REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: Flyin6 on October 06, 2014, 11:17:59 PM

Title: SquareD Part 3: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:17:59 PM
In this section we get into the body work, painting, a roof rack and a host of changes that cause this truck to depart the restoration/mod course it was on and onto a whole new project much more advanced in nature and purpose than what you have a feel for so far.

Seat belts on...Lets go!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:19:21 PM
The bed of my truck...That nasty, faded looking piece of crap had a brand new bed hiding underneath all that faded paint!

Look what they found:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:21:01 PM
So we loaded it up, strapped it down, drove it home, and unloaded it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:22:06 PM
I still can't believe just how well it turned out!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:22:52 PM
the spots on it were from either me walking on it, or moisture drops from the trip, or touching it. It was as perfect as a metal part could possibly be.

No question, most of the rest of the parts are going up there next week.

I plan to lay some self etching primer down on it today after I wash it. It needs to be washed to remove the protective rust inhibitor that was sprayed on it before it left the shop.

So that's the plan for today, get some paint on it.

In fact, If all goes well, I will actually get some real paint on the underside, since that area is essentially, done.

SO here was the DGS (Don's Garage Situation) last night before I had to go out and be sociable:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 06, 2014, 11:24:11 PM
Well, I got some paint on the thing today

First I washed just the outside areas. I'll paint this, then flip it and paint the inside and top side of the bed next
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:04:49 AM
While I was at it, I hosed down Square D to remove some of the dust which was about to ruin the truck and cause it to become totally destroyed!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:05:44 AM
It took maybe 15 minutes to wash the coating off the bed surface
But
It took almost 4 hours to get it dried off!

I did get a little browning on one side, but both the paint strippers and the paint guys said that would happen and not to worry about it at all
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:06:42 AM
Here is the 2 part acid etching primer. It is a mix and shoot affair with an eight hour pot life.

The directions said to spray on only one medium coat!

With the color of yellow, there is no way that will cover with even color anyway, so I expected some striping. the bottom line is just to get the metal covered with this stuff which will burn in as it dries
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:07:15 AM
It mixes a simple 1:1

I wanted to try a small amount first to see how the stuff flowed and to work on the gun settings.

It likes 35psi and a slightly narrowed pattern with a hefty flow rate. That is a for sure recipe for drips and runs!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:08:09 AM
Here is the area that amount of material covered

ekes! That's not much

With both parts I only had 2 quarts, and this was shaping up to be a gallon sized job!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:09:18 AM
So I mixed all of the rest of what I had which netted me 1.3 guns worth of paint...unfortunately, not enough
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:10:39 AM
Had some striping, and I ran out of material so the front of the box as well as the whole underside and the tailgate remains uncoated...
And it's Saturday night
And things don't open on the Sabbath,
So it will be Monday afternoon before that bare paint sees any primer.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:11:17 AM
That rounds out build day 75

I believe with the ease of working parent steel, I will get the hood and fenders stripped as well. I'll probably yank them off first of the week.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:12:10 AM
Quote:
Originally Posted by notquick View Post
That stuff is so thin spraying it doesn't go far.
Read the back of the can good before you start to finish it. Its been a while since I used etch primer but I think you have sand it before you spay on top of it after a period of time. I know epoxy sealer has to be sanded after 7 days but not sure on etching primer.

You have a nice project going on!

Copy that.

I was going to wait an hour and top coat the bottom with the OD Green to finally see what it looks like, but when I ran out, those plans got chucked in the trash.

I use the abrasive pads to sand with, and now I will finish the priming, then after that dries scuff off the whole thing and lay down a coat of black primer, then top coat with the paint.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:12:45 AM
Quote:
Originally Posted by notquick View Post
Primer to sand or primer just to paint over. I'm a fan of the slick sand primer if your going to block sand it before painting. If your just painting it I would just use an epoxy primer.


The underside of the bed will get the standard lacquer primer then top coated with the color coat.

The outsides will of course get block sanded after attending to a couple of small dents, then color coated

I'm probably not going to mess with a sealer though
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:15:56 AM
I sprayed some color swatches on both the bed and the fender last night to see what the "New" color looked like.

It is a BUST!

Not what I thought at all

The color of this Cherokee is 24087 Gillespie

Look at the swatch

And look at that color sprayed on the underside of the bed

Am I crazy or are they all different colors?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:16:50 AM
The left is WW2 OD green

The right is supposed to be OD green 1957-present

I have used the latter a lot and this brown stuff is no color I ever saw in the Army!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:17:59 AM
Quote:
Originally Posted by KensAuto View Post
That ww2 stuff looks closer to the jeep from my laptop...that new stuff sure looks like to much brown, paint not mixed enough, or like Bobby said, the base was to light. maybe try a dark primer and put a good 3 normal (light) coats on a spot to double check, waiting the proper time in between.


I thought so as well, Ken, so I sprayed three coats, 10 min in between on the green/yellow primer and on the silver/moss/dirt fender

Looks the same to me, brownish

and I doubt I can send it back since it came via a hazmat container that the D@mm%! red dog chewed up already

Nope I think I own it.

I gave the two gallons of OD green to Duane already for his Cobra...Guess I'll have to ask for it back since that is closer to what I want.

Question of the day: So, just how many gallons of paint does it take to paint a Dodge truck
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:19:22 AM
From JR

Don, I keep waiting for that "rotisserie" to show up  I would go for 3 gallons too.

Are you HVLP or standard? Thats make s a huge diff to.


The Miller 211 has a few auto features and is dual voltage. And it fits on the 140s cart!!

Anything in the 50 amp area for the plasma will do the trick. They are so much better now than when I got my 40amp hyper 10 years ago. Saw a portable one friday that had its own compressor on it!!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:21:11 AM
Quote:
Originally Posted by Dustoff 35 View Post
Negative on the wrap, for the same reasons previously stated.


OK, tide has come in against the plastic baggie idea

So here's what we'll do

I'll finish coating the raw steel with the etching primer, then cover everything with either paint, liqueur primer, or undercoating.

I just came back from the paint store where they sold me the cavity rust proofer stuff along with some 3 foot long wands with 360 degree nozzles on the end. Insert them into the recess, then pull the trigger and withdrawal the wand and just like that, it's all weatherproofed for a few more decades.

I'll paint the bed and add in the bed liner so it is a finished unit.

While that is going on, the doors, hood and fenders will get stripped up at the alky tanks. I'll scuff out and finish the cab section and paint that as well, then paint the fenders, doors, and hood and reassemble. I guess when I screw in the last bolt, the truck will actually be painted!

Then I'll go about doing all the other mods and if I scratch the thing up again, will I'll scuff it all down and shoot the whole mess again.

OK, satisfied??
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:23:36 AM
Now as for the Kintucky camouflage, I might just take a shot at doing it myself, as in my own pattern. I did my Gator last winter with a unique pattern, that would be easy to duplicate, or I could just leave it green
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:25:18 AM
The big news was over at the paint store.

I bit the bullet and purchased this DeVillbis paint gun set with 4 different sized nozzles. These guns are excellent and when you think about it, something I really need to lay down the kind of paint job this build deserves
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:26:07 AM
And all these paint products:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:26:53 AM
The gallons are the acid etching primer. I think I'll easily consume that, considering all the bare metal parts I am about to have coming back from the strippers

This stuff is the material I am going to spray with a 3 foot long wand into the recesses of the structure which I can not spray into. The good thing about chemical stripping is that it removes everything
The bad thing about chemical stripping is that it removes everything.
That would include any protective material in the cavities. Nossir, now those cavities are bare steel just waiting to fester like an open sore in this snow/salt kintucky environment
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:27:28 AM
I picked up this cool little spray system so's eyes kan reach into the spots coons and other kritters normally git into

You just pour the paint stuff you want to spray into the bottle, then attach the pressure can and spray away. It's useful for throwing at red dogs and kats if you catch them misbehaving
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:28:54 AM
From NotQuik:

That gun actually sprays pretty good. That's what I used when I started out.

I would buy a dedicated hose for that and loose the filter on the gun. Nothing worse than your hose getting caught and you brake the filter and the hose goes wild. I would make it to where you can use two filter at the start of the hose. Not in a line but kind of like two Y pipes if that make sense. One filter really cuts down on the air flow. That worked for me before I got a real set up.
__________________
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:29:41 AM
These silent sentinels are two cans of high quality undercoating for the mounting pads and the wheel wells, and a kan of spray gun cleaner
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:30:34 AM
buy the way, I is missspellin' on porpoise, both to aggravate you and cause I kan
So this the current sitietation in Don's garage. Even have the red dog caged like a wild animal and the sled dog outside. Heck, ever since it snowed, that eskimo dog just plops down in a pile of snow and snoozes away!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:32:15 AM
Quote:
Originally Posted by BobbyB View Post
The new paint gun is so shiny and purty. If you have a decent piece of scrap metal thats clean take it with you, bonus if it has the primer you plan to use. That way if they do happen to have the paint the say will match, you can check it on metal and see if it really matches.


Oh make sure that the Sherman Williams you are going to is the Sherman Williams Auto Supply or Auto something.... Its pretty pilot proof but you never mentioned if it was the Auto one or the normal house paint one.

Good points Bobby

This one does house paint

They know us well

They once told me they never mixed as much paint as they did for my house

Wife built it while I was down range

She opted for some 16 different colors!!!!!!!!!!! As a wall would turn a corner it would change colors or a few shades.

The painter said he was installing his mail box cause he spent more time at my place than his home.

Well, she paints the place, THEN sends me the pics.

I am sitting at a computer, minutes after landing from an armed escort mission, I am checking my emails. The other pilots are standing around, some behind me.
I see an attachment and hit download.

The server is slow

As the picture builds I am stupefied! The chatter in the room stops as every eye is now watching the unfolding of this...this.., well whatever it was.

Then a voice says, "That's the Ronald McDonald fun house!"

Really...true

So I get into it with her, some 9500 miles away. My first words, "That looks awful. I thought I asked for the interior to be moss green, as in all of it!"

She admits to hiring an interior designer...a new one...right out of college...

I just said flatly, "I'm paying for it, get that crap off the walls!"

Yep, I'm surprised I'm still married as well, but to continue

So she gives the bad news to the college kid and fires her. Then wifey decides she has learned enough during this first "Training round," to take a whack at it herself.

So using more muted colors she goes at it again, yup, 16 colors.

But to get to those 16 final colors I think she had them mix some 50 or so pints of different colors, because for a month or more I'd get an attachment of some blotch of brandy wine, or tinsel twine or strawberry shake color smeared on the walls in a 4 foot rectangle.

I was thinking it looked a little like Beirut during the 80's in there. It was getting to the point where it needed cleaning with several frags, then she laid down some neutral stuff, 16 shades of it and we were done.

Sherwin Williams remembers it to this day!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:34:03 AM
Note: At this point in the truck/thread development there are a ton of good and funny sidebar conversations which are taking up a lot of space. So from time to time I might draw one out of 10 or 20 over here just to give a hint as to the actual "community" that was developing around this "Oil change run amuck" project of mine
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:35:10 AM
DOT Homework

We did this before

DOT 101

Connect the DOTs


. . .

. . .

. . .

Connect all the dots with 4 lines

4 lines only

But, once you begin, you may not lift your pencil from the paper, it must remain in contact with said paper all the time

Mostly for the new DOTs

Edit: Dots were supposed to be equally spaced, however it doesn't load up that way, so make the korektion yerself
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:39:21 AM
Going to get busy this afternoon so I did a little painting this late morning after the workout.

That new guy worked really well, and the little portable spray bottle did an OK job of "Distributing some paint" not necessarily spraying it in an acceptable pattern.

I needed something small and maneuverable so I could get into the tight places and in and behind stuff to get everything coated.

I don't believe everything is indeed coated so that is the reason for the fall back rust proofing fogging device I'll eventually use on all those recessed areas

Here's the little bugger with a reservoir full of the good stuff
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:40:06 AM
And some of the damage, err, coating it did
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:41:08 AM
Those wheel wells get sprayed with rubberized undercoating so smoothness does not matter. The name of the game there is just to get something on there

THe new gun laid down some decent paint, although this is showing one light to medium pass and nothing more. Again the purpose of this stuff is just to get a layer burned into the metal to provide a layer for subsequent materials to adhere to

Here is that tailgate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:44:24 AM
And the front of the bed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:45:23 AM
Some of the detail areas such as the inside of the mounts and recesses around the wheel well got another spraying
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:47:41 AM
And any other area that needed touchup
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:50:23 AM
Sorry, some dupes on the el-photos there

Anyway, the gun cleaned up and here's what was left
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:53:53 AM
Quote:
Originally Posted by Armalite View Post
Question:

you mentioned a rubberized coating for the bed. Underside and top side? Or just the fender wells. Did you consider just using the raptor liner coating for the fender wells, compared to the rubberized coating? Wasn't sure of the price difference/quality of the two...

Good questions Ash

The bed is getting a plethora of coatings.
(That's a bunch!)

The underside gets acid etch primer, then primer, then paint

The outside, same-same

The underside of the wheel wells gets a very high quality rubberized undercoating.

The inside of the wheel well, as in the part hidden by the bed skin and the insides of all the box sections gets whatever primer I can spray in there and that rust preventer brown film stuff.

The inside of the bed will get two coats of the Raptor product on top of the acid primer and the black lacquer primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:59:18 AM
Quote:
Originally Posted by Armalite View Post
ok. So the rubberized coating in the fender wells is same quality I assume as the raptor liner...


Next question:

Why go through all the trouble on this bed, if you are still wanting to install an extended cab? Now, I don't know your timeline here, and there may not be one, but wouldn't you be better off to have found a short bed, and invested the money in to it, instead of this long bed? Of course, you could probably sale the long bed to another Dodge owner somewhere, some day, such as Duane...

But, just thinking ahead, and maybe too far ahead...

Quality??

Sort of apples and oranges.
Yes they are both "High quality" products

But the rubberized material will protect and be more sound deadening and will stand up to things bounding off of it being thrown around by the tires.

In the bed, a rubberized product is not appropriate and would not hold up, so the much harder raptor product is best suited.

As for the extended cab: I am freezing the design the way it is. Otherwise I will simply never get this truck done. I think it is best to move ahead with the current configuration, get that done and live with the limitations.
It will remain a standard cab/long box
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 10:59:55 AM
From Ash:

ok. Good plan. I like it.

Now the coating makes sense. I wasn't putting all the pieces of the puzzle together... Forgive me.


Back glass question:

Keeping a solid piece unit, or installing one with a sliding rear window? That way you have access to the rear if need be, without breaking the back glass.

Or you put on the shell, and the prerangers have a riding/holding area, while you and the Mrs. take control of the cab interior...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:20:32 AM
Speaking of boneheads, I feel fine thank you berry much!

Lets get busy building that rear alcky tank.

Here is the area we will be adding to:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:22:10 AM
Then the painting started

First was the tailgate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:22:58 AM
Then the bed underside. That was difficult. I had to craw in there and spray at all sorts of weird angles. I almost qualified as a contortionist!

I suspect it is not completely done, but I'll be able to tell when I flip it over later on
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:23:46 AM
Then the hanging jungle:



Note: parts in the pic from a failed rear water tank project are shown as well

That water tank later did not fit with the bed in place! It was scrapped in favor of a better design!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:25:36 AM
After some dry time, on went the first of two double coats of gray.

I changed the color just a tad, taking it one shade darker
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:26:17 AM
Then the final coat and that concluded a pretty productive day
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:27:49 AM
That can was kicked down the road far enough, so time to move on, and with this truck, there are always plenty of projects to do.

After I visited the paint store and talked with the guys in the know there, I changed the game plan on the painting of the bed.

I had planned to scuff the yellow primer and lay down a coat of liqueur primer, then the paint. The guys at the store didn't like that much for what I am doing. They eventually convinced me to shoot a coat of epoxy primer, then lay down some bed liner on the bottom and the top side of the bed!

So that is now the plan. The underside of that thing is going to get the full epoxy/urethane treatment. It will be impervious to just about anything except submersion in the great salt lake, but I'm not headed in that direction anytime soon.

So with a fresh gallon of epoxy sealer in hand, I started with what all paint jobs start with, sanding

I used the scuff pads to handle the job
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:28:23 AM
After a couple hours of detail sanding in the myriad of nooks and crannies, I declared it finished and ready for paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:28:54 AM
Here is the epoxy, two part sealer I will be using:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:29:39 AM
And here is the first cup sprayed out.

I used the second gun of the set with the largest 1.8 nozzle which did a great job of laying down that paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:30:17 AM
A second cup of paint finished the bed top surface
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:31:04 AM
Then a final cup of paint finished the detail areas inside and covered the inside of the tailgate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:31:38 AM
I had taken some pictures of that Cherokee with the correct OD green color on it down to the paint shop to show them. That started quite the buzz. Before long they were pulling out formulas for US Military paints, but with each case there was some sort of a problem. One would be a single stage without hardener. If I add hardener, then the paint turns glossy. Then some of the paints was a 2 stage with the second stage being a flat clear which costs $100 a quart.

It got these guys so interested that they started mixing up 3 oz paint samples. They plan to call a the Air Force museum curator up at Wright Patterson Air Force Base and see if all of them can figure out how to mix me up a single stage semi flat correct green with hardener.
I think we are in the process of inventing a new paint for this project!

Here is the bed a couple hours later and nearly dry
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:32:44 AM
To wrap up build day 78, here is what it all looked like when I kicked the dog, sprayed the katz and threw in the towel
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:33:37 AM
Quote:
Originally Posted by duramaxdarren View Post
looking great...i have a few concerns...rear end articulation and ground clearance of that tank, plus the elements getting at the battery back there. those open batt terminals and wiring under bed need a sealed enclosure some how. plus the filler neck. is it just gonna come up through the bed?

The battery terminals do not need to be in a sealed enclosure.
Military vehicles by the thousands do not shield their batteries. When I was a tanker, I sometimes buried the batteries, all 6 of them under mud...soaking wet mud.
The air pump is more or less waterproof, and the fuse IS waterproof. Only the relay is questionable, but unless I wade 4 feet of water it will be high enough.
Finally, there is protection going in under the tank when the rear bumper thing gets built
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:34:12 AM
Quote:
Originally Posted by duramaxdarren View Post
I'm very interested in the bumper build. plus im writing down part numbers of the paint supplies you got.

...Happy to be able to blaze the trail so to speak.
There are lots of great products out there. I have always preferred DuPont paints and Centauri acrylic enamel in particular. This Nason paint is essentially a newer Centauri. The Centauri product has grown spendy over the decades and this Nason product is priced better in the market while maintaining all the quality.
I started spraying Nason in 2003 when I was building the Tundra. I built a hefty rear bumper for that truck, and painted it an anthracite color. It had good gloss and laid in nicely. When I sold the truck this year, that 10 year old bumper looked nearly as good as it did day one out of painting.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:36:51 AM
Once I sprayed the epoxy primer/sealer on the bed underside, I had 3 days to spray the bed liner on it and be done. The last two days it has been a super humid, rainy mess...not to mention Christmas shopping and social commitments.
Bottom line is nothing has yet been sprayed since I don't want to take a chance with so much moisture in the air!
It's Sunday and it's...yep...raining and super windy, but in the 60's! Coming right up is a plunge into the artic temperatures, which with the judicious use of the heater just might open a window.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:38:00 AM
Quote:
Originally Posted by streetrodchev View Post
Just got it, haven't had chance to fire it yet. Need to add/change a few things yet.

Saigas can be very squirrely

Definitely not a novice gun

The gas port system is very, very touchy. If you change anything expect the gun to start to run funny.

I own one, had $1500 worth of modifications done to it to get it to run reliably. Find the ammo it likes to digest and stick to that. Do not use a Saiga 12 as your go to combat gun...back up gun or evasion gun, but not primary as it will let you down.

Mine likes Remington 1 oz slugs and Remington 00 2 3/4" buckshot and some cheapo Spanish 00 buck and little else.

Do not mess with the gas port system at all
Do not mess with the barrel length, if you do you will have to rework the gas port system.

Find which mags run, most will not. Those MD arms drums are marginal. I don't know...I'd have to say given the utter reliability of the AK-47, this gun is not up to standard.

Here's mine:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:39:08 AM
Had a chance to spray the underside of the bed in between the monsoon and the tornados.

Here is the underside of the bed with the epoxy sealer all cured and black lookin'
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:39:59 AM
The kit, Defender Pro, comes with 4 cans of part "A" Epoxy, and 4 cans of part "B" which is also loaded with Kevlar for strength
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:41:35 AM
Each can comes half full and mixes up to the consistency of hot tar. It is nearly impossible to spray all of it out of the can, so a good bit of it is lost, just due to it's thickness and the fact that it has to come out of 8 cans.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:42:29 AM
One can does not go very far at all. The paint guys say 4 cans is enough to spray out a 6 foot bed, but I would not agree unless you just want it on there paper thin.

You need to take care to mask off everything you don't want to get coated or over sprayed
I bumped the trigger and now I have a nice pattern on the maple tree side of that pretty new red toolbox!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:43:04 AM
Here is the bed after the first can was used up. It takes about a minute of spraying at 50 psi to empty the can
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:43:56 AM
Allow me to correct myself, that is after 2 cans were sprayed, not 1!

Here's some in-progress shots
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:44:48 AM
Some more:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:45:33 AM
And here it is after the end of a very short Build Day 79
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:47:30 AM
Quote:
Originally Posted by FBJR View Post
Does look good, all 4 cans did it??


All the more reason for a tilt bed. It is lined with kevlar, just tilt and you have a 007 rear shield

To bad there isn't a foam type sealer/anti rust for places like those closed under-bed rails and such.

I would have felt better with 5 cans. If I had to do the inside of the bed (Oh wait,...I still do!) I'd vote for 6-7 cans min. I'll just buy two more kits and use the rest to spray that red dog. Remember that tape I was using? When I wasn't looking, the da@#$! thing carried it off and chewed it up!

I have a product which seems like a sprayable cosomoline that had to wait until the end. That gets sprayed next into those recesses. Best to leave them open and ventilated, rather than filled with some foam which might breakdown and allow moisture in and trap it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:48:07 AM
Quote:
Originally Posted by Cudakidd53 View Post
Great progress, glad the weather broke some for you!

Tomorrow, the bed will be ready to flip to start on the top side. Get the body work done, then scratch up the thing and paint it with real color, then finish with spraying in the bed liner, and that part of the truck will be done. All I have to do is get the back side of the cab sprayed and all the wires and lines run and the bed can go back on.

It will look like a mo-complete truck for a short time until I take the fenders/hood/doors off
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:53:07 AM
Here's the manifold I ordered yestertag:

It's a 3 piece design that prevents cracking and is actually made from Ductile Iron, same stuff as our turbo exhaust housings are made from
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:53:28 AM
That thing is a "Pulse" design designed both to improve flow and to keep velocity high. This manifold along with that 14 CM exhaust housing will allow the 6 to spool very quickly.

I have to be judicious in the adding of power here. Considering the fact that the truck starts out nearly 1.5 tons lighter than the Duramax truck and given that it should be coming out the chute at somewhere around 1000 ft lbs, it is going to be pretty fast, as in losing traction and getting uncontrollable.
I only need enough power to do what I need to do in some of the situations I have described, so I think with the twins and much bigger injectors I AM there.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:54:36 AM
THe power upgrades will happen in two stages I think.

About anytime I think I'll drop all that stuff into the injection pump and perhaps get that running.

I may have found another cylinder head. If so, then get that O-ringed, bigger valves and ported. Install that with the ARP studs and goddin' head gasket, then get to the turbo stuff.

That will commence with the overhaul of the stocker center section. Followed by the addition of the 14CM exhaust and the 60MM compressor. Mounted up to the new manifold and prudy painted stuffins' I'll fab in the second turbo and get that all sorted out.

I'll need to add in the mucho bigger injectors and sort out the exhaust, but that will soon, be that as they say in the movies. That's when things are going to get a little custom. I'm thinking I'll have the fenders all dipped, cleaned and primed and remounted by then, so It would be time for something wild with respect to the air intake. I'm thinking the air needs to be coming from the level of the top of the windshield.

So getting a 6" ID pipe to come out of the fender, then snake around and up the windshield pillar to arrive up top is going to be quite the chore. But, I have done it once before so I know that I can.

That is the plan for all that, oh, and the addition of an intercooler twice the size of the stocker...



Note:  I was so wrong here as you will discover in pages to come...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:55:43 AM
Quote:
Originally Posted by FBJR View Post
I was wondering when you would get an exhaust manifold. Sounds like you may as well just do another motor and drive that pup as is for now.

I may hunt another motor...I am always looking.
It is a real possibility of "Upgrading" the survivability aspect of the D-Max truck by transplanting a Cummins in there and taking a huge leap backward!

If I can score a cyl head it will make the build just that much easier...


Note: Is this where I got the idea for what is to come???
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:56:19 AM
Darren, you paying attention?
With this installment we will finish rust proofing the underside of the bed and essentially be done with it

here's what we will be using, a long flex line and a 360 nozzle
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:57:14 AM
The line is a couple of feet long and the nozzle is a cool brass gizmo with a bunch of cones drilled into it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:57:55 AM
All you need to do is to find an opening and fish the hose into it, spray and pull out with an even speed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:58:49 AM
The material got all over everything as evidenced by the extra stuff running out from the seams
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 11:59:52 AM
The excess wiped up easily, but within minutes the stuff started to thicken and get sticky

You can see some pretty good coverage inside the bed between the inner and outer skins
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:00:34 PM
After wiping down, some still shows, but it's not too much and I don't think it detracts from the new appearance of the bed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:01:24 PM
The inside of the bed looking from the inside got a coat as well. This will be a moisture collecting area
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:32:28 PM
I wasn't bashful at all about letting it rip in and around the tail light cutouts.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:33:31 PM
With that stuff thickening up nicely, it was time to flip the bed and get it on the work horses to finish it off

None of these pics show it flipped, but do show it in the light of day, outside, finally!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:34:38 PM
Next project is to remove the stock fuel filler and install the aircraft style unit, and cut in another filler neck for the water/alcohol tank.

Here is the cap unit(s) we will be using
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:35:39 PM
First I made up a template that I will use to construct a plywood piece from.

That plywood will help me cut the pieces out of metal and accurately locate the holes
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:36:20 PM
The fuel filler, will, obviously, go back into it's factory position

The new plate measures 7" X 8"
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:37:22 PM
Then the H20/Methanol filler will go aft of the wheel well at the same height and equidistant from the wheel well arch
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:38:53 PM
I'll chop off a short section of the 4" pipe and weld it to the filler cap mount, block off the back, and then weld a 1.5" nipple to it to attach the rubber fill pipe to
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:39:39 PM
I'll try to keep from using the bed as a welding table, but the temptation is high since all my other welding tables burn up!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:40:20 PM
I need to prime the naked strips in the bed floor and the top of the bed itself, but that is easy stuff!

Here it is at the end of build day 80
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:45:08 PM
Well, let's get some more of this thing built.

I have been focusing on the back end of the truck because the bed was off. That theme continues with today's project.

I need to install reliable fuel ports that are large enough to pour right out of a can if necessary and seal up well.

No fuel cap that I know is better than the cap from an aircraft, a military aircraft that is. SO that is what I decided on and purchased a couple weeks ago.

The alcohol tank is in, and the main fuel tank is refurbished also, time to connect everything.

Since it involves sawing on the bed, it too, is necessary before I can paint the bed and call it done.

First up was to finish the patterns and check all that out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:45:58 PM
That pattern was transferred onto some 1/4" plywood, which I will use to cut the steel plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:55:40 PM
Fit looks good so far
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:56:35 PM
The plywood was clamped onto some 10 gage plate and the cuts were made with a plasma torch
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:57:23 PM
Two sets were cut out
A set consisting of the outside plate which will hold the cap, and a stiffener which will bolt on the inside of the bodywork, sandwiching the thin steel of the bed and making it much stronger
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:58:07 PM
After some close up and personal time with a grinder and a 40 grit flap wheel, the pieces were looking better and beginning to fit.

THe hole for the cap is still somewhat crude, since it is still not done. I'll wait until I figure out what the 4" tube that fits on the inside is going to look like.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:58:53 PM
Then the drilling commenced.

I had to drill a total of 44, 1/4" holes to fit all these parts.

That is going to be a pretty good drain on my hardware stocks!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 12:59:30 PM
44 holes later:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:00:07 PM
THis is how the outside parts stack up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:01:03 PM
And here it is fitting over the stock fuel cap recess:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:02:00 PM
Don't worry too much about that panel sitting there and all those bolts sticking out in the wind disrupting the smooth race car like lines of this truck...There will be plenty more disruption to come.

You will see a vent grid cut into each fender, all military style like this, and another transmission oil cooler mounted to the underside of the hood (Yes the underside of the hood) with a wire mesh top side, and a snorkel pipe sticking out of the right fender.

Here is where I left it all tonight so I could cook the pre-rangers up a pizza.

Oh did I mention we had a new baby grand daughter today? That's where I was all morning and what was going on here the past couple days!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:03:32 PM
OK, build time again

We are building the fuel and water/alcohol filler assemblies

I want to duplicate the stock angle so I can utilize the stock filler neck, so I'll be using nearly the same angle
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:04:11 PM
And it will fit something like this
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:04:50 PM
The backside will be capped off and have a hole to fit the filler neck
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:06:56 PM
That piece will get massaged so as not to look so crude, although it remains hidden from view. I drilled the holes in it to match up with the stock filler neck
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:07:49 PM
This is what mates the filler neck to the new fuel port
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:09:23 PM
I am working with a section of 4" exhaust tubing I pulled off the Duramax when I converted it to a side exhaust

Next, the pieces of the water filler neck were made in about the same way
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:10:38 PM
And this is how that part fits together
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:11:37 PM
Then I welded up the fuel filler neck adapter
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:12:51 PM
It was about then when I looked up on top of my cabinets and much to my surprise, discovered a new welding helmet, complete with preinstalled flames. I believe the flame helmet is faster than the standard black one
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:14:11 PM
I installed the cap ring, then test fitted the new adapter piece. I knew it was going to be tight, but there was not enough room to fit a round pipe section and still retain the nuts which are pretty necessary to hold that all together, so something creative would be required
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:15:30 PM
After tapping the marked areas in to flatten them somewhat, I ended up with a big hexagon which fit rather nicely!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:16:38 PM
I welded most of the outside except around the nuts, and welded them to permanize them to the mounting plate
I then welded the ring on the inside 360 degrees
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:17:32 PM
It seems I had grinder problems again. Tomorrow, before I do any work...I'm going out to purchase some leather gloves
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:18:20 PM
After some grinding the filler cap assembly wasn't looking too awful bad
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:18:56 PM
Once I enlarge the hole, it will fit well me thinks
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:19:55 PM
Next I welded a nipple onto the flat plate in the water/alchy filler
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:20:52 PM
Next I welded a nipple onto the flat plate in the water/alchy filler
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:22:28 PM
I gave that dude the same hexagon treatment
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:23:10 PM
Set it up and welded it in the same manner
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:23:55 PM
Using the 40 grit flap wheel. I cleaned them up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:24:46 PM
And gave them a double coat of U-Pol copper primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:25:23 PM
The process went fairly well today and after about 5 hours of work, I called it a day and went over to see the newborn meet her brother for the first time

Here's the end of build day 82
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:26:05 PM
Oh, almost forgot, the white and purple truck brought the bed liner today. It will not be dormant for very long!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:34:02 PM
Before this thread falls totally away from anything remotely related to what ever it was way back when it started, let me throw in some pictures so someone else can start talking about tidal currents or problems with their girlfriend or something reverent like that!

You always hear the saying, "Safety first," right?
Well what that means is if you have pictures of safety stuff, show them first!

Considering the fact that I am taking more hits here than an average operation in the Hellmand valley flying gunship support, I thought it prudent to buy some safety stuff.

You can see rubber gloves, leather gloves, yellow fuzzy gloves, the old reliable brown ones used to warm your nose when working in a cold garage and a face mask. I didn't mention the piece of steel that got stuck in my face. It came out OK, but I'm on-to this stop work demon that is visiting my shop.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:34:56 PM
Didn't have to waste any more masking tape on field dressing of wounds today! I did get to use the tape for what tape is meant for though!

I finished the backing plate fab by welding the nuts in place, effectively creating a big nut plate. It will make assembly, hillbilly-easy, which is what I like
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:36:23 PM
After some careful marking, I positioned the backing plate and marked it's outline with some black paint, then drilled the 8 holes with a 5/16" drill bit
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:37:53 PM
Then cut out the inside area
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:39:04 PM
After measuring and marking the first hole, I marked the second one
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:40:01 PM
Just like before, I drilled the 8 bolt holes and checked the fit before cutting any metal.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:40:53 PM
Then surgery was performed using a cut off wheel spinnin' really fast!

A quick check of the back side showed I had gotten a goodly amount of material sprayed down into those recesses
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:41:49 PM
Note to everyone wondering about the yellow gloves: They are not suitable for scratching one's nose...They leave hairy fibers all over your face that bother the living heck out of you until you break camp and wash your face off!

And lookey there...Uniformity. Holes that look like they duplicated themselves on either side of the wheel well...Purdy
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:42:49 PM
With that done, it was time to do some painting.
First up was to finish spraying the remaining spots of bare steel with the acid etching yellow stuff, which I did
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:44:05 PM
Then the nut plates and the fuel cap panels
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:45:21 PM
Next up was a couple of coats of John Deere blitz black with hardener.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:46:10 PM
After spraying those fuel cap panels, I have to say I do not think they will pass muster. I could see grinder marks in the paint and it occurred to me, that this is unlike everything I have painted so far. This part shows! It is part of the finished appearance of the truck and needs to look straight and flat. So my money says I'll be pulling it out of the hanging jungle tomorrow and sanding it and doing a lot of smoothing before repainting it, we'll see

The side of the bed came out OK after a coat of the yellow stuff blended it all in and sealed those cut edges.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 01:46:53 PM
So there it is boys and girls, the end of another build day on Square D

OK, DOTs take over and derail to your hearts content!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:03:08 PM
Well, no compressor showed up today, so the projects just sort of fizzled out.

But I can post the incomplete build day from Tuesday when things went sparky.

I started off the day with the knowledge that my new gloves did not survive the night with the Red Dog (Soon to be dead dog
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:03:41 PM
After inspecting the paint job on the fuel cap plates, I'd have to say I'm not happy with the results
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:04:35 PM
I'm giving them a thumbs down!

I'll sand that mess down and coat the whole business with some body filler to get the whole thing even, then repaint with that good Blitz JD paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:05:50 PM
Before the light and spark show on Tuesday, I started the body work.
First of all, I used some 40 grit or was it 36 grit??? Anyway using a good solid straight edge...Duane's forehead was not available, so I grabbed something just as good, a 2 X 4 and wrapped the paper around it and sanded around the dented area to allow the scratch marks to show me the high and low spots. It worked fairly well.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:06:25 PM
After tapping down the high spot, I ran over the area with the 40 grit flap wheel to roughen it up so the body putty would adhere
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:07:01 PM
...And hit two small dents.

That's it! That's all of the dents in the whole bed! Well on the outside surface. The bed has seen WW2 apparently, but I don't care what that looks like, it will be covered
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:07:48 PM
The standard of body filler, Bondo, was given the nod to do the filling of the dents after I got as much of them knocked out as possible
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:08:33 PM
After mixing up a liberal amount, I spread it over the affected areas with a 6" paddle
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:09:17 PM
If you want to save yourself a bunch of sanding, then as the stuff hardens and gets to a point where it is setting up but not hard yet, you can use a body filler file on the stuff and plane it into the rough shape, that you will later work from to sand to the final shape
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:10:18 PM
We'll have to await the arrival of the much anticipated Eaton V-4 compressor to watch this process play out.

So in the meantime, let's look into some boxes

The Diesel Performance Parts high flow exhaust manifold showed up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:10:59 PM
This manifold will make more power, and will not crack, adding to the reliability of the truck.

The port size is larger and flows well, utilizing the existing pulse to help flow, but not too large so as to slow down velocity which is what spools the turbo
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:11:35 PM
This manifold is actually three pieces which have been lightly pressed together. As it expands and contracts, a stock manifold will grow as much as 3/8" in length. That movement will now be accommodated at these two machined joints
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:12:44 PM
Quote:
Originally Posted by nmeyer414 View Post
Definitely looks as though the red dog needs to go.


It almost went tonight
The sled dog was at the front door barking
That's odd, she doesn't do that
I opened the door and she and the cats dog-piled me getting in the house.
Note that the cats don't come in the house very often and neither does the sled dog. That's when that icy blast of artic air hit me.

Hmmm

There's a stack of locust logs burning up a storm in my fireplace and everything in the casa is toasty warm, but outside its a different story
So I check the thermometer.
Not good, it's reading 6
And the wind is howling.
A quick check of the weather channel tells me it's 1 outside. Where in hades did that come from.
Anyway, I suddenly realized the red dog is not well equipped for 1 degree temps. So I go out and just before I froze solid myself I find her. She was definitely not doing well, so I hauled her inside. Dammed dog snagged one of my boots on the way out to the garage!

I should just shoot her and be done with it, but I guess I'm just a big softie inside. So much for the steely eyed killer thing...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:13:18 PM
Quote:
Originally Posted by lutzjk913 View Post
So what kind of dog is the red dog?

Well, I wanted a GSD, so my wife found a GSD that had a litter, but father was unknown.
...Yea
So she finds this little puppy that to me looks exactly like a golden retriever, just a tad reddish, like a Chesapeake bay retriever.

But wife insists as it grows it will look more and more like a GSD and it's ears will stand up.

Other than the droopy retriever looking ears, red color and striking resemblance to a golden, the first place the dog goes when it gets out of our electric fence is straight into the neighbors pond!

I don't recall my other GSD even liking water...This red dog has gills, talks to fish. Only thing it likes more than water and chewing is mud. If it can't find it, it will make it and roll in it.

So my money says that this German Shepherd is a golden retriever
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:15:17 PM
Quote:
Originally Posted by BobbyB View Post
You're welcome. Thought you'd like a little cooler air. I'm sitting at a -6 without windchill atm, with not 1, but 2 windchill alerts, informing me that its going to be -35 to -55 during the later afternoon into night time until 7Jan. I could send some down your way if you'd like...


No thanks my frozen friend
Don't freeze, stay warm, or not, your choice, but don't get hurt in that wind chill!

Worst I saw was -29 static with wind. Wind from a Chinook that is. Had to fly one day at -29F. Rough, rough day...heater wouldn't do much more than knock off the edges.
But the coldest I ever was, was that time I wrote about in the book. With a zero dark early takeoff, flying gunship cover for a 100 mile long convoy of several hundred trucks going from Kandahar to Kabul. I remember the mess sergeant trying to keep me from shaking so much that I couldn't hold onto the coffee he was trying to force down my throat...Yea, I was really cold that day. I bet if we would have crashed, I would have shattered into shards of pilot pieces.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:16:11 PM
Quote:
Originally Posted by flyin6 View Post
No thanks my frozen friend
Don't freeze, stay warm, or not, your choice, but don't get hurt in that wind chill!

Worst I saw was -29 static with wind. Wind from a Chinook that is. Had to fly one day at -29F. Rough, rough day...heater wouldn't do much more than knock off the edges.
But the coldest I ever was, was that time I wrote about in the book. With a zero dark early takeoff, flying gunship cover for a 100 mile long convoy of several hundred trucks going from Kandahar to Kabul. I remember the mess sergeant trying to keep me from shaking so much that I couldn't hold onto the coffee he was trying to force down my throat...Yea, I was really cold that day. I bet if we would have crashed, I would have shattered into shards of pilot pieces...

One of the coldest times I remember was Gardeyz in 2003. We were still building the FOB up at that time so our front gate had an "uparmored" Humvee as a guard post. Well wintertime in Gardeyz sucked balls since it was surrounded by openness and mountains so the wind coming off went right through everything.

So myself and my buddy both PV2s' at the time were assigned the 0000 -0200 shift. 2' of snow had fallen between my first shift and the 0000 shift, so we trudged out and assumed the guard. The SOG fell asleep in the TOC and forgot about us. Now I should mention that the Humvee was deadlined, i.e. no starting which means no heat.

I'm on the .50 in the turret with snow falling and the wind blowing and my buddy is in the truck with the radio. He is wrapped in woobie trying to keep warm and calls up to me "how you doing bro"...

Well at this point I have a mound of snow where my shoulders and head are located, my hands are stuck around the spades on the M2. My buddy sits with his back to my legs and wraps the woobie around my legs to give me some sense of warmth... At this time it is 0300, at 0400 the SOG must have woken up and grabbed the 0400 shift and they trudged out relieve, who they thought was the 0200 crew, but instead found me.

It took the SOG and the oncoming crew to pull me out of the hatch, I had no strength to hop out, my hands were stuck in the "grabbing the spades" grip and I wasn't happy. 3 hours later I was woken up by the PSG and myself and the other privates had to fish mortar rounds out of a frozen flooded FDC bunker... thus began my hatred with cold AND wet.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:16:48 PM
Quote:
Originally Posted by Cudakidd53 View Post
!

Question- did the Afganies fight in crap like this or did they lay low?  If you start looking like that guy, cut back on Colloidal Silver or we're gonna have to call you Papa Smurf 

Mostly they laid low. Fighting starts up in the springtime after the rains and continues on until maybe june of so then it's 120F in the south, too hot to do anything. Up in the hills, fighting can go on all summer, but then snows in early stopping everything again.

But with Obamas PC rules of engagement, the enemy is growing very strong and brazen, propped up by our presidents rules. I'd expect them to be lobbing grenades over the walls this next season.

The only way to fight them is to route them out everywhere they are and kill them. One by one, every last one. Our guys now have to certify by name that no civie collateral damage will occur. Yep, you have to put your name to it. Then if something goes aerie, you're up for prosecution. I saw the Dutch do this in 06. One of their soldiers killed a Taliban. Hey, cool I thought. But someone in their musloid government filed murder charges against him, and convicted him! Yup. Thereafter the Dutch contingent at TK would not come outside of the gate to fight!

In my book, you'll see the pictures of the Hueys all shot up. That battle happened less than 2 miles from TK with thousands of Dutch infantry hanging out. Our guys got ambushed, three times. Every time they ran for it, they found themselves in another ambush. We were screaming for help. The Dutch had Apaches. None came. For hours we tried and fought back. Old Hueys with mini-guns and finally just with M4's. Many of our folks got shot. All of our vehicles were destroyed. Luckily our gunships peppered the rag heads killing a lot of them (Cool!) and after ward a lot of rag-heads start showing up with mysterious bullet holes in them at our military clinic! Yea.
Finally after the battle was over, the Dutch launched two Apaches which fired hellfire missiles into what was left of our trucks! Yep shot up our stuff so towel head couldn't get it!
That's what happens when _____ politicians get involved. These coward woman-man real man simulators lack the moral courage to fight a fight. Even to allow our warriors to fight it. Doesn't help that the prez sees our forces killing his people and doesn't like that, so he's evened up the odds. We fight and maybe we sacrifice our careers, maybe do a little time as a murderer?? Pretty stick mess when you're in the middle of crap land and you're listening to the song an AK makes.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:32:44 PM
Parts, compressors, and quoffee...

Update time boyz and girlz.

First of all, John owner of Stazworks has shipped the HMMV wheel centers and bead locks. Yup, stuff is finally on the way.
Used to say that in tanks. Gunner or commander says "On the way," then squeezes the trigger. Back then utter violence was unleashed as that 105mm breach recoiled violently rocking the tank and blasting the living snot out of anything out front.

Oops, digressing...DOT Effect I'm guessing, or old age, or loss of memory, or possibly a combination of all the above, who cares...?

So wheel parts are finally inbound

So are the engine parts. Gillette Diesel finished making the custom injectors, and will be sending me the turbo upgrade parts, and the new S-300 turbo for my custom twin setup.

Finally, Although Duane and I worked most of the afternoon on the compressor, it has yet to make a sound. Best either of us can figure out, the wiring in the unit as shipped is wrong somehow. Duane wired it up several times and I double checked his installation. But every time we flipped the switch to start it, it popped the circuit breaker and threw sparks out of the switch.
We checked the wiring in the wall receptacle, we checked the 50 amp extension chord, we checked the wiring in the new power cable he made up, and we wired and rewired the magnetic starter hookup at least three times. Still it does not work.
Looking at the schematic, one of the wires as the thing was shipped appears to be wrong, but how could that be? The unit had a test tag attached to it, showing it ran over 3 minutes, achieving rated pressure, then denoting on and off pressures for the switch.
So my big question is if it ran at the factory and the receptacle and extension we used to plug it in to has for years powered my welder, then how could it not run now?
Dunno, but I need to call Matt over at Eaton and send him some pics to figure this thing out
__________________
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:35:28 PM
This project is in the discombobulation/confusin' phase right now.
With so many bones connected to so many other bones, I am afraid that if I want to switch mu incandescent tail light bulbs out for LED ones, I might have to first change the crankshaft main bearings!

I was werkin' on the bed

Fabbing in the fuel ports so that I could do the body work and paint it. Then I can put it back on the frame.
But before I can do that, I really need to paint the backside of the cab while I can still have access to it. But there is no real good spot to break off the paint so I really should just paint the whole thing. Well, to do that I need to pull the fenders and hood to get to the areas that need to change colors. I also need to lift the cab up some to get to the top of the frame which so far has only seen high pressure water, then paint.

When I pull the fenders it is the right time to fab up the twin turbo system for the engine and the right time to fab in the new radius arm/coil spring suspension.
And while all that is going on, we still need to figure out the tires and wheels.
At some point I just need to make decisions as to what is coming next and I am at one of those crossroads now. With John Staz owner of StazWorks off road having just delivered some really cool looking and uber-strong wheel centers it is time to build up the tire-wheel setup and get that mounted so we can see how all this is really fitting.

So that is the next project, starting today or tomorrow. Build up the new wheels. While I have the tires off, I am going to do a little modifying to them as well. The Goodyear military MTR's can easily crunch up an optima or an elantra, and still give you 50,000 miles. But they lack a little ability in the gooey stuff. Personal experience here as much as what I read.

So I'm going to cut some new tread into these tries with the tool below making the stock jap kar killin' tread shown into some kintucky hill climbin/jap kar destroyin certified DTP (Don tread pattern)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:38:03 PM
Project next is the creation of the wheels.
Here's a look at the new centers:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:38:35 PM
Look carefully at the end of each spoke, at what appears to be a rough cut.

It is actually several welds that have been machined to drop a certain distance into the wheel and no farther. Inside the HMMV wheel there is a lip or swell that extends backward about an inch. With these little machined nibs protruding, the centers tap neatly and solidly into place with no fuss at all.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:39:30 PM
The other cool part about that is it exposes some of the underside of the spoke to allow for a deep, penetrating and filling weld. I'll make the primary pass on the back side, then make a cosmetic pass on the front side

I haven't measured but I'm guessing I'll be somewhere around 3.5" Back Space with the center positioned here
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:40:48 PM
Everything else is still OK, having survived the onslaught of the red dog and all it's destructiveness. The screwdrivers Duane used out of my tool box were not as fortunate. They have been reduced to a pile of what looks like wood chips

Here's the internal double bead-lock I'll be using
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:42:49 PM
Hey, let's get on this wheel conversion thing. Since I'm sitting here with a sore back and a belly full of home made spaghetti, let me tell you a story about a man named Jed, poor country boy, barely kept his family fed

Sorry, was getting into it there...Duck Dynasty is on in the background and it has me in the mood!

Anyway here is the stock assembly with nary wrench turned (Yet)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:43:23 PM
First pull this thing out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:44:02 PM
Then take these off

They are 1/2 X 20 (Fine thread)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:44:39 PM
The wheel halves don't exactly fall apart. Nope you have to pry, kick, drop the thing, curse, spit, drink something to cool you off, then repeat until this happens:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:45:12 PM
There is a big O-Ring located between the tow wheel halves. I removed it and stored for future reuse
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:46:19 PM
At this point, I sprayed a generous amount of warm soapy water into the recesses, then turned the tire around and pried the other half of the wheel out the back side using pry bars and a lot of umph!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:47:09 PM
I made several futile attempts at removing the big rubber run flat thing. You are not strong enough to pull it out. I thought I'd just cut it into two pieces with my sawzall, but I discovered the limitations of that saw. You have to get through 6-7" of hard rubber and that just isn't happening anytime soon, so I abandoned that idea
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:48:17 PM
As the day progressed I disassembled more and more of the wheels
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:49:27 PM
The Marines say you can get proficient at changing HMMV tires, but you never get fast

I understand that now!

To cut the center of the front disc out, simply slide it back onto the wheel studs and invert it on a table

I used my Hypertherm 45 Plasma cutter
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 02:50:39 PM
I cut the first center out using the inner wheel as the cut guide. The torch kept hanging up making for a notchy looking cut. It will grind smooth, but there had to be a better way
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:37:02 PM
After thinking about it, I just happened to have some nozzle dip I use with my mig torch

Its like a thick paste, more paraffin wax than grease. It keeps spatter from sticking to the mig torch when welding. I was thinking it would act like a high temperature grease to allow the plasma torch to glide around the rim
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:38:29 PM
I was right! It helped a bunch. Here's how and where I used it:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:39:04 PM
Using flame decals on your welding mask helps you remain flame proof!

That's right...Right?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:39:39 PM
The cut quality improved:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:40:23 PM
I ended up with a stack of centers. Can anyone say future spare tire mount rings?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:41:12 PM
The cut discs cleaned up with soapy water and some brush action
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:41:58 PM
Next up was the wheel prep. This is when I really began to realize just how high quality these wheels actually are. After grinding for awhile I wasn't seeing any metal. These wheels are power coated or something like that. It took my sanding disc to break through.

I cleaned a 1.5" wide band on the inside of the wheel in preparation for the new center
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:57:19 PM
If you've noticed I am surrounded here by some really smart and skilled guys who "Help" in their own amusing way, but help they do.
There's Shawn. He builds the best differential covers in the business. He just suggested building a jig for the wheels, which I did.
Take Ash, he has a ton of experience with all sorts of diesels, heavy equipment, you name it
Daune, a fellow Armee pilot is more detail oriented that I am. He takes things to a level scarcly seen in construction, or car crafting, and gives me constant advice. Bobby is a warrior with a heart of gold who tries with the little that he has. Ken is a master mechanic who easily spotted when I bolted the brakes on BACKWARDS! Darren is a master electrician, Dominic knows boating and trucks, Mikie is a smart guy from Chicago who is way better versed in truck building than you'd expect from a suburban school teacher. Nick who lives very humbly and still serves in the Army is also a hot rodder and a builder like me.

We enjoy comments from several law enforcement officers, a pastor or maybe two, engineers, soldiers of all sorts, which includes our brave Marines, and the list goes on and on.

So what you have here is not Don. What is really happening is definitely my antics, but mostly a synergy of sorts with all the folks who hange out here.

But this thing probably would not exist at all, or have attracted such a diverse group of good people without the will of God himself. He made all this happen. One build thread now seen over a million times, and this one headed in that direction. Many of you have contacted me privately to discuss your beliefs about him, and we talk... If you want living proof that God works in mysterious ways, look no farther than this build thread!

Be good!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:57:57 PM
Quote:
Originally Posted by TXSarge View Post
Ah yes, the special tool. A 5,000 lbs ratchet strap and a strong Soldier works just as well.

Be careful with that run flat. That sucker is in there pretty good. A giant rubber projectile can damage things.

We don't build tires anymore because Soldiers couldn't figure out how to do things without getting hurt. Those Soldiers become NCOs, the problem perpetuates itself, and so on and so on.

I hear experience talking here. One thing I learned was to always listen to those select few NCO's who know what they're talking about. I think I'm hearing caution here...

I got the idea by watching a guy pull the centers out of the tires with his truck! He chained the tire down, hooked a strap around the run-flat, then to his bumper. As he eased away the thing popped out. Not as violent as I imagined.

Talking to John Staz, Stazworks, maker of the centers, he said he cuts them out with a chainsaw or sawzall. My sawzall failed, and I'm afraid the chainsaw might nick the bead, destroying the tire.

If I winch the center out I plan to keep it well lubed with soapy water which should allow it to pop out just like that baby grand daughter we had on the 27th of December
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 03:58:32 PM
Quote:
Originally Posted by stlaser View Post
Let's not forget Tate with Randy's Ring and Pinions extensive database. I've been dealing with HD 4x4 3/4 and 1 ton drive trains for 20+ years and I'm amazed at his resources.


Absolutely, Tate and so many more...I just cut off after naming a few because I didn't want to write on and on!

It's a risk one runs whenever mentioning broad spectrum thank yous. Inevitably you fail to mention some of the most important people. Like acknowledging the receipt of an award and forgetting to mention your wife...
It's all problematic, but I still like to throw names out there.

For those of you who don't know, Tate of Randy's ring and pinion fame is the resident gear expert who became involved in the Duramax build well over a year ago, or has it been two? He smoothed out the wrinkles of the gear swap and Grizzly locker install...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:00:04 PM
Let's get some more of these wheels built.

Shawn suggested welding some bolts to a welding table and use them to position the centers. That is a terrific idea, so I built a jig to make the process repeatable.

Over the past two days I developed the process about how to set up and weld up these wheels and keep them with industry