frame reinforcement looks like sound materials and a good plan. I'm liking the idea of the larger radiator and intercooler on the older truck, can't really go wrong there. Stop breaking stuff and get back to work!

I've been doing a lot of related stuff...but takes time

I sorted out the new turbocharger with Steve over at Gillette Diesel. I am shipping back all the VE motor stuff, he will do the hand off and ship me a new single turbo, injectors, and a down pipe to fit.

I am ordering stuff, ciphering out the front suspension...still not in the bag exactly, and talking to folks about the transmission build

Here is something which I find interesting about the 93 and earlier Diesels.

My truck came with a A518 or 46RH transmission. It is diesel specific and pretty strong. It has an old school torque converter, which means it will not lock up. That means that going down the road it will constantly slip driving up fluid temps 20-40 degrees and cause the motor to run about 500 RPMs more than if I had a later lockup transmission.
Sounds bad doesn't it?
Well, not so quick Mr. Watson
You see a fully built transmission with the best of everything and a three clutch billet converter and deep pan goes out the door around $3400

The one later lock up transmission costs an astounding $7500 in the same condition...here's why

A Lock-up converter will transfer shock loads directly to all these steel shafts inside. No cushion, all shock. That means all those steel parts need to be carved out of exotic metals and stellar matter. That's the cost...expensive billet parts.

The slush box automatic absorbs those shock waves as a momentary flare in RPMs then squeezes back on the power and lights tires. A transmission expert says the stock A518 internals has held 900HP on his shops dyno without breaking. They will guarantee the trans for 5 years! no matter what sort of power I put in front of it.

So it seems to me for $4000 I buy a few hundred RPM and 20-40 degrees temperature...
$4000 buys fuel for 21 months @ 1000 miles per month
$4000 also bubs all the tires I will ever use for this truck the rest of my life.
It buys maybe half of the upcoming trailer project.
I think I am staying old school
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:34:06 AM
From ElTate:
Quote:
Originally Posted by flyin6 View Post
I've been doing a lot of related stuff...but takes time

I sorted out the new turbocharger with Steve over at Gillette Diesel. I am shipping back all the VE motor stuff, he will do the hand off and ship me a new single turbo, injectors, and a down pipe to fit.

I am ordering stuff, ciphering out the front suspension...still not in the bag exactly, and talking to folks about the transmission build

Here is something which I find interesting about the 93 and earlier Diesels.

My truck came with a A518 or 46RH transmission. It is diesel specific and pretty strong. It has an old school torque converter, which means it will not lock up. That means that going down the road it will constantly slip driving up fluid temps 20-40 degrees and cause the motor to run about 500 RPMs more than if I had a later lockup transmission.
Sounds bad doesn't it?
Well, not so quick Mr. Watson
You see a fully built transmission with the best of everything and a three clutch billet converter and deep pan goes out the door around $3400

The one later lock up transmission costs an astounding $7500 in the same condition...here's why

A Lock-up converter will transfer shock loads directly to all these steel shafts inside. No cushion, all shock. That means all those steel parts need to be carved out of exotic metals and stellar matter. That's the cost...expensive billet parts.

The slush box automatic absorbs those shock waves as a momentary flare in RPMs then squeezes back on the power and lights tires. A transmission expert says the stock A518 internals has held 900HP on his shops dyno without breaking. They will guarantee the trans for 5 years! no matter what sort of power I put in front of it.

So it seems to me for $4000 I buy a few hundred RPM and 20-40 degrees temperature...
$4000 buys fuel for 21 months @ 1000 miles per month
$4000 also bubs all the tires I will ever use for this truck the rest of my life.
It buys maybe half of the upcoming trailer project.
I think I am staying old school

I agree with your assessment; especially since the 20-40deg is going to be arbitrary considering the superbad trans cooler system you have erected there. Keep it simple sounds like a great plan.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:34:58 AM
I know, I know...

No intercooler in view at the moment. That sort of created a stop point. I really want to spec out that radiator support before getting too deep into anything else.
That's why not much work is going on...I'm staying focused
I am proceeding though.
Today I dropped off the alternator for a total reburb...
I'm ordering parts and even picked up a cool custom shelf unit that will mount where the visors currently mount in just a day or two.
Little bit here, little bit there.
I really need to find an I/C...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:36:50 AM
From ChrisLib:
Quote:
Originally Posted by flyin6 View Post
I've been doing a lot of related stuff...but takes time

I sorted out the new turbocharger with Steve over at Gillette Diesel. I am shipping back all the VE motor stuff, he will do the hand off and ship me a new single turbo, injectors, and a down pipe to fit.

I am ordering stuff, ciphering out the front suspension...still not in the bag exactly, and talking to folks about the transmission build

Here is something which I find interesting about the 93 and earlier Diesels.

My truck came with a A518 or 46RH transmission. It is diesel specific and pretty strong. It has an old school torque converter, which means it will not lock up. That means that going down the road it will constantly slip driving up fluid temps 20-40 degrees and cause the motor to run about 500 RPMs more than if I had a later lockup transmission.
Sounds bad doesn't it?
Well, not so quick Mr. Watson
You see a fully built transmission with the best of everything and a three clutch billet converter and deep pan goes out the door around $3400

The one later lock up transmission costs an astounding $7500 in the same condition...here's why

A Lock-up converter will transfer shock loads directly to all these steel shafts inside. No cushion, all shock. That means all those steel parts need to be carved out of exotic metals and stellar matter. That's the cost...expensive billet parts.

The slush box automatic absorbs those shock waves as a momentary flare in RPMs then squeezes back on the power and lights tires. A transmission expert says the stock A518 internals has held 900HP on his shops dyno without breaking. They will guarantee the trans for 5 years! no matter what sort of power I put in front of it.

So it seems to me for $4000 I buy a few hundred RPM and 20-40 degrees temperature...
$4000 buys fuel for 21 months @ 1000 miles per month
$4000 also bubs all the tires I will ever use for this truck the rest of my life.
It buys maybe half of the upcoming trailer project.
I think I am staying old school


not so quick on the 46rh bulletproofness there sir. Yes they are stout, one of the reasons they hold power better than their lockup counterparts is they have a solid input shaft (no lockup= no need for the hydraulic passage), but otherwise they have the same foibles as a 47rh. Two weak links in a 46rh, the aluminum 4 pinion front planetary...fixable by going to a 47rh style 5 pinion steel unit and matching intermediate shaft (reason for the int shaft is the splines are diff between the two...i.e. steel front planetary wont spline onto and aluminum planetary intermediate shaft)....that and the low/reverse band is a single wrap unit which is said to be a bit less durable than the 47rh n up counterparts. cannot upgrade that without going to a later case in which case you might as well just build a lockup init. Alll that said, a solidly built 46rh is able to take heaps of abuse, and no matter which route you go spend the $$$ for a good converter (Goerend is my choice and what I use but Suncoast and Specrite both have good reputations).
The unit in my heap is far from exotic, the aforementioned later planetary and matching shaft,stock borg warner frictions (in stock counts...no addl) good billet hydraulic servos (2nd gear band and low/reverse band...to cut down on internal psi loss...another achilles deal) a transgo shift kit, and a good converter...that will hold you to about 400-450 hp or so as long as your not doing silly abusive stuff like 25 psi boosted launches....and I dont see Square D going down any dragstrips soon....or?

Ahhh the myriad world of the Dodge diesel transmission...theres literally a million ways to skin that cat...welcome to the club lol.

rec reading...this dude has found about every weak spot there is to find in a 46rh
http://www.dieseltruckresource.com/d...d.php?t=160276

and how could I forget this one...invaluable info from when I rebuilt mine...
http://www.competitiondiesel.com/for...d.php?t=100506
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:38:38 AM
Quote:
Originally Posted by ChrisLib View Post
I have about 2K in mine, thats with a $600 converter but I was able to get all of the other internals at jobber cost, my boss at work (back in New York... I`ve since moved to a ...uhhh "redder" state...Tx) is friends w/a trans shop owner (said owner thought I was crazy for bothering to swap out the planetaries btw lol...but he just does bread n butter repair work mainly)

So, you have 2K and bought stuff at a bargain.
I might be able to get some stuff at a bargain so let's say I pay $2500
$3700 - $2500 = $1200

Not a bad savings

But I also consider additional factors.

If I just purchased it, then I'd get a 5 year warranty...sort of. I mean if the trans failed, I'd have to pull it and ship it back to get the warranty, and with shipping costs and down time, that's not so much of a great deal.

On the other hand, if I got inside that thing, instead of just eating the fish, I would have learned how to fish!

I'm thinking you are both a great asset to this thread and a trouble maker!

Great because you bring so much to the table, trouble because you will likely get me to do this thing myself and cause all sorts of pain and strife for me!

Ah, it's all good...and part of this do it yourself extensive "Oil-change" project
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:39:24 AM
Quote:
Originally Posted by FBJR View Post
I like the idea of DIY Don, looked into it myself. Lots of vids on utube and they show the PVC too.

Thought I might ween myself on a 200r4 I have, then try the 46, then maybe even the ally.

I think the parts saving would be much more though and a warranty does you no good across the country, much less towing, shipping, removal. Heck, I see ready to go trannys for less than rebuild parts on the bay. But you get what you pay for.

Solid rebuild, good converter with a few upgrade parts.

Well, I'm certainly entertaining the idea at the moment.
After I bolt that engine in, I'm going to need something to hold the back end up!

Well, got some work done today.
Still no intercooler, so my primary objective can't be achieved just now.
I needed to fix that pesky leak I created on the right aft wheel hub by installing that seal backwards. Therefore I decided to make that right

Here's the starting point
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:39:55 AM
Oh, wanted to share this. I found these cheapo gloves at HF and I have to say, they work pretty well and as long as you don't have a bored red dog, they should last
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:40:34 AM
Back to the wheel repair.
THe parts under the brake drum are holding up pretty well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:41:16 AM
The seal is essentially new, so I decided to just press it out and reuse it, which I did
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:42:01 AM
All better!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:42:32 AM
With that installed, I set as a goal for today to have that wheel mounted for the first time. First I need to address the fact that raising the body an inch, spaced the body/exhaust hanger an inch too high. So I pulled the old one
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:44:00 AM
Then I built this simple "L" bracket with a welded in 3/8" stainless bolt
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:44:57 AM
Then welded it to the top of the tailpipe, which in all actuality, made for a cleaner installation than the earlier exhaust clamp
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:45:48 AM
Then the wheel was bolted on for the first time
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:48:16 AM
Kind of cool how the camera captured falling rain drops in the last couple shots.

I picked up new wire, so I finished welding in the right side plate
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:49:11 AM
With that done, I decided to prep a patch of frame on the drivers side and mount that new steering box so I could complete the crossover steering

First it was cleaned up a bit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:49:55 AM
That wasn't enough so I wire brushed the whole area
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:50:50 AM
Then coated the bare metal with some rich copper primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:52:06 AM
That area of the frame had almost no rust on it...amazing!

I coated the area where the box goes with rubberized undercoating which will dry overnight before the box gets bolted on
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:54:02 AM
 wasn't all that impressed with the rattle can paint job the new Cummins engine got when it was rebuilt. So I scrapped, sanded, wire brushed and used everything I could find to remove or scratch up the paint which had recently been sprayed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:55:36 AM
Then the bare/scratched areas was given the copper primer treatment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 09:56:50 AM
Then it was given two coats of Dupont Nason acrylic enamel with hardner
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:00:30 AM
And that folks, is it for build day number 153
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:02:06 AM
DOT's...

OK now for everyone's nightly fix of meaningless drivel and parts stuff.

The paint job on that motor turned out really shiny!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:02:50 AM
I started assembling the motor accessories today. First thing I noticed was that the dip stick handle was attached to the stick part with a nail!

Yup, bent over nail! Knowing Duane would find that quickly on his next garage visit, I corrected it immediately with a proper rivet
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:03:40 AM
Time to remove the stock manifold and turbo. Neither will be used here. The manifold pictured is a three piece pulse manifold designed to keep exhaust velocity high, increase horsepower, and stop unwanted cracking
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:04:30 AM
Unbolting the stocker is a whiz with the motor on the stand
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:05:14 AM
Still new and fresh...nary a carbon spec!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:06:50 AM
The smallest pre-ranger showed up for an inspection. I had him out in the flower beds pulling weeds and building character.

This is the little guy who's arm was nearly bitten off 2 years ago. It was 70% detached, and I was dammed lucky to find him almost as soon as it happened. If I hadn't he would have bled to death shortly thereafter.

But you can see God was at work and his arm is as good as new
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:09:04 AM
That manifold tucks in there like a champ. And the allen head attaching bolts are much less bulky than the long stock stuff
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:09:45 AM
I painted up the repaired dip stick and tube and reinstalled that
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:10:24 AM
Then I started bolting on engine stuff starting with the coolant lines
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:11:46 AM
Then the fan was disassembled and prepped for painting
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:13:00 AM
That thing will get a coat or two of the Lycoming gray I have been using for things all over the place

The frame area where the steering gearbox mounts was dry and ready for it's new companion
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:13:58 AM
So that beautiful box got installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:15:51 AM
It fits perfectly in the factory recess thanks to a well thought out kit made by "Jungle" at Ramcharger Central
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:21:20 AM
The box moved aft maybe 2" so that means the steering shaft was about that much too long.

So next order of business was to shorten that critter until it fit "Jest bout' right"
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:22:04 AM
Had somewhere to be so had to cut it off there. (Get it..."cut it off there...)

So that was the end of build day 154
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:37:46 AM
Quote:
Originally Posted by WVRigRat08 View Post
I'm with Ken, the suspense is killing me, I can't wait to hear that thing growling.

OK, menses here is another installment

Thing is, there is a lot of work going on.

Let's take for example the front suspension

There is a ton of research going on in several places right now to get that right. Jungle Jim up in New York had the new mount laser cut this past week and is assembling the parts as we speak. I'll get the prototype along with a selection of different shackles.

You see we are inventing some of this stuff while we go. You get to see the installation part, but be assured a lot of cipherin' is taking place. Folks like Jim will hopefully be the benefactor when because of this research and my trying out and adjusting the parts and others as well. You all get to just order some pretty kick-butt parts as a direct result.

Transmissions: I have been talking to Dynotech in Minnesota about a revival of this old transmission using everything we have learned from the latest transmissions. We will be creating a more cost effective, non-electronic transmission that fits this survival concept perfectly. There has been hours of computer and phone time spent so far on that...

That all takes time of course, which I'm sure you appreciate

Square D is about as far from a bolt on lift kit, blacked out Chevy emblems and super star mags as one can get. But what you get here is the real deal!

So let's get started on today's, after church garage activities.

Here's a box:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:38:32 AM
The box contains one of Jungle Jim's new creations...A shelf unit that bolts in where the visors mount and provide a place to store things or in my case, a place to mount a couple of radios and a map light
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:39:28 AM
Look at the quality of this thing!

I know, what does this have to do with the suspension, or the engine, or the radiator core

Answer: Absolutely nothing

And that is why I'm doing it...I just wanted to shake things up and mess with you'lls minds
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:40:18 AM
It fits here:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:40:57 AM
First up I painted a couple areas black. Just in case those would show after I covered in in black vinyl
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:41:32 AM
I'll be using spray on adhesive, a yard or so of Vinyl fabric and the itself to be covered
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:42:11 AM
The process is simple, really. Just spray both parts and work slowly, smoothing from the inside out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:49:26 AM
And pretty soon, you have a covered piece!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:50:00 AM
I did a bit more smoothing, then cut the access holes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:50:40 AM
The two recessed areas are where the factory visors will remount, a couple of inches lower than before

Time to play parts again!

Who likes to play parts?

Here is the rebuilt parts that are going back onto the front of that purdy motor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:51:17 AM
The alternator, a 120 Amp Denso unit was rebuilt at a local shop. It got new bearings, new brushes, new brush holders, which were the incorrect units for this alternator, and the electrics. Cost of the rebuild was $53.
I wire brushed the thing then cleaned it. Heck it practically looks new
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:51:52 AM
I coated all the aluminum parts with my favorite Shark-Hide aluminum protector stuff which keeps things purdy a lot longer than they deserve!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:52:40 AM
There is a new Hayden fan clutch there and a new air conditioner compressor as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:53:44 AM
Next the alternator mount, throttle linkage, turbo elbow, and fan got the treatment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:54:40 AM
The aluminum was left natural, whereas the ferrous stuff got the anti rust stuff, then given to the hanging jungle for some painting
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:55:46 AM
Then everything was sprayed with that Lycoming gray utility color I have been using everywhere
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:56:42 AM
I decided to change up the 95' valve cover thingy
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:57:16 AM
I'll do something cool to the letters when I figure out what that is...OD maybe??

Well, that's what I had time to get to today. That's it for Build Day 155
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:58:03 AM
Got a couple hours in on the truck today, so I concentrated on bolting on what ever I had lying around onto the new engine, and installing that excellent shelf unit Jim built

First up on went the new air conditioner compressor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:58:44 AM
And then the rebuilt alternator
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 10:59:47 AM
Followed by the fan and new clutch assembly
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:00:18 AM
Next the throttle linkage mount became permanized to the injection pump
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:00:47 AM
And one really big battery ground lead
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:01:41 AM
The power steering pump is fine so I started on it, cleaning, sanding then painting it...however it wasn't dry enough to mount up just yet
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:05:46 AM
While I decide what if anything to do with the valve cover, I set it in place for the time being
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:06:42 AM
Next up, the shelf unit

It mounts in place of the factory visors
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:07:31 AM
Once both "feet" are securely screwed into place, you attach the shelf itself with the supplied machine socket head screws
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:08:20 AM
Then attach the visors and you're mission complete!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:08:50 AM
And that, my good peoples is all she wrote for the short build day 156
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:09:24 AM
Pushed the ball down field a few more inches

First up, bolt up that power steering pump to prevent the dog from chewing it to pieces

It fits into this cross-key
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:09:55 AM
It slipped right into place...then I discovered I don't have any fine thread nuts to fit. I think it is some weird metric size
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:10:38 AM
Enough engine stuff for now...I still don't have the new injectors and turbo, so I'll have to wait on going too much further.

So, let's get back to the steering. Time to build the srossover steering link

First up, I tangled with the stock Dodge 2WD pitman arm
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:11:21 AM
That's a big ole' 3/4" drive ratchet!

Here's the parts I will use to make the crossover link. Those are 1 ton Chevy tie rod ends, RH and LH thread, and the weld in inserts along with some DOM tubing
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:12:12 AM
Those tie rod ends links are really hefty
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:13:02 AM
The weld in ends make for a nice end to the tubing and allow for a hex surface for the alignment guy

Here's how that fits:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:13:38 AM
After a little welding and grinding
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:14:15 AM
On this end I turned the heat way up and laid on a thick weld, then dressed it down to size with a flap wheel. On the other end I ground a bevel into the tube, then just filled the gap up level with weld.

I must confess, I like the other technique mo-better-er. Sort of wish I had done it here

So here is the stackup and the amount of gap I'm putting in there
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:15:47 AM
When I fitted the semi finished link into the pitman arm, I discovered the Chevy taper is much larger than the Dodge, which is a good thing, but makes me have to choose to ream out the stock Dodge arm or use a new 4" drop arm I just happen to have which had the proper taper.

I chose door #2. Pulled the dodge arm back off, and reinstalled the Mr. Chebby part
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:17:48 AM
This shows just how much thread is still available with the 1/2" gap I am using
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:18:55 AM
The opposite end was a simple task of marking the cut point with everything mocked up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:19:56 AM
Set up ready to weld
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:20:52 AM
I like this weld much mo-better-er
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:21:30 AM
And after welding the final fit test

It's a pass!

That fit is perfect, and with good clearance for when things get twisty
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:22:22 AM
Prepped for painting
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:22:52 AM
Fresh coat of Lycoming gray color
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:23:45 AM
I pulled the air conditioner lines to have them replaced or rebuilt

Next I'll pull the blower motor and have it rebuilt as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:25:02 AM
 had some time left, so I ran the CB antenna cable from the whip up to the new tray where the radio will someday live
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:44:32 AM
I'll tuck that cable in when I pull the window trim to route some more wires for all the lights and other things.

Right now I'm thinking I'll run the LED, spot lights and NVG lighting switches all out of the overhead shelf to uncomplicated things lower

And that boyz and girlz is the happy end to build day 157!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:46:12 AM
Quote:
Originally Posted by Cudakidd53 View Post
Thanks for an early installment of progress pictures! You're making me a convert to "old school" diesel trucks! 


These things are so much better than the new trucks!

Sure the newer trucks alert you to upcoming stock market swings and automatically adjust their tire pressures based on telecast NOAA forecast weather information, but they are nearly impossible to work on, and host so many EPA tonnage that owning them seems, well, like voting democrat...It sometimes just doesn't feel right!

But there is nothing wrong with any of the old square fender trucks. My 94 F250 with the 7.3 powerstroke engine was around before they turned into power-jokes. Dodge trucks are going to outlast Hueys, the oldest known operating machines in the history of mankind. Chebbys ARE the standard, and they still look great.

I like my Chevy, but given half a chance I'd swap it for a square V3500 with a Cummins
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:48:22 AM
Quote:
Originally Posted by Armalite View Post
You know you have a soft spot for those big blocks Don... You've toyed with so many in the past, you should still enjoy them, kinda.... 


Here's my big block:

Lycoming L-712

835 lbs,

4,500 horsepower

I had two of those monsters strapped to the sides of that Chinook I flew for years.

Two of them + 6 really big rotor blades + a long aluminum tube would pick up 17,000 lbs of John Deere JD-550 bull dozer and fly it 115 miles low level!

That's a proper big block!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:49:39 AM
Today is a run around to find out nothing I need or want to do is available or possible.

I took the intercooler to a radiator shop. He looked at it and told me to order a new one!

I tried to pull the starter off to have it rebuilt, but ALL THREE bolts are stripped!!!!!!!

I took the fan motor over to the electrical shop to have it overhauled. Bad news is he wouldn't do it. Good news is he said it is perfect and doesn't need rebuilding!

Then I went grocery shopping.

Just had a yogurt instead of a doughnut so all is good with the world!

I ordered 1987 Chevy K20/K30 HD rear springs. They are 52" long, have 6 leaves + an overload which I will remove and have a centered pin. They have 4.75" of arch and are rated at 2770 lbs capacity each, so they should be a good match for that lump of Cummins iron hammering on them from above. These rear chebby springs will become the front springs for a flexier Square D
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:51:37 AM
Quote:
Originally Posted by cruizng View Post
Don, Are those springs heavy enough just in case you decide to keep that big honking front bumper?  I crack up every time I see it in a picture.

Looking really good by the way! 


Yea I think so
Reasoning:
Springs support 2775 each
Total = 5550

The truck without mods weighs about 6000-6500

They are really light trucks

I'll add approximately 1000-1500 pounds of stuff to the truck (Sprung weight)

So the vehicle weight will be 7000-8000 lbs finished

But the springs only support sprung weight

Unsprung weight includes

4 tires/wheels @ 145 ea = 580
2 axles @ 500 ea = 1000
Total approximate unsprung weight = 1580 lbs

So sprung weight is somewhere in the range of 5500-6500 lbs

I think the weight distribution will be around 60%- 40% front/rear bias

So 60% of the weight will equal 3300-3900

So if I'm anywhere near the correct numbers here, those springs will more than support that weight, and in fact might be overkill and require me to go to a lighter spring

Now a set of springs designed to support 5550 lbs supporting say 3500 lbs might seem like overkill like I just said

However these are 2-stage springs

They have a large overload leaf bolted onto the bottom. Don is going to remove that overload leaf which will decrease the load carrying capacity of that spring and if I and Jim have chosen correctly, then that spring just might be perfect for this application.

We'll see...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:55:04 AM
Descent work day today

I had pulled this heater blower motor earlier to have it rebuilt, but it's in great shape, so I'll just clean it all up and reinstall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:57:07 AM
The crossover steering link got installed, although loosely. I think all of that stuff may find it's way back out one more time before we call it done
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:58:35 AM
With that done, the turbo parts, the springs and the new hangars all enroute, it was time to get back on project core, the remaking of a 91 radiator core support

I made the decision today to go ahead and run the much larger 2nd gen parts but that would require significant fitting to get that core to accept it

All of this is in the way
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 11:59:21 AM
OK, first lose the radiator overflow resevoir
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:00:25 PM
Original radiator briefly fitted to get critical measurements
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:01:25 PM
It would have been easy to retain this heavy brass core radiator, however I'm not sure it could handle long pulls of that much more powerful engine, so it's gone for good

THe radiator sits into these mounts, which are going to have to be moved
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:02:33 PM
I just drilled off the spot welds. First a 1/8" guide hole, then a cleaning cut with a 7/16" sharp bit and the things pop right off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:04:05 PM
A quick pass with the hypertherm plasma and the ribbing was history
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:05:46 PM
Then the other side
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:06:21 PM
Then with a little grinding it was all cleaned up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:07:14 PM
I decided to reconnect this base support section as it seems more importanter than the other sections
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:08:38 PM
That was accomplished with a simple bent section of 12 gage
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:09:37 PM
This about where the lower mounts will fit, however they needed to slide aft another 1/2" necessitating a stiffening/extension plate to be welded in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:11:35 PM
Here's what the lower mount looks like all welded in
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:14:05 PM
Next, the upper old mounts had to be removed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:15:14 PM
With a more or less clean slate, the new 2nd generation Cummins truck radiator slid into it's new home
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:16:40 PM
I just happened to score a couple more plastic tanks, so I cleaned them up and replaced the dirty stuff I had
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:17:50 PM
The factory battery tray was not fitting any longer, so I redrilled some holes a little farther out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:19:01 PM
Then came the upper mounts

They are simple tabs with a nut welded to one side and rose welded to the support. It will look factory after a coat of OD green
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:19:33 PM
And just like that, you have one second gen radiator living in a 1st gen truck!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:20:07 PM
Now for the front end...It has to fit an air conditioner condenser and a large intercooler
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:20:44 PM
And that, my loyal friends is the end of build day 158!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:21:39 PM
Quote:
Originally Posted by OVERWATCH_09 View Post
What was the reasoning behind the HSS between topper & bed?

Hard point

The top of that bed is flimsy at best, the steel tubing made that all good. Then with the way I tied it into the only hard points on the bed itself, made all of that a semi-monocoque structure.

That strengthened all of that up enormously

Secondly, the hard point aspect. The rear gets a swing away tire and fuel can carrier. I plan to anchor that to both the bumper structure and to this steel cage.

On the opposite side there will be a ladder anchored at those points as well.

On the inside, same/same. Hard point on the "Wall" to bolt things to like a fold down desk/bunk and shelving and storage bins...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:22:47 PM
More popcorn...

Bordem, anticipation, or enjoyin' the show???

Well, for tonight due to weed pullin' grass cuttin', meal cookin', and baby sittin' we're limited to playing parts!

WHo wants to play parts???

OK you in the second row...We'll do it for your sake

I got the springs, spring front mount, shackles and other things in tonight.

So we're staged to put the ball in play

Here's the springs:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:23:36 PM
That's six serious leaves of pure Mexican steel (Or melted down stolen American cars from mexico) plus the overload spring.

I am going to change things up a tad. First of all those monsters weigh in @ 71pounds each and that's a bunch!

I plan to discard the overload spring to start with. Then if you look carefully at the pack, one of the springs is doubled...I think I'm going to pull one of those leaves, and use the remaining 5 leaves as my spring.

The Skyjacker spring I have on there now has 5 leaves so I think removing the two will be a good point to start with.

Next, I plan to drill the ends and install friction pads to make the springs slip against one another much better. Finally, I plan to liberally coat the steels with dry film lubricant to aid the slippage even more.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:24:18 PM
Here's all the parts to mount the 4" longer Chevy springs into a Dodge truck chassis
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:25:14 PM
Jim actually sent me all three sets of shackles. The ones on the new super beefy hangars are stock length
The long ones are for a 2" lift which should be correct to keep the geometry correct with a 2" lower spring location. Those shackles also move the axle about 2" forward

The strange dog leg looking units keep the axle near the stock location, perhaps 3/8" forward of stock. THat is where I plan to start with all this.

Take a look at the utter strength and build quality of Jims shackle mounts:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:25:57 PM
Notice that the units are greasable and the larger sized 5/8" bushing bolts are even drilled for a means to grease the bushing from that end.

THe front mount replaces the wimpy factory stuff. This mount is obviously one piece which ties everything together and strengthens the front end a bunch

Between all the mounting holes and the various shackles, I'll have a wide range of axle positions and mount options available.

By moving the axle forward, I reduce approach angle, increase wheel base, and lessen the drive shaft angle, all positive attributes
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:27:17 PM
That's one good looking bolt/bushing setup!

And I can keep it lubed!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:28:13 PM
Two of the optional shackles...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:30:05 PM
The old and the new...Things are about to get a whole lot stronger!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:30:43 PM
I picked up some new spring pack bolts as well to reassemble the "Donized" spring pack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:31:15 PM
The hardware is top notch all the way
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:31:54 PM
This cool template will help me drill the correct sized hole in the exact spot called for
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:32:51 PM
Quote:
Originally Posted by ChrisLib View Post
Jungle does build some absolutely top notch gear for sure! And that front mount eliminates a weak link in the factory Dodge front end as the o.e. front spring mount rivets sometimes work loose and then the whole mess gets to shifting around which usually cracks the spring brackets and wallows out the frame holes, something every 1st genner needs to keep a watch for....well, not you now lol. Are the rear shackle mounts going to stay in the same location as stock, even with the longer springs or will you have to move them back on the frame?...OR is that what Jungle`s new design front spring mount is for? His earlier designs did not have the multiple mounting hole setup. I`m betting that SD is going to have a nice comfy/flexy front suspension with those longer springs as even a good set of 48"`ers makes a huge improvement.


Copy that

If you noticed the dog leg shackles, those allow for the 52" springs only moving the axle 3/8" forward I believe.
If one uses the straight shackle, then the axle is pushed about 2" forward
The multiple holes allow for the use of a stock 48" spring, or a 52" spring in several different positions to help you place the axle where you want it.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:33:24 PM
Well, got a few hours in today, surprisingly!

I started with sanding the big front spring mount
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:34:20 PM
Then the new robust shackle mounts. They were treated to some quick wrist action and some #180 grit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:35:06 PM
Then it was all treated to a fine dispersal of mist containing various chemicals and some cool gray pigment!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:35:52 PM
OK, movin' on. Time to tear down the springs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:36:34 PM
The prior Chevy's that were stolen by Mexicans and melted down to create these came apart easily. The leaves were well formed and required only hand pressure to squeeze together to pull out the bolt

Next off comes the bolt holding the military wrap together
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:37:09 PM
Then the thing falls apart
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:38:08 PM
Initially I pulled out the two leaves pointed at in the pics. I thought a 5 leaf spring would approximate the Skyjacker springs already in the front

I was wrong...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:38:58 PM
That created this spring, which at the time I thought was what I was going to use
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:39:41 PM
Here's a stocker and a modified spring
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:41:01 PM
Moving right along, next up is removal of the spring eye bushings. I'll use mo-better Poly bushings with mo-bigger 5/8" bolts

The work is crude, but you have to beat the lip up and away from the eye so that you can cut it off, then hammer the bushing out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:44:19 PM
Mine came apart fairly easily
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:45:47 PM
Here's the new hardware that will be used:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:47:10 PM
Afterward I reassembled the springs to take some measurements

5 Leaves each...the ones I built and the ones on the front of Square D

Should be the same, right?

But...What if the leaves are different thicknesses????

Hmmm, better take some measurements...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:47:49 PM
Hmmm, seems my five leaves are a bit thinner than the Sky Jacker springs

Check out the measurements

By adding in the leaf I removed, I brought the spring pack back to almost the exact thickness as the Sky Jacker spring...Within .035"!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:48:40 PM
OK, enough on the leaves for now. I am waiting on the friction pads to show up so I can drill the leaves and fit them, then paint and coat the leaves, install the bushings and finish them

After cleaning the blower motor and its housing, I reinstalled it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:49:28 PM
Oops, forgot to show the compare shot showing the factory 9/16" hardware, and the greasable 5/8" bolts I will be using:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:50:21 PM
I added some sound deadener to the firewall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:51:25 PM
Then the cleaned and touched up factory cover was set back in place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:52:23 PM
Then I transferred the fan belt...It is a bit too long...ERRRR!!!!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:52:58 PM
And that is all she wrote...I hear a fat lady singing and some burgers getting ready to be cooked

(No the wife is not fat! Nor are the girly daughters...)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:55:02 PM
The turbo is built and shipped
It ended up being a HX40 style twister with a 65mm wheel and a 12cm housing selected to spool quickly and to eliminate the smoke from the large injectors
The injectors remained the Cummins 370 horsepower marine units and I will be using a new HX-40 down pipe. This motor will produce approximately three times more power than the stock engine that resides in there at the moment. Torque should be well north of 1200 and with the super high gearing the truck has the potential for amazing fuel economy
The spring friction pads came in and I procured a couple cans of the graphite dry film lubricant to coat the springs with.
I think they will get a multiple stage process of cleaning to remove the poor quality paint from the edges. Yup edges...Only the sides of the inside leaves were painted, the rest of the leaves remained untreated raw steel. No wonder why these things rust so badly.
I think I'll pay attention here and get some good red oxide primer, then follow with a good epoxy primer, then John Deere blitz paint with hardener. I'll top coat all of that with the graphite and hope for the best after that!
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:55:41 PM
Quote:
Originally Posted by DuramaxExpress View Post
Curious as to why you would run marine injectors in your TRUCK?


On a more serious note, everything I have read on marine injectors says they have a different spray pattern and like to run hot and hazy. Which was something I thought you were trying to avoid with the build.

The tech at Gillette diesel and I had a load of conversation on that subject.
One thing about that injector is the pricing. Whereas most of the bosch and aftermarket injectors run $100 or (a lot) more each, these go out the door for $72. Economy of scale principle and all that. Since it is an injector built by the scads for all the Marine purposed engines, you get a high quality part that costs less because of the large production runs.

Next, yes, they are smoky injectors. Smoky that is if you don't do something about it. We did...Did you notice the tiny 12CM exhaust housing? That housing will run the turbo up quicker eliminating a lot of that smoke.
I stayed on that point...No snail trail, and they heard me loud and clear. They feel strongly this combo can easily meet the 550 HP requirement and probably produce 600HP or more with reduced smoke.
If it hazes, that is acceptable. I am going to spray in alcohol and water so I think I have a good means to get on top of the higher temps.
Now as for the spray pattern, I believe they spray somewhere from 155-159 degrees. That is a tad bit problematic with stick pistons, but not so much with the Marine pistons I have installed in this motor.
Ah, in the end, I hope this combo works out well, but if it doesn't, I'll sort it out then
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:56:42 PM
Quote:
Originally Posted by FBJR View Post
Which primer will bite and remain flexible? 


JR, you knucklehead...

I'm going to use that red Obamaoxide stuff

It's guaranteed to change the rust but doesn't. Somehow I feel, that, despite the overwhelming evidence to the contrary, that the stuff actually does work.

It's manufactured by the Golf adventures and paint company in Moscow, but also in China and North Korea I hear. No one actually knows for sure where it comes from though! Some people even think it's made in Hawaii! HA, I don't believe that either, the part about it coming from the commies...Nope, again I sorta know for reasons I can't explain that it must come from Hawaii. In fact I once goggled the founding documents from that company. And there it was in black and white: "Incorporated in Honolulu Hawaii, USA, 11 September 1775!

This paint remains flexible. Flexible enough to change at a moments notice into anything the manufacturer can think up...Actually had some of it change into environmentally stable bubble gum once! Had that stuff sprayed on the left fender of my Chevy back then...It Kept attracting deer...Weird? Don't worry, though, I treated them in an environmentally responsible manner along with some barbeque sauce and a bed of hot coals...

Yup Obamaoxide is some good stuff, even though it actually doesn't work. You see when I first started using it, I found out that it prequalified me to company dividends. Yes, it's true. All I had to do was to keep on using it and they sent me all sorts of things...free things mostly from my working neighbors. Naw, I don't quite get that part of the Obamaoxide experience, but as long as they keep sending me my neighbor's stuff, why, I'm gonna just keep on using the stuff.

One thing I don't like about it, is that it smells like bull crap! Really, and well, I just sorta got used to it. Heck most of the environmentally responsible people who also use Obamaoxide don't bathe very often (saving water for the plants and fish I guess) so the bull crap smell of the paint sorta gets lost amongst them if you know what I mean.

I just hope those deer don't come around licking my freshly coated springs though. Although I don't mind seeing my EPA buddies on a regular basis (We all hang out together when they aren't stickin' it to those capitalist and imperialist pigs down at the factory), and drink beer the ATF confisicated from one of those capitalists. Ah, what the heck, if the deer come, we'll just treat one of them in an environmentally responsible manner, build a barbeque pit, and have a party on the beach!

Yup Obamaoxide is the stuff. Get it on you, and even though it doesn't work, it is hard to get off...I mean you just can't get rid of it. Then if you do, someone puts your name on some list somewhere for some reason...market research I suppose, well, whatever. I'm mindless, brain-dead, in need of some freebees, and loving the change with obamaoxide paint, and it's time to get out and vote! Gotta go
See ya'll later!
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 12:59:29 PM
Quote:
Originally Posted by FBJR View Post
Which primer will bite and remain flexible?


That turbo sounds great!

JR, ya know I think as a responsible citizen and father I should point out something rather obvious about your avatar...Not that we've had avatar issues with you in the past...

How old is that child you have in your employ?
He appears from my viewing angle to be around 6 years, 2 months, 23 and a half days in age...Am I close?

I know that you being an officer of the law, you have intimate knowledge of the law with respect to the child labor laws. Now here in the tucky we consider you an adult (and married) at 13, but Kalifornia? I thought with all the video games, and surfin', and playin' around, your children finally hit puberty around 31?

Am I correct?

So why are you employing a mechanic who is only 6?
I'm sure you have the proper state county and town approvals and licenses, and have signed the release forms, gotten the environmental impact statements, site surveys, and town commune studies and approvals. You certainly are paying employment tax, labor tax, air purity access fees, land use and future reclamation fees, have him registered with the social security administration and enrolled with a proper OB kare policy.

But with all those things completed, did you consider the sensibilities of your Mexican, Palestinian and Hamas neighbors? I mean do you think they could have been emotionally scarred by such an early display of "an intent to work" attitude? How exactly does that play into the girly sensitive fabric of the local socialist society?

Me, I think someone is headed your way to have a very politically correct conversation with you about you truing to instill a work ethic into a member of the Kalifornia collective. That's very disruptive you know, and shows just how thoughtless you law enforcement types really are!
 
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:01:29 PM
I fixed it!

After all that business, and I was buttoning it up, I discovered the MCU (Motor control Unit) had vibrated out of its mount. Yup, that was it! With it moving about, it was tugging on this wire or that causing an intermittent connection which caused the brain of the thing to throw a miscommunication code. So with all connections pulled, wiggled, and reinserted, I got a load of towels through! I figure short of washing an Armee tent, towels would be the most abusive...Passing that test would prove it works...AND IT DOES!

OK, now back to the Square truck project.

Parts continue to arrive, creating somewhat of a backlog of sorts

Here's the 4" down pipe for the HX-40 style turbo that will soon rest in SquareD's engine bay
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:02:17 PM
Quite the difference between this pipe and the old style 3" down pipe from the 1st gen engine!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:03:20 PM
The new injectors showed up as well...Compliments of Gillette Diesel of Utah. They decided I needed these Bosch Marine injectors and they sure are purdy!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:04:01 PM
The box also contained a pretty new looking Turbo Charger
Based on the HX-40 series units it will make all the power SquareD (and I) can handle
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:04:31 PM
65mm compressor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:05:04 PM
I know Steve had said he was building it with a 12CM exhaust housing...but I can't tell from these casting numbers
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:05:57 PM
It's one clean looking unit...If it would only stay that way!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:07:44 PM
OK, back to the front suspension

But first a note: Anyone with a third of a brain will have noticed how much I jump around here. Going from torqueing main bearings to installing headliners back to setting pinion angles and then over to LED lighting!
Crazy, yes?
Not so quick!
I could just stay on, say the suspension until it was completed, then go on to fabbing up the radiator core support. The reason I jump around so much is because I have to get parts. You see right in the middle of doing something on the core support, I'll need some special hardware, that gets ordered that night. But so that the day is not a wash, I jump over to the steering gearbox.
You see, by having three-five things going at the same time I can get SOMETHING done all the time. Now we are putting together the engine, building the core support, modifying the front suspension and dilly-dallying on the lighting, interior stuff and a host of udder stuffes.

Comprende?

Well, it doesn't matter if you don't, that's the way we roll here. I was just trying to lower the blood pressure in about twelve thousand of you out there in forum land!

OK in the spirit of anything is in play, lets look at the new shackles Jungle just sent me. According to him a simple math error, adding 3/4's of an inch in stead of subtracting it caused Mr. suspension geometry to have a headache.

These laser cut shackles fixes all that!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:09:00 PM
The dogleg shackles push the axle 3/8" farther forward, whereas the straighter ones push the axle 1.75" forward

I assembled Jungles HD front shackle mounts that will be going in the frame soon
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:09:47 PM
That Dupont Nason paint with hardner sure makes parts sparkle!

Next up we have the spring friction pads. The el cheapo springs I purchased for $145 each (A deal!) were just cheapo springs, Hey I just said that!

Installing these anti friction pads, treating the springs to a process you are about to see, and adding in the poly bushings bring them up to a whole new level
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:10:24 PM
These require a 9/16 hole to be drilled into the really hard spring steel

I did that by using a cobalt drill bit, plenty of cutting oil and a slow drill speed on the drill press
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:11:48 PM
And they fit just fine
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:12:43 PM
And then for the next couple of hours 19 more holes got drilled in all these leaves little bit by little bit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:13:47 PM
The next step in the spring pack prep was to give each leaf a through sanding to get it as flat as I could. There was a bunch of surface gunk and slag stuck all over the steel. After another 1.5 hours I had all the leaves sanded smooth
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:14:41 PM
Then the leaves got wire brushed and thoroughly cleaned with solvent to prepare them for painting.
During the sanding process, all sharp edges were rounded off and blended in so nothing sharp could dig into anything near it.

The first step in painting is with a red oxide primer, which we all know is a very good rust preventative primer, which was actually developed for ship hulls that cross stuff like oceans.

It took two full cans to give all 12 leaves a heavy coat
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:15:21 PM
And, no, I didn't forget the main leaf...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:16:34 PM
The springs are resting on the box containing the new turbo and the injectors.

I am now waiting for some fasteners to arrive to bolt that turbo on. So for now the box is just a work bench and welding table!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:17:42 PM
Quote:
Originally Posted by EL TATE View Post
Lookin' good there buddy. I wish I had the shackle options when I did my jeep, but cutting and moving the spring perches back got me close to similar results.


I know...as time passes and the smart guys get to looking at things, they eventually come up with mo-better ideas. Jungle is definitely one of those people.

I just finished assembling the springs...
Back out to the salt mine...90F and 80-90% humidity
I'd prefer the total heat of the stan to this wet stuff...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:18:24 PM
On to work stuff, got the springs in primer and paint:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:19:01 PM
My favorite J Deere Blitz black with hardener
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:19:45 PM
John Deere also provided the spray graphite that I used to liberally coat the leaves
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:20:30 PM
The stuff gives the steel a cast iron appearance
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:21:10 PM
Then the anti-friction discs were installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:21:59 PM
Using a new spring pack bolt with liberal amounts of anti seize applied first, one by one the leaves were assembled into a spring pack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:44:46 PM
Starting to look like a spring!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:45:29 PM
No room to use the old spring clip bolt, so in the fashion of many of the clips I have seen in the past, I hammered the ends around the top leaf
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:46:32 PM
Then came the poly bushings and just like that, the springs were done!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:50:41 PM
Of course, I'll trim the bolts after I determine the pack is the proper thickness.

On to project next: Fixin' up an old intercooler

If you remember I was going to scrap this one because of some holes I found in one tube. After thinking about it and thoroughly checking the thing over I decided to repair it.

First the cleaning:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:52:14 PM
I used several layers of JB Weld Epoxy to address the holes and the corroded seam
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:54:49 PM
I top coated the cleaned and repaired unit with gray epoxy sealer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 01:56:19 PM
The repaired side looks just as good
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:03:45 PM
That thing is going to get mounted in a soon to be "Way-mo modified" core support
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:04:57 PM
I started removing things in preparation to pull the engine/transmission/transfer case

First was the down pipe, then the driveshaft

It got wrapped up and stored in the bed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:06:19 PM
Then I started pulling the wiring harness off the engine, and marking every lead for reference.

That took some time
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:07:14 PM
The sled dog lent a hand!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:08:42 PM
Not wanting to get too much farther into the really heavy lifting today, I painted up some suspension parts, the shackles, and removed, sanded and painted the modified steering shaft
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:14:43 PM
While I was sandin' and paintin' I started getting all creative.
Not like creating life, creative, but messin' with stuff, garden variety creative

Witness the valve cover.
The gray was only the first of several layers of stuff I planned to dress things up. Ya-ya-ya...Don doesn't do that, I know, but today, I must have been feelin' it or something
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:15:59 PM
That's OD green...
I think I'll sand off the letters, leaving the outside ones aluminum and paint the "DODGE" red in keeping with the factory colors

So, that was it for a pretty good day at the races!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:17:09 PM
Quote:
Originally Posted by KensAuto View Post
Big D, you think wrapping the spring bracket is a good way to lose articulation?



I do.

Wait, I have more....epoxy on a system that holds 40ish pounds of pressure, that when lost, will cause the supercummins to have the power of 4 cylinder fiat ,billowing clouds of un-concealing smoke? I would ditch it now instead of later.....more poking
Everything else looks top notch!

Special K...

I've owned a bunch of springs wrapped just like that. I don't see anything wrong with it at all.
You don't want the leaves pulling apart and that is all the clamp really prevents.
I don't see the spring losing any articulation because of that clamp

Epoxy on the 40 psi intercooler bad.
Again good buddy, don't agree. CHeck with Ashley. He seals oil well blowouts with epoxy. THe military uses it for all sorts of things. Some radiator shops have repaired IC's with epoxy as well. Not to be taken lightly, the grip of properly installed epoxy nearly equals the parent metal.
Now let's say those small holes blew out during an emergency. That's one tube of over a hundred that is partially compromised. You could lose what 1/4 of 1 percent pressure? or volume. Remember the big ole' 65mm wheel pumping half the air in the county every minute.

Nossir, I think that is a good repair and it will hold.

Guess we just can't agree today, maybe tomorrow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:17:54 PM
More worky today.
I started the matra during the morning exercise
"On the ground, on the ground, on the ground"
I was refereeing to the transfer case and hopefully the transmission

So here's the scene underneath before all the fun and action:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:18:41 PM
Sled dog was helping again today

Parts coming off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:19:23 PM
That driveshaft fought me a lot. Surprising since it was off recently

It will probably get replaced with a stronger unit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:19:59 PM
All that was holding the transfer case in was it's linkage and these nuts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:21:03 PM
The nuts were simple enough. albeit loosened with difficulty, but about then was when the lack of height of the transmission/motorcycle jack became apparent
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:22:39 PM
Well, this next series on jack modification cost me the time I would have had to unbolt the transmission

But I decided to make the jack taller to work with Square D
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:23:20 PM
Well, this next series on jack modification cost me the time I would have had to unbolt the transmission

But I decided to make the jack taller to work with Square D
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:24:12 PM
So I cut it apart, made up some 8" legs to extend it's height and applied fire and smoke to the assemblage
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:28:24 PM
More firey smoke and sparks, then this happened
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:29:11 PM
And it fit!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:30:19 PM
With some coaxing I achieved seperation
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:31:44 PM
Lets play "Tools" a bit longer
Since the trans and the crossmember is next on the removal scene, it was time to support the engine for removal

Picked up this engine tilter thing ah ma gig over at the Chinese tool store otherwise known as harbor freight
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:32:57 PM
Fitted to Duane's engine hoist. You can see it's in about the same shape as the rusted out frame on his jap Suv!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:33:45 PM
I just hope it doesn't rust in half before I get that fine chunk of American made iron out of that unrusted 75 year old American truck frame!

Messing around the engine got me to lookin' at things

Every time I start lookin' at things, I either 1. Buy them or 2. take them all apart and modify them.

I noticed this block heater cable hanging there so I removed it and set it a vat of that purple degreaser and jap car dissolver stuff
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:34:26 PM
Messin' with that caused my brain to look at other wiry things to take apart, so I started to strip the wiring harness away
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:35:01 PM
Then I got the idea, why don't I just remove it altogether?

Here's where it disconnects:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:35:54 PM
And sure enough, it comes right out!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:36:25 PM
Starting to clear things up nicely!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:37:32 PM
The parts I painted up yestertag turned out nice!

I was so into working and sucking down water like the intakes of the grand coulee dam, that I forgot to eat. I was snacking all day on almonds and wondering why I was so hungry!

And that is all the KY Kid had time for today, off to find some pizza
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:39:18 PM
Wow, you people are afflicted!

Red dog, alien abductions...Those are some potent theories

Naw nothing as cool as all that

Just mandatory family reunion fun time

I did launch out in the family camper thing. Had an electrical failure and pulled my back out trying to unhook that monstrosity!

We did manage to run through 1400 of my rounds and probably 1000+ of other peoples.

I tested out that Canik 9mm and have to say: Not impressed!
Trigger pull is in feet. Even reset is super long...

Ran the new bump-fire M4 I built. WHOA!!!!!!!! That thing pours out the lead

Cousin filmed me doing a 60 round mag dump. Only took seconds while I blasted huge rents into the once thriving Kintucky blue grass. Turned into blew grass!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:40:05 PM
Well, I got the motor and trans out today.
My back went out yestertag, so pumped up on aspirin, I got it done.

Here's the situation as aspirin #1 and #2 are starting to loosen things up somewhat
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:41:14 PM
I figured the easiest way to get it out would be to lift the engine, then slide the truck aft until clearance was all around the motor in a uniform manner!

So I mounted up the tires, then realized this is the first time the wheels have been on all four corners!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:42:06 PM
The thing suddenly looks short, like a stretched blazer or Ramcharger...

So again beneath the bolts and nuts were a flyin'

Here's the cross member which is out for the very first time
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:42:56 PM
Tilt motor and watch trans fluid run all over

Hmmm, forgot to drain trans fluid--Check!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:44:00 PM
Despite all that cleaning earlier, things were still plenty dirty

This step will complete the cleaning and rejuvenation process. From this point on everything will get completely renewed and I'll be working with fresh everything
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:45:06 PM
Grease! Dirt!

Gonna be gone PDQ
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:45:56 PM
And it's out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:46:32 PM
The trans is free

It's about to undergo a huge transformation!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:48:16 PM
Then all the accessories and mounts not sold with the motor came off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:49:03 PM
Then everything gets soaked in that purple cleaner/degreaser
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:50:40 PM
Then thoroughly pressure washed.

I washed for an hour even laying on the creeper and spraying the undercarriage again. I got everything really clean, and ready for the rotary wire brush.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:51:19 PM
The engine is ready for delivery to it's new owner.
It's been sitting in those frame rails for 23 years!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:52:27 PM
Better:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:53:27 PM
Electric power steering
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:54:50 PM
And that's the situation at the end of build day 163!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:56:33 PM
Quote:
Originally Posted by Cudakidd53 View Post
With longer springs going on the front, will you make a pan hard bar like you did on the rear? Is there even such a thing for front axles?

I also was wondering if you'll be dyna-matting the balance of the firewall and trans tunnel now that you have easy access?

Looking like you'll be finishing up quickly now that you've removed the motor and can finish that fluid change...


Not a panhard...A traction bar or wheel hop eliminator...
Not required.
Power distribution is something like 70/30 rear/front
Chevy and Ford all use longer springs so it won't be a handling issue other than making it ride much better.

I believe I am going to dynamat the firewall, although not decided if it gets on the outside or the inside yet.
I wrapped the heater motor area because I have no access from the inside for that area.

It will go faster, but not as fast as you may expect. Remember once the power plant and sheet metal goes back on, next comes an extensive bumper system that will wrap the vehicle and take a bit of time to complete. Then comes the exo-skeleton needed to lift those pesky 2 X 4's out of the way
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:57:08 PM
Well just as I was getting started today, I noticed the red dog had struck yet again.
Funny because I was chuckling over the fact that that D!)*%!! mutt was in the front yard chewing up the mrs's new sandals.
Ha, joke was on me!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:58:01 PM
The main press for the day was prepping the frame for the spring removal and reinstallation of the longer springs, but I fit a few other things in as well.
I wanted to get the starter off to the electrical shop to be rebuilt, so it got cleaned up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:58:44 PM
I didn't want to lose all the little parts that are scattered about after disassembly from the old motor, so I cleaned some of them for reinstallation
Here is the cast iron engine mount adapter assemblies
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 02:59:29 PM
They got the standard wire brush cleaning and primered prior to painting treatment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:00:14 PM
Then some John Deere Blitz enamel
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:01:02 PM
Then reinstalled onto the new motor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:01:47 PM
With all the sales about, my friendly Lowes yielded this new Bosch drill to replace the aging unit that has been retasked to operating the leveling jacks on my camper
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:02:37 PM
After the aggressive pressure washing, things weren't looking bad at all, but time to bring it back to near new looking
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:03:12 PM
Had to clear the frame of all remaining pieces parts.
Here the proportioning valve is off. I'll evaluate it for reconditioning or replacement
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:04:09 PM
After what seemed like forever, I had all the old rust and undercoating stripped off the frame
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:05:20 PM
Then everything was washed with solvent to get it really clean for the next step.

I only finished back to near the shackle mount since those will soon be removed to make room for the new HD parts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:06:56 PM
Then the rust converter and metal conditioner was brushed on and chemically did it's thing turning black in the process
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:08:41 PM
These parts which are transmission cooler lines which actually mount to the engine are next in queue for reconditioning. When that big round cooler goes back on, then the turbocharger is next. That will get the motor pretty close to being ready to reinstall.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:09:34 PM
So, that's the situation in the build at the end of build day 164
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:10:16 PM
Haven't posted in a few days

My back's out

I've been practicing being horizontal since Saturday

I did manage to get that day of grinding in, but that set me back big time

I cleaned out the local stores of Tylenol and that helps keep the pain at a comfortable "9" (on the 1-10 pain index)!

Yesterday I dared some driving. That was good right up to the point where I had to use my leg to step on the brake. That part did not work so well, but, hey, it's an off road truck and a bit of four-wheeling in the local drainage ditches only served to exercise the suspension and prove that all that expensive suspension stuff in the D-Max works as advertised!

So I made it to the paint store and picked up more acid etching primer and some more rubberized undercoating so I'm "Primed" and ready to get back on the frame project and get Jungle's parts in and installed.

Then I read all about injector replacement, as I'm chomping at the bit to get all that stuff installed on the motor and essentially, finish it up to the point where it is ready to reinstall.

I have been talking to the folks at Dynotech, who are renowned transmission builders. I am vacillating between doing it myself and having them do it. We will be using a Goerend torque converter who's stall will be decided after consultation with Steve at Gillette Diesel to properly determine the stall, but the decision is to go old school, non-lockup.

One thing Dynotech does that I could not duplicate is that they machine the case to actually bolt in the sprag clutch. Normally it is set into splines in the case. However if one were to do shuttle work such as snow plowing where direction changes are frequent and sometimes under power, the sprag can fail. Bolting it in pretty much eliminates that.

From a combat perspective I can see proceeding forward, then come upon a bunch of knuckleheads at a choke point or ambush site, then without thinking (Fear) slamming the trans into reverse to get off the "X"

Not that I won't be able to control that fear (I won't of course...War has taught me that fear is a pretty large motivator, and so are bullets) But I will hack, well, let's say, hastily to remove my presence from the situation. I would not want my transmission to fail at that critical point...SO likely Dynotech will get a big box showing up.

They will build the original trans, thus keeping those parts that were born together, still together through the truck's next life.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:11:15 PM
OK,
I'm going stir crazy with all this laying and sitting around, so I pushed it and did a little light work on Square D.

First up, I didn't like the way the valve cover piece turned out, so I redid it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:12:08 PM
Those colors just weren't working for me, and even though I'm not a color guy, hey, I want the thing to at least look professional. So I decided I'd spray it with wrinkle black, then sand off the lettering later
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:12:58 PM
Even though it's a Krylon product, it did a pretty good job me thinks
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:13:33 PM
On the motor
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:14:03 PM
Hoping to get rid of more and more of these new parts, It was time to throw in the new Bosch injectors.

First the injection lines are loosened
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:14:53 PM
Then the inlet pipe
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:15:28 PM
Here's a good look at the inlet heater grid:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:16:02 PM
Then the other end is unbolted using a 19mm wrench
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:17:10 PM
Then the front lines come off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:18:29 PM
Followed by the back
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:19:22 PM
Next, the fuel return line comes off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:20:12 PM
And finally the injectors themselves
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:21:06 PM
Mine came right out
With the new head and having just been assembled this part of the task was easy
The new injectors came with new collars as well, so installation was a snap
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:21:39 PM
They get torqued in at 45 ft/lbs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:22:19 PM
After tapping the rubber O-Rings back into the recess in the collar, the injectors are officially installed

I want to clean up the injection lines to see if I can remove all the paint and show off the stainless steel. I also want to check them thoroughly for chaffing or cracks
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:23:05 PM
Looking at how well that valve cover turned out, I eyed the intake elbow and decided to scratch it down with steel wool
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:23:37 PM
And after some drying time thar she goes!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:26:03 PM
Well, even though my back feels like there is some welding going on back there, I'm still pressing forward

Parts orderin'

I picked up a set of B&D Diesel intercooler and hose silicone boots and super duper clamps for when that IC finally finds itself front and center ahead of that stormin engine. Thanks to Holton over at Alligator Diesel again!

I have also been spending hours and hours combing through the transmission builder information.

I am ordering a ton of parts.

I interviewed a few builders and after a lot of thought, decided to build it meself of myself, well, I'm doin' it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:26:30 PM
So, transmission...
Interviewed some really great companies.
None bad in the least
Gorend
Dynotech
SunCoast
The purple part people

After all that I had acquired a lot of good information and met some knowledgeable people. But I felt the firm "Click" of things falling in place when I talked to Andrew and Ernie at Sun Coast in Flordia.

So they will be supplying the parts for this build. Something Andrew, a former combat Marine said made a ton of sense. He encouraged me to learn how to do it myself so in future times, I can also fix it myself

SO here's a partial list of what I will be getting/doing to improve that transmission to a near indestructible state

6 pinion planetary gearset
shift kit
steel stator
Steel flex plate
Custom lower stall converter
Billet servo
Billet accumulator
47RE intermediate shaft
Billet input shaft
Direct clutch pace from 4 to 6 clutches
Front servo 5:1 apply lever
Billet band strut and apply levers
Sonnex spring plate
Longer overdrive clutch spring
48RE direct O.D. clutches (23 in lieu of the factory 8!)
New sprag clutch
OD clutch added clutch/steels
+ 4 quart oil pan
15 degree O.D. sun gear

I'll also pick up some special tools and a factory service manual

There is a lot more stuff going into this build, but's that's the strong stuff
Expect to see the red clutches a solid band new bushings and a few other goodies.

And

Expect to see about a thousand pics of all that ruckus right here!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:27:16 PM
Quote:
Originally Posted by TexasRedNeck View Post
It'd been easier if you'd have just gone stick....

There was a big discussion earlier about why I'm not using a stick

In summary

I've been in a few crashes, aircraft and vehicle...and a few scraps.

One thing I noticed is almost no one gets out unscathed with many a broken arm and leg.

So can you drive a stick with a broken leg?

An automatic?

That's pretty why I made the decision
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:28:43 PM
OK back is still inop, but doing back exercises (Uber painful) tonight I actually stood up straight! First time in 2 weeks!

But I am not wasting time. Reading hours a day about transmissions and getting good advice from readers here like ChrisLib, thanks.

I am in the acquisition process at the moment ordering both new stuff and good used parts from EBay.
I now plan to build what amounts to a hydraulically controlled 48RE (48RH???) stuffed inside an ancient A518 case with a fluid coupling converter, although it will be a lower stall unit.

So that process is ongoing and I am looking at rebuilding the NP205 transfer case as well. All good oil changes should include a rebuilding of the transfer case!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:29:34 PM
Quote:
Originally Posted by FBJR View Post
I am afraid to ask what the approx cost is of just the trans parts, but probably heading more or less the same way.

As for the 205, it is so easy you could do it in your sleep. About the hardest thing is getting the right number of needle bearings to stay where you want.

Definitely over 3K, possibly over 4K
clutches, steels, seals and the like are not too bad, dunno but $600ish.
Converter $600-$700
Billet shafts upwards of 2K+
Special tools are around $250
Assortment of all the other parts (drums, accumulators small billet parts...), which I can find used with time, probably near a grand
Shift kit $150
Flywheel $300??
Deep Pan $300.

But this transmission will be close to the ultimate. It should be able to handle almost anything I throw at it. With normal driving it should last forever. It follows the model for folks who do 25psi boosted launches!

NP205 parts around $200ish
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:31:16 PM
Well. as my back sorts things out I am getting little things done

I wanted to inspect the condition of the fuel injection lines, so I had to remove the 2 layers of paint that had accumulated there

Paint stripper works fast, removing both old paint and spots of skin on my legs!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:32:03 PM
May not look like very much, but after all the paint remover work, I had to "Sand" each individual line with 00 fine steel wool to get everything off
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:32:48 PM
There was only one area where some chaffing took place to be the least bit concerned about, so I painted them up and will reinstall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:33:36 PM
While I was making a mess, I wanted to get the old paint off the block mounted transmission fluid/fluid heat exchanger. The "Goop" took a bit longer, but did it's chemical work just as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:34:14 PM
The thing is looking to be in pretty good shape, just like everything else
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:35:05 PM
Still wanting to keep it light, I went after the valve cover, sanding off the letters like I wanted to earlier
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:36:03 PM
Just got the old starter rebuilt. THis one got a lot of new parts and only cost me $60!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:37:02 PM
The injector lines got reinstalled after the cleaning and repainting
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:37:37 PM
That turned out pretty well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:38:23 PM
That turned out pretty well

Next up, the intake elbow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:39:07 PM
Alligator Diesel supplied the BD Diesel silicone boots and ultra high quality clamps that will be used to seal this monster up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:39:59 PM
The cinch nut is about 1.5" long and slides inside the spring which serves to provide constant pressure on the clamp.
I have had the hoses blow off my D-Max truck maybe half a dozen times. I do not want that to happen here.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:40:58 PM
The boots are multi layered with steel expansion wires. They fit rather well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:41:38 PM
After coating the sanded aluminum on the valve cover, that piece was fastened into place
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:42:20 PM
On went the new high volume lift pump
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:42:58 PM
I'm trying to figure out what to do with this fuel shutoff solenoid.

You see voltage is used to hold the thing open while the engine is operating. But what happens if I wish to continue driving after a complete electrical failure and a dead battery?

I am contemplating using a push pull mechanical cable to shut off the fuel and delete this part altogether
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:43:57 PM
Today was mostly about reconditioning these parts so that I can reinstall them and get them out of the way
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:44:49 PM
After some wire brush action, this trans cooler is ready for some primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:45:21 PM
So it got a very heavy wet coat of acid etch primer
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:46:03 PM
Then came a bunch of other parts getting the same treatment
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:47:10 PM
Still keeping the work medium heavy I continued on to the transmission crossmember

First I cut off this vibration absorber/counter weight pad that is not needed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:48:07 PM
Then the wire brush action continued
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:48:57 PM
Since I had gone through some scale rust, I treated the part to the rust converter material
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:49:43 PM
Then the other parts as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:50:15 PM
Then off to the hanging jungle
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:51:14 PM
There, they received two generous (runs) coats of my favorite Lycoming engine gray with hardener
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:52:32 PM
Quote:
Originally Posted by rparlee View Post
What... No SOB pic today?


Ah, my bad

Got in a hurry...Had to finish in time to shower off a full inch of rust dust and caked blood from several million holes that formed in my legs during the grinding process. The little pre-ranger had football practice and that coach does not do late
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:53:37 PM
Quote:
Originally Posted by DrunkSailor View Post
Im intrigued...

Navee guys...

OK kimosabeee, this is what I was thinking

With that solenoid removed, first off I can remove a leaf from the new springs because of weight savings!

Well, maybe not that much but certainly close, I think we can all agree!

Anyway working out the linkage will be a bit tricky because I believe the solenoid contracts to allow the fuel to flow, and relaxes (Extends) to shut off the fuel flow.

Therefore a direct connection of the linkage would make the pull handle work backward, i.e, pull to run, push to shut off.

Now that would work, however seems counter intuitive. The thing with combat or emergency stuff like guns for example, things that are designed to be used during heightened emotional states ought to work like you "Think" they ought to work. If the trigger of a gun worked by pushing it forward, well, the weapon would fire and be just as deadly, but who could remember to actually do that during a gunfight?

Sorry guys, I'm talking to Navee here so I'm splain'in things sort of slow...

Well if I come in to the injection pump through the hole that was vacated by the removal of that huge hydraulic D-9 Cat looking solenoid, then the thing will work backwards.

So I think the cable will look like one of these GA cables like you'd find in one of those cardboard Cessna's, but how it hooks up might be something of a science project.

In the end the forces of good will triumph and we will go on to other pressing matters...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:56:26 PM
Quote:
Originally Posted by BobbyB View Post
It's officially tomorrow.

Yes it is, and you my Airborne Friend will see Square D minus the old suspension!

Whew after a 9+ hour day, I have it ready to start going back together.

So let's get busy with a big update.

First I just snapped a pic of the crossmember parts after the rust converter, converted them into something a bit better looking...and ready for scuffing and paint
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:56:56 PM
Next, I wanted to get some of the parts in the hanging jungle reinstalled in stead of placing them on shelves, so the trans oil cooler got reassembled
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:57:44 PM
And stuck back onto the engine
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 03:58:44 PM
Then the motor mount adapter plates
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:00:17 PM
Then the turbo was loosely bolted up. I am awaiting two shorter bolts for the lower mounts...They are enroute
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:02:57 PM
Here is a couple of new Cummins oil line to block and turbo fittings. I decided to go all new with the oil supply stuff
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:04:08 PM
Next, the front end was set back onto the cribbing/support thing I built and the wheels removed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:06:04 PM
A reference photo of the stock stuff...final view
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:23:50 PM
The old spring plates came off after quite a bit of effort. The impact wrench, neither of the ones I own could budge the nuts, so I cut the things apart with a grinder
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:25:10 PM
I plan to remove these wedges and reuse them on my homemade spring pack to keep pinion angles friendly
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:26:22 PM
The old Skyjacker 6" lift springs and my new pseudo-Chevy rear spring pack
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:27:15 PM
In this shot, I am removing the stock front spring hangars the easy way, with a plasma wrench!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:28:08 PM
No wonder the stock suspension rode so poorly, the bushings and bolts were all rusted together!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:29:36 PM
Next the shackle hangar rivets got ground off and beat out
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:32:20 PM
This old stock stuff can't hold a candle to Jungle's heavy duty parts:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:33:14 PM
Not much left of the factory front spring mounts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:33:58 PM
Here is all that remains up front now:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:34:28 PM
These may not look like much, the remains of the factory rivets, but I can assure you they will not leave the truck easily! Expect a bunch of work getting those little jewels out!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:35:25 PM
With the supplied template bolted to the frame, the frame holes were enlarged to accommodate the more robust poly bushings that will soon reside there!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:36:22 PM
With the major work in the rear view mirror time to mask up, wipe down the frame, and apply the rubberized undercoating
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:37:52 PM
Then came 4 large cans of super high quality rubberized undercoating. I don't want this thing to rust again
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:38:56 PM
And that was the day, all 9+ hours of it

Here is the S.O.B. at the end of build day 168:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:39:37 PM
Transmission update:

I reported earlier that I was buying a bunch of parts from Suncoast. Well that plan changed.

They haven't gotten back with me after my calling many times.
I don't know about you, but I really don't like that. I talked to Andrew there and Ernie their builder and both of those guys were top notch. Then Andrew went away for awhile and the ball got dropped. So I started calling, always getting a fella named Jimmy. Nothing further happened so after a week of my asking if anyone got the list of parts together, today I pulled the plug.

I hear good things from Suncoast, so perhaps this was just a fluke.

I contacted Rev Max this morning and talked with Frank. He was literally all over it. He knew this transmission intimately and steered me to all the right parts. He has to order in the billet input and billet intermediate shafts, and build my custom converter, but other than that, he has every part I need and was able to talk about each one and the reason he thought I needed it.

So, in about 10 days everything should ship from Charlotte N.C. and then I'll be tearing into the A518 and making it a transmission worth of this truck.

In addition to the high performance over haul kit which consists of the clutches, seals, steels, and stuff like that I ordered
Custom Valve body
Low Stall Converter
Billet input shaft
Billet intermediate shaft
Kevlar band
3.42:1 ratio apply lever
Billet band strut
Billet band anchor
Billet accumulator
Billet servo piston
steel 5 pinion primary planet
deep aluminum pan
New sprag clutch
New bearings
and a couple other goodies...
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:40:30 PM
Quote:
Originally Posted by Cudakidd53 View Post
As Texas stated, "a show", but I was thinking a spin-off of the Robertson's - "Truck Dynasty" -with all us DOTs, filling in the rest of the cast would be a piece of cake! 


Not a show, but I am starting to close in on the web site.
I hired a site designer to draw up a proposal for a forum based site that could also do sales possibly.

I want it to have both free and a subscription based sides. No, I don't wish to get rich off anything like this, but I will need to earn money to cover monthly fees, the 2K-3K design fee (So far) and hosting fees from the company I'll have to hire for all of that.
Plus, I want to do "Real Man" That project in itself needs gravel, buildings, sewers, ranges, campsites, rappel towers, and the like. Don has already paid well over 100K into that project and is not able to go on forever donating. Plus I'd like to have a large sum of money to do good things with.

I am already part of a project which has as it's goal, giving away a free home a year, on veterans day to a veteran. In that I was asked to come alongside a larger non-profit to act as an officer and the guy who finds and vets potential candidates. But Don wants to do it himself. Nothing I'd like to do more than help those who give so much and get so little reward.

And not only soldiers. Police officers, firemen, clergy, good Samaritans and that struggling widow we all have in our neighborhood. And I would like to do it anonymously if possible.

Anyway that takes moneys...Lots of moneys, (Yes I know it's mispel'd, ded it on porpoise)

So general design

Several sections

Vehicle modification
- including trailers, motorhomes, campers, things with wheels
Weapons
- including reloading, ballistics, storage, concealing...more
Food
-Obviously Nate's corner
-I'd like to keep Nate's corner intact as he started it
-canning
-wild food
-game processing and recipes
-long term storage
-section on nutrition
Home prep
-talks about modifications to make your home more secure
-Shelter construction
-Garage section
-Barn section
Intel
-Links and postings from intelligence gathering organizations
- community defense topics ranging from watch groups to militias
Spiritual
-An area to talk about spiritual topics from any "religion"
Political and general
Tools
Parts and Products
Finance section
Vendors Section
Real Man Section

Now, that is only a working concept, and (I'm hating to say this) I invite comments from everyone as to what you would like to see or would feel is significant.
Remember the overall subject matter is Survival as in after a breakdown in normal society. The site will be rated G to PG. It will work like this site fundamentally. Some of you (boneheads) will be invited, can apply/ask to be moderators. The themes will be being a real and responsible man. Acting in an intelligent manner, being a believer in the constitution and a patriot.

I want a place which tackles serious subjects and in a monitored/guided way address those subjects in an intelligent manner. You see I think it shows quite the opposite to name call, curse and degrade another. It takes more of a man to stand on fact and present his argument in a manner which he could be proud of.

I will take a copy of everyone's credit card first. I reserve the right to fine people. If I make the determination you are a DOT, someone such as, say Duane, Bobby, Shawn, Ashley, or a thousand others of you like those despicable people, then I will assess a fine not to exceed $100 for each infraction. I will be the sole judge and jury and you will have no recourse. During certain times, fines will be doubled, of course, say for interfering in a discussion on veterans rights with some off the wall stupid question!

Well, maybe I can't legally do that, but you get the general idea

So, that's the S.O.W. for now (State of the website)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:41:10 PM
OK got a bit more done today

Went over to the truck repair shop and had them bend me up some new U-Bolts
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:41:58 PM
They got the acid etch primer treatment, then a coat of Blitz black
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:42:44 PM
The rectangle things are the wedges that were bolted to the old sky Jacker springs.

I sprayed the trans crossmember to transmission mounts with hammerite dark titanium paint
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:43:42 PM
The sled dog was on her "A" game, alert as ever to possible approaching trouble!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:44:25 PM
Time to mount the spring shackle mounts into the frame pockets
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:45:28 PM
The fit and precision of these parts is exceptional
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:46:24 PM
The shackles themselves are odd in appearance but look plenty stout. I had to play with the washer stack-up to get that right, but the fit is snug and square
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:46:55 PM
No comparison between the supplied 5/8" spring bolts and the factory stuff:
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:47:49 PM
Ready for the springs!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:48:41 PM
Next up the front spring mount was bolted up
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:49:16 PM
It may not look like it, but that was a lot of work. You didn't see the disassembly of the old springs which was a bore and some of the painting, but that's OK

Tomorrow should see reinstallation of the springs and possibly the axle, although I need to prep the spring plates first, and I am contemplating putting a locker into the front axle...

So that's the S.O.B. at the end of build day 169
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:50:28 PM
Got some things done today.

Wasted some time running around to pick up the new Cummins turbo oil supply line which didn't show up ERRRRR....

So I returned to the FOB and started.

With the goal of installing the springs and bolting back the front diff, I started on these nasty front spring plates. They obviously need some work
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:51:37 PM
Which they got in abundance
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:52:57 PM
They got the rust converter/metal prep then the thick red oxide primer, then finally a thick coat of rubberized undercoating
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:53:50 PM
Wanting to recycle as many old parts as I can, still, these plates are not impressing me. Jungle sells them new

Next I transferred the angle wedges to the bottom of the new springs
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:54:29 PM
Then after applying some gooey poly grease to the surfaces, slid the springs home (Literally!)
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:55:10 PM
I selected the front hole to move the front axle forward as much as possible. Earlier I thought I'd keep things in their stock location, but this is an all out vehicle so outboard the wheels go!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:55:50 PM
It was about now that I realized I had the U-bolts all bent on a 4" center. Well that works for the passenger side but the drivers side remains a 3.75" OC so I have two new U-bolts with nowhere to use them!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:56:39 PM
With some time to kill before football practice, I decided to get the sound deadener applied to the firewall. I found the missing brake parts in Canada and they are in the postal system somewhere. When they get here, I'll be installing the hydro brakes and finish that all off, so now is the time to prep the firewall
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:57:11 PM
Still had time to wire brush the steering column extension and get a coat of paint on it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:57:46 PM
And that. boyz and girlz is the quiet end of build day 170
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:58:28 PM
Quote:
Originally Posted by B20 View Post
Looking good!

Thank you!

Getting some trans parts now.
Have the billet flywheel in from Alligator Diesel, thanks Holton!

I have a UPS notification that part or all of the order from RevMax transmissions is headed my way, scheduled to arrive Tuesday. With that, most of the trans pieces will be here.

Getting ready to order the NP205 rebuild kit. Shawn discovered some old (NOS) Billet bearing retainers for the 205, so right out of the blue, that case is going to be getting an upgrade. Yippee!

It's all coming together.

I'm sure that within a month we will see that New Cummins sitting between the frame rails with a renewed trans and transfer case sitting behind it
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 04:59:32 PM
Quote:
Originally Posted by TexasRedNeck View Post
Who got baptized? Was it a new conversion or an addition of a new member to your assembly?

Keep up the good work. I get tired when I catch up on your progress.

How's the back?

Grand Daughter...Really a Christening, Baptism comes after she grows a bit and makes the decision for herself as you know.

Back is GTG

OK today got several loads of laundry done, the upstairs storage room all prudied up, clothes folded and two wheel barrow loads of weeds pulled. Garden is still a bit of a mess though, but after all that I needed a fix of partizination.

So I took a hit off the metric bolt bag and got into my happy place

The metric 10.9 X 35mm bolts showed up so I fully attached the turbo.
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:00:19 PM
With that cat in the bag, it was time to get the new Cummins turbo oil line out of harms way (From red dog attack) and installed

It's a brandly new Cummins part
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:01:13 PM
Some fast wrist action with the 16mm wrench and that line was installed
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:02:04 PM
Next up the oil drain tube assembly

It got a new gasket of course
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:02:50 PM
But, the bolt holes would not line up

Hmmm

Close inspection revealed interference from the much larger 66mm compressor wheel on this turbo. The compressor housing is now occupying the space where the oil line needs to be.

Looking at matters, I noticed a big casting ring that could be partially removed so I went about doing just that
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:03:45 PM
That got things pretty close although not yet perfect. But football practice was calling so I had to set this aside until tomorrow
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:04:39 PM
No more time to work, but we can still play parts...Who wants to play parts?

Thought so!

The boxes are stacking up once again

I had to go all the way to Ontario (A great place btw...) to get these brake adapter pieces to complete the new master cyl and hydraulic brake booster installation but here they are

Also I scored this trick little water nipple part which will allow me to plumb in the trans fluid/fluid cooler
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:05:26 PM
Next up is the Alligator Diesel (Holton) supplied ATS explosion proof flywheel. I wanted to go full billet to rule out the possibility of a failure of the flex plate in the future
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:05:54 PM
This guy always seems to be in the vicinity of hot roddin'
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:06:24 PM
I swear, that kat always looks like it's drunk!

The sled dog was hanging out as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:07:26 PM
RevMax supplied the low stall torque converter. It stalls not far above idle so going down the road there will not be as great a difference between the non lock up unit I am building and the lock up 47RH transmissions of the 2nd gen
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:08:17 PM
Just a pic of a dirty, tired NP205, but not for long

I found a good rebuild kit that replaces all the bearings, seals and gaskets for $150. Additionally I will be adding a rear mount that it currently lacks. THat new mount will bolt to a new cross member which I plan to weld into the truck frame rails. My thinking is that this transfer case is a pretty big piece of iron just to be hanging off the end of the aluminum (read: Flexy) transmission case. Might as well anchor it as well so that when I return to earth contact following a jump, the case will stay under the truck where I need it to be
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:08:49 PM
And that's the S.O.B. for the close of a very abbreviated (Why is such a long word used to describe shorter contractions??) build day # 171
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:09:53 PM
Busy week...Family visiting, farm activities, then I crunched my knee causing me to be a pogo stick man.
Aah, that's life, no one survives it!

Well today I just couldn't stand laying up so I cut the grass, and well, that worked OK! So then while balancing in an exaggerated front lean and rest, I pulled weeds for twenty minutes. Hmmm, was thinking I'd give the garage gymnastics a spin and here is what I did:

First I replaced the water temp sensor with a new one
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:10:33 PM
Next up, the block got a new oil pressure sending unit
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:11:09 PM
American made parts!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:11:53 PM
Then I spray painted the new U-Bolts, the ones which are actually the correct size... and that master cyl adapter
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:12:38 PM
After a little more "tweaking" I got the turbo oil drain tube to fit like it was meant to be there
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:13:18 PM
Then the new water distribution "T" was final painted
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:13:50 PM
I found that part in Ontario, Canada and it will be replacing this fitting so I can get cooling fluid circulating back from the transmission oil cooler
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:14:51 PM
With a quick flash of some shiny wrenches, that new/old fitting found it's new home
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:15:37 PM
So far, so good. I am all about getting these parts off the shelf and installed. It's an endless process, it seems. So even though it could be done later, well, that is if the red dog didn't snack on it, I decided to install this turbo hot end heat shield
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:16:24 PM
The idea is two fold. 1. Keep heat in the turbine section to help it spin up faster
and
2. TO reduce the heat signature as seen from overhead.
I am going to do quite a bit more as you will soon see to keep spies in the skies from locking onto some hot spot on the truck
I think you'll like what I have in mind. I actually saw an army sergeant use this technique to mask his vehicle and drive up on a hovering Apache once.
I made a mental note of that for later use!

So here is the thermal blanket laced up, but not permanently secured yet
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:17:00 PM
As seen in the earlier pic, I installed the turbo discharge elbow as well
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:17:33 PM
Since those U-bolts were dry, they too got tightened in place, finishing that part of the front suspension install
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:18:10 PM
And that was that, the conclusion of a short build day 171
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:18:57 PM
OK, here it is:



The Great Candy Bar Fire
By
Donald Harward

As things go, occasionally we come across or get to participate in something that could not be duplicated, conceived or actually believed. This story, “The Great Candy Bar Fire” would be just such a thing. I would have hoped to just be the casual observer, you know, the guy who looks at the person next to him asking, “Did you see that?” in utter astonishment. Nossir (All one word in this instance, because I want to, thank you very much), Nope, I got to participate in it, and apparently I get to continue to participate for many months to come.

This is one of these totally unexpected things that utterly changes your life. A thing for which you could not have prepared, and a thing which if you were actually watching the vid delivered by a time traveler who witnessed the event, would conclude you were seeing nothing more than an elaborate hoax.

So what is a candy bar fire? How does it happen? Is it even possible? Has it ever happened down through the annals of time? Probably no, I would say, even though I got to live it, but life really isn’t predictable for those who jump in and decide to live it, now is it?

Sitting at my desk last Friday evening I was pondering the visit by my brother who had departed to return to his home earlier in the day. It was a nice visit. We got to hang out, go to watch the pre-Ranger smash heads on the field of honor while wearing his beloved Kintucky blue jersey. We had played around on the farm with my sister and her children as well, and shared cups of heavenly quoffee (Mispronounced as a tribute to my New Yarker friends). We talked about this roll bar, and that set of wheels, the effect of gearing on turbocharger size and we pulled weeds in the strawberry patch. It was a good time and I was savoring the memory.

My desk is arrayed majestically in my office in what we call “The Harward Room.” A formally designed and decorated room which contains a heirloom desk. The desk commands the rest of the room which is festooned with all manner of Harward families past. It’s somewhat “Church-like” generating a feeling of reverence of sorts. Purposely designed that way, I wanted the room to be the setting for the important talks one has with his children. Designed to add strength to any discussion with the trappings and majesty of several honorable generations. I remember having the awkward, Sex talk with the boys from that desk. The desk, however also is tucked in, in such a way as to make access a tad bit difficult. You have to bob and weave around the gun case, carefully avoiding the corners of that black walnut monstrosity also mindful of the desk top which threatens the casual passerby with its own ornate wood work buttresses of Walnut and Maple.

On Friday evening last, with a mind full of the memories of the visit, and while staring at the WW2 map of Dad’s 35 B-17 bomber missions on the wall opposite, the evening calm was abruptly interrupted. With piercing triple soprano, their voices which are not yet even close to puberty, began shrieking the words one never wants to hear. “FIRE, FIRE!” It hit me like a 7.62mm round fired from a distant sniper. Totally unexpected but with the impact of being stepped on by an elephant or some of those “wobble people” I saw all over airports when I used to drive jets for my money. Fire, What the heck?? Fire!!!!!!
So with the agility of Michael Jordan and the strength of an Olympic sprinter I made the first hard turn around the desk in a micro second. One could argue that I might have actually exceeded the speed of light, but I’ll have to await my time traveler friend to confirm the exact speed.

Made that turn OK, but the next ninety degree turn in the opposite direction around the gun case must have imparted some forces upon my body which exceeded structural limits. With a loud “Pop” sound and some white hot fire like pain commencing in my knee, I didn’t yet know what had just happened and I continued the accelerating turn. Having exceeded structural limits of my aging carcass, the whole body mass thing known as Don collapsed in a highly energetic mass of flailing body parts onto several objects which have now been permanently pressed into my torso.

Well, let me evaluate (All in the next micro second). My leg just blew up and gave out, I feel like I have been chewed on by a big dog, for a while, but know what? I’m still hearing that word, FIRE!!!!!!!!!! OK, back onto auto pilot (Automatic reaction and I AM a pilot!) so I get up and take off again, oblivious to the fact that I am now a one legged man. Well physics takes over and the non-working parts continue not to work and I go down again. Narrowly missing the corner of the (yes, Walnut) staircase, which immediately reminded me of the fall I had mid-winter which, thank the Lord, was stopped by the safety concrete in the floor! The good news was that I didn’t hear more of those obnoxious popping or grinding sounds, but that pain was getting to be a real problem, and of course, the fact that I no longer had a right leg invited its own set of problems.

Never the less, I pressed on like the brave although not so bright soldier that I am and finally made it to the offending scene. The door to the stainless steel wall mounted micro wave oven was open. There was a single filament of smoke wafting out of the door and rising slowly like the smoke from Humphrey Bogart’s cigarette from a scene in the movie Casa-Blanca. I pressed forward.

Inside, on the revolving table I see that the smoke is coming from the wrapper of a candy bar. The paper wrapped FOIL cover of that melted mass of once good quality Swiss chocolate. It seems the boys had chosen that time to enjoy the “Special Chocolate” which daddy had bought for them. Wanting to preserve it, they had unknowingly (to me at least) buried the candy bar beneath layers of cubes in the ice maker. Their plan was to simply micro wave it when ready to enjoy its decadence and all would be right with their world. So that’s what they had done. Retrieve the candy bar, and put it into the micro wave for, hmmm, let’s see, how about 3 minutes! Yep, that should thaw it slightly and then we’ll get to eat that tasty treat.

Judging from the melted blob, I would say the candy bar had made it through about half of the “Thawing” cycle, because when I reached in to grab it and slung it toward the sink to extinguish this raging single filament of smoke, it slung onto every surface within 10 feet within the arc of swing. Maybe a half ounce of the actual chocolate plus the deformed wrapper actually made it into the sink.
Emergency adverted! The “Fire” was out and my children would be safe from the fiery inferno that was surely going to happen. The house was saved and all was well!

Actually all was not well. You see, moving at slightly faster than the speed of light, Most of the pain had not reached my brain case group. Those pain signals now required a one inch thick nerve to handle the sheer volume and the actual electrical impulses were simultaneously converging on the pain center of my rather smallish brain. Hmmm, something hurts! Something really hurts! I mean Really REALLY hurts. As in let me see, a human can handle like 750 mega volts of pain (I just made that up) and I was trying to process, like 1,700 megavolts. So I wasn’t actually understanding how bad it hurt. You see my knee was hurting like 1.63 times more than what was humanly possible, but somehow I was still able to process that pain for a while. Part of my head exploded, another part of my leg caught fire and burned off and the pain energy raced to and fro with nowhere to go causing patches of hair to fall off here and there!

What I’m trying to say here is IT REALLY HURT!!!!!!!!!!!!!!!!!!!!!!!!!!!!

So after a while, off to the emergency room I go, wife driven of course. The nurse practitioner I see doesn’t actually touch me, but diagnosis me with a stretched MCL tendon and gives me a pain pill. I forget what it is called, but it’s the kind of thing one can also purchase at your neighborhood street pharmaceutical from the kid known as “Jimmy the bean.” So I take this thing and get all woozy but the pain is unaffected. I don’t care because my mind is now occupied with thoughts and computations concerning the ballistics of the .45 vs the 9mm for a suicidal head shot. I think in the end just go .45 and “git er dun!”

The wife is sharp. She is helplessly watching as I bite off a filling which I just paid $268 for and decides that her big old tough Armee guy must really be hurting and that the pain med isn’t working. So she calls the hospital, explaining that this narcotic designed to subdue elephants is having no effect. The nurse hands off to the doctor who advises her to give me TWO of these narcotic things. Much to my chagrin, I swallow two more of the things. The doctor further advised that in two hours, that if the pain does not abate, she is to bring me back to the emergency room, and that would serve as proof that they had mis-diagnosed me.

Well I took those two things at 2200 and by 2400 I was in absolute white hot pain. You see since every part of me down there was swelling up so much, that my nerves had finally reached 1” in diameter and were finally able to accommodate all the pain impulses that Mr. Knee was sending. I thought about harnessing a deep cycle battery to the injury to store the energy, but kept losing the concept amidst the evolving thoughts of suicide as a possible pain control measure. At one point I thought that if I had the wife just hit me in the back of my head with an iron pipe, I would find the bliss of unconsciousness and that would be a good thing. But then I further reasoned that either she would 1. Miss my noggin completely with the swing, 2. Hit a glancing blow which would only heap additional head pain onto my abundant knee pain, or 3 somehow be successful, but then while harboring thoughts of something awful I had just done like leaving the toothpaste on the countertop, swing hard enough to dispatch me to the pearly gates. Not so bad, really, but then the thoughts of my beautiful wife separated from our beautiful children by those pesky iron bars of the state pen, was just too much to bear. OK scratch that, back to the .45…Glock of Colt???

About this time, around mid-night I learned firsthand that pain meds makes one sick, as in projectile puking sick. Not so bad really because while you are wrenching at least all that pressure and additional pain is added to and felt by the broken up parts of the knee joint assembly as well…Yea…

So she makes the call and they request my presence. I am now speaking in tongue due to the arrival of the fully functioning 1” thick nerves, she thinks I am also going crazy, and surmises it might not be a great idea to load this crazy man with one leg who has learned a foreign language into the caddy for the drive over to the emergency room. So after some time they all decide to just see me the next day.

I finally get to a very bright orthopedic surgeon who takes one look at my knee and says, “Man, that’s one ugly knee!” Then he starts probing around and shoots some X-rays. He concludes that he needs an MRI and suggests that I am headed into surgery. He says, “I’m thinking you have torn your ACL and MCL. He says with all this irregular swelling, you might have other things going on as well!

Then he asks “How did you do that?” And I answered, “Ya know, just your standard candy-bar fire accident.” He nodded with a smile and said, “One of those, hugh.”

So this story has no moral. I mean anyone knows (Except for my pre-rangers) that you don’t cook foil wrapped candy bars in a micro wave. And I couldn’t say or ask any real man, not to sprint to the safety of his children or home. Nope that doesn’t work. I can’t talk about the dangers of arranging furniture this way or that or even comment on the inherent unsafe attributes of walnut. Again none of that makes any sense anyway, so this my friends ends up just being a story. A story which is yet to end and one with which I dearly wish I was not a participant!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:19:54 PM
Quote:
Originally Posted by KensAuto View Post
Great Chapter...sucky outcome. Big D, I Hope this story gets better but probably not near as much as you do!

Ah-Men!

I'm stir crazy. Taking some narcotic pain killer, which it doesn't!

Head all buzzin' and leg still hurts...what the heck?

I am driving forward in the acquisition of parts

Only have the trans special tools now to get, then wait out the rest of the RevMax stuff, then we will get that fired up. Ought to be able to get that done while seated at a stool, I hope!

Have all but one transfer case part. Shawn graciously sent me some billet bearing retainers for the NP201, so that little project is about ready to run...

I'll figure out a way to get everything working again and integrate that into the surgical plan. Hey, life goes on regardless of whether one chooses to participate!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:20:42 PM
Quote:
Originally Posted by stlaser View Post
Glad to hear you received those NP205 bearing retainers was wondering about that. You know I think you can rebuild that t-case from the comfort of a stool, hope you get feeling better.


How on earth did I call that box a NP201?/

I have a theory

I am on narcotics for pain control. Fact is they barely help, but I feel loopy all the time. Turned into a jokester as well...messing with the nurses and doctors.

Went to get my MRI the other day. Came through the door on crutches wearing a knee brace. I was moving like one of those 80 year arthritic people who take really small steps, then stop and look around, then proceed...

So I walk up to the counter and the nurse asks, Sir what is your problem? I immediately answered "Hand trouble." Hand trouble, she asks looking at the crutches and peering down at the wrapped knee. Yes Mam, you see my broken knee forces me to use these crutches and now my hands hurt!

She laughed

Anyway, I can't wait to get into that NP207
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:21:39 PM
Quote:
Originally Posted by jms89 View Post
I am praying for a quick and easy recovery for you. Those narcotics are no fun to be on!! Seem to drain all the ambition and productivity right out of ya.

Thanks for the prayer
Surgery is scheduled for Thursday for meniscus and MCL repair and some joint smoothing for arthritis.

Concur on the drug thing. So how on earth does a segment of our decaying culture actually use those things recreationally? I actually stopped taking stuff today to try and just deal with joint pain and not have to be sick while doing it!

Had some interesting observations at the hospital, I'll share

At the Ultra Sound (Screening for possible blood clot) the lady there says, "well, you're different." Of course I asked why. SHe said almost all of these type of ultrasounds for clots she does, she does on heavy people. She confided there was a male in there this week who weighs 507 lbs!

Now how does that happen? I mean if you start drifting north of your normal weight, you'd think you'd take a notice and possibly DO SOMETHING. OK lets say you hit 100 pounds OVER your normal weight and what 7-10 pants sizes. One would think that would be quite the wakeup call, but past double your normal weight?
OK suppose it's been a few years since you were able to find your size in the big and tall shop? Can that go unnoticed? The nurse told me the average male they were seeing now weighed 361! Three hundred sixty one pounds!
These are unprecedented times and those added layers of blubber in a sperm whale look alike contest show you do not know God, have little self control, and say that to everyone else as well. SELF CONTROL America
BOD (Book of Don) says that attitude is a bye product of a life gone way too easy, the effect of this safety Sam attitude, and a loss of a focus on one God and more about ourselves!
Today, as I was getting out of the back seat of my wife's caddy in front of the orthopedic building, she parked in such a way so that my door was facing outward into a turnabout. I pointed that out to her and she brushed me off. You see, you could just steer into the other side of that circle and not come anywhere near us. But here comes Mr Cadillac with the 80+ year old driver headed straight for me. TO get by he would either have to drive into the grass or push me into my car. But he kept coming! So I yelled at him, like really loud. and he even acknowledges me by nodding... But does he stop? No and as He drove past me I swung my crutch at him. THe swinging motion of said crutch pulled violently at my destroyed knee and all I felt was white hot pain. I can't even say if my intended target, his windshield was even hit.

My wife was very upset...AT MY REACTION!!!

Am I crazy here, Am I so detached from the reality that American society has become?

Tell ya what if that is how we are, then to hell with it, nothing left to defend, let them suffer the fate wrought from a self serving life!

Back to the hospital. A few days ago I am standing behind this mother and her barely 20's child, a girl. THe girl has on a set of shorts that would make any stripper proud. She is also wearing a painted on halter top and add to that...She is pregnant...AND HAVING CONTRACTIONS.
Sticking out of her back pocket is a pack of Pall-Mall cigarettes.
What the heck is wrong with people? Obviously you can blame that do nothing mother who would stand for such a thing. My wife dam sure wouldn't!
I say it again, you are looking at a total lack of God in this person and indeed family's life! And she's reproducing. For a moment I wondered which self respecting male would inseminate her? Probably that 507 pound guy wandering about. No guidance, no morals, no education, no common sense, indeed...NO CLUE
__________________
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:23:57 PM
Quote:
Originally Posted by FBJR View Post
I like the way you think,,,,,,,,,,,,run over the ideas in your head so much that when you do the work, its easy.

Pool is done and kids are back in school, I may have a little more time to play now myself.

AEV, I like it, just needs some armour in a few critical spots. Awhile back I picked up several blast vests at an auction that would have worked great but lost them in the garage fire.

I was using vicodin for twisted ankles and knee issues some time back. 1st they would knock me out, then I had to have more, then got sick from them. Easier to fight and deal with the pain.

Problem is I have all the time to think and ponder and no shop time...but that is going to change.

So I now have all the transfer case parts except for that mount which never came in.
I have all the transmission parts except for a tool to compress the OD section spring.
I have the sway bar and the new frame mounted shock mounts, which are some trick parts, wait till you see them.
I still want to do something crazy with the sway bar so some custom machining is coming up...
I am on the hunt for the interior seat/seats...have to see what scares up.

Engine is essentially done awaiting mating to the transmission. I'll install them bolted together. Then the transfer case and some quickie fab for the new cross member with some frame tabbing for a upcoming belly pan and all that will be done.
Then I'll get the rad core modded to fit the bigger I/C, then fit that to the engine, then paint it. After that, it's fender time and then I can finally do the bumper and side rail build which will be extensive...

Yea about those narcotics...How do the idiots get addicted to that horrible stuff?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:25:26 PM
Quote:
Originally Posted by BobbyB View Post
So, I was bored at work and looking at trucks, and etc. I had a question about fuel tanks. My idea/question is: lets say instead of putting an oversized fuel tank under the truck, would it be feasible to buy one of the 60-110 gallon fuel tanks in the tool box that go in the box and plumb everything from there? Or would it just not work?


If it'd work it'd give you more room underneath for other projects, or just clear up the clutter.

Yea those would certainly work, but
1. They take up a lot of space that is already dedicated
2. Fuel fumes in a enclosed space
3. Humans will at times inhabit that space

So best to just stuff the tanks elsewhere

With all this down time...over a month so far, I have been thinking a lot bout the design and tweaking it in my tiny mind.

Tightening up the mission statement a bit, I think this is definitely get out of Dodge (Get it...Dodge...) vehicle, but because of it's smaller size I make it more of a fast strike and scouting vehicle.

It will have a limited ability to support a person or two by sleeping in or around it and using features of the vehicle to make the "Camping" less of an effort.

The total concept for this vehicle is still to have and tow a tactical camper/trailer similar to that AEV 490 the Aussies sell. With that you can stop anywhere and cook up a meal, get some shut eye, have shelter, medical support, better communications and so forth. One can quickly detach the trailer and make a fast run across the valley via the back roads and forests to snatch up something you need, like a cow, then ditty-mau back to vicinity of the "Camp"

So the truck will work best as a part of the system it creates by being attached to the trailer, but can focus in on fast/light activities by itself

No matter what you're doing, you'll need lots of fuel storage.

I plan to carry 3 NATO fuel cans on the back rack to give me that reserve we aviators always carry, but looking at the undercarriage, there is a lot of unused real-estate.

While being laid up, ice machine making a frozen treat out of a once perfectly useful knee, I have assembled that fuel system in my mind.
Although I don't like it as much, the bell 412 I flew for awhile had 6 fuel tanks in the floor, connected by a common line. Refueling it, as you might imagine was no fun.

I thought I'd rip a bunch of 1" sections of fir then assemble the various boxes inside the voids from below. Then I fashion up a mount, then wrap the thing with a satin sheet and coat it with fiberglass resin. Follow that with 6-7 layers of fiberglass cloth and just like that, why, I'd have a tank
Add in a couple of them and I might be able to get my fuel capacity up to around 100 gallons or so.

That's what I'm thinking anyway when I get back to building that sort of thing

I think that first we need to see a refurbished transmission and transfer case sitting in those frame rails
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:26:19 PM
Quote:
Originally Posted by Cudakidd53 View Post
Glad to see your fingers tickling the keyboard again Don!

Any idea of the US cost of that Aussie camp trailer? Really like it- pop-ups have lots of room and that baby's got space usage down!

I contacted the company probably a year and a half ago. I was interested in getting my hands on a 490 for the real man fall meet last year that did not happen.
They told me that the Australian trailer is manufactured in South Africa and shipped back down under. Orders kept the factory pretty busy back then, enough to keep them happy just selling into that market.
The VP I spoke with thought I had a good idea with introing the trailer into the US market as a part of this/that activity connected to Combat max at some controlled yet well covered event.
However that was not the problem
DOT is the problem.
With all the overburdening rules and regulation required for anything that will be used by obese Americans in their girly man society, well, they just weren't interested in playing.
Same/same with Land Rover
Ever wonder why the excellent Defender 90 is no longer imported?
DOT...
DOT was mandating all this safety stuff that any one with a brain never needs but marsh mellow head (and butt) girly men need to keep from bruising their fat round tosh's. Well Land Rover said, OK, no worries, plenty of real men elsewhere, we just won't send any more to the Americans
DOT
And Government
Always looking out for ya!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:27:38 PM
OK, I graphed this thing out

It is your simple pain vs time with a yellow "Norm" line and in the X/Y axis is spotted, angonizing micro second by micro second the actual suffering indicated by the red line

The time scale is not graduated since with the use of all the mind bending junk I've been ingesting, I have no real concrete idea about how many days, or even what day or month it actually is...so screw that
Time will just be seen as longer the further right we travel from the candy bar fire.

The green line indicates my desire to get in the garage and turn a few bolts and scrape some rust or similar activity. You will notice it starts low in the beginning. That's because while one's knee is on fire, one does not always want to delve into some recreational hobby, although when one isn't biting holes in his tongue, he still wants to do something. SO the line starts out by meandering a bit.

It will tick upward, then flatten out, indicating times that through gut determination I just wanted to get out to the garage, dam the torpedoes and all that, but I would have forgotten my crutches or to detach the coolant lines from my leg freezer unit which would have caused me to topple over like the proverbial oak, or simply spend the next twelve hours trying to sop up a gallon of icy water from all over the wife's expensive Persian rug

The red line is ever climbing due to the added pain from holes in the tongue, falling over and things like that. It stops near the top of the chart because with any increase, immediate and spontaneous death would have occurred.

Then we see a nice down trending of the line due, initially to the effects of one overdosing on narcotics which had me feeling less and less pain, but at the same time I was becoming overcome with the idea that Obama might really be correct about everything...
Well, never mind all that, it was like a hippies days in the 60's at some jimmy Hendrix concert, he was so doped up he was probably having sex with a stray dog all the while imagining he was conquering Marilyn Monroe!

We see the green desire to work line crossing the yellow "Norm" line early on indicating had all things been normal and I had only been shot or something like that, I'd have been getting back in the saddle about then. Later on the "Norm" line crosses a down trending pain line creating a region where I might have gotten things done, but with as bad as the pain was, I might have tried to hook the fan belt to a USB port in my laptop. Best to have stayed away and sit back and contemplate suicide and other pain control measures at that time.

To the right of that vertical black line we see three separate shaded areas.
The lower area shaded in orange does not really exist. It is free of pain and below the desire line. You see it is normal to have desire when being free of pain, so duh, yea, of course we'd be werkin! On the other hand with no real pain and all the desire, might this area suggest laziness? Well, dunno, haven't gotten there yet...I'm still hangin' with OB with "Lets not get involved with ISIS, it will all just go away, idea...

The area of colored in green is your go time. You're out of pain and you are wanting to work. In this utopian model I am working from sun up to sun down installing this or welding that, and it is all going perfectly. Reality however is a different matter. Reality would suggest that while you have been dragging butt and laying around the past month I have been driving the boys to the games, going to my job, shopping, cleaning the house and about every other thing imaginable...so now it's your turn...Strong enough to walk, strong enough to scrub a toilet I've heard her say...
So although the green area exists, you can never get there!

That leaves us with the blue hash marked area: Here we're still close enough to the pain to be able to use it as a crutch (Get it: Crutch...pain...I'm using crutches...) I can complain about how it still hurts because it does, but the psylogical desire line now forces me to get out there and bolt on something. I'm driven by it. I feel kinship with the lonely and dying salmon fighting a strong current just haven watched fred being eaten by a bear, pushing on relentlessly just...just until I finally spin the first 3/8-16 nut onto it's grade 8 bolt.
In this area there will be no good workmanship. I don't care about quality. Only that in the seconds before I trip over the dog because she refuses to move and twist my ankle...In that fleeting moment, come hell or high water, I am going to get one hole drilled and one LED light mounted...anywhere. In the bed, on the door, into the driveway...anywhere as long as it gets mounted.

Therefore this area is one where the little and poor quality work will all have to be corrected, but even so it is a victory over pain, over meds, over silly crap like candy bars catching fire, and all the rest of the insanity. For one small region in that convoluted map, the dusty semi deflated and cob web covered ball gets moved down field just a tad bit!
And that my friends is VICTORY!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 16, 2014, 05:29:41 PM
And that right there boys and girlies is the end of the historical build of Square D

All of this appears over at Duramax Forums along with a couple thousand more "Chat" posts that have some to little bearing on the subject of building a truck.

Next, we press on with the continuing build of this ever evolving Dodge!
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: JR on October 23, 2014, 10:17:43 PM
Did I hear you made some great progress?
Title: Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on October 23, 2014, 10:28:49 PM
Don't know about great, but some progress...yep!
Title: Re: SquareD Part 4: Paint, topper, Roof rack, and continued change!
Post by: duramaxdarren on January 26, 2015, 09:18:12 PM
finally caught up.looking great don!
Title: Re: SquareD Part 4: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on January 26, 2015, 10:31:38 PM
Hey Darren, there you are!

Caught up???

Hardly, there is a whole new section, keep looking, you'll find it!
Title: Re: SquareD Part 4: Paint, topper, Roof rack, and continued change!
Post by: duramaxdarren on January 27, 2015, 09:50:33 AM
will do! miss allie has a liking to playing the drums on the keyboard so i gotta go stealth mode. good to hear from you guys. nate keeps me on my toes with long distance trouble shooting.
Title: Re: SquareD Part 4: Paint, topper, Roof rack, and continued change!
Post by: Flyin6 on January 27, 2015, 10:56:32 AM
How cool (About little miss Allie) Good thing she doesn't think the keyboard is a trampoline!

Welcome back to the fray!
SimplePortal 2.3.6 © 2008-2014, SimplePortal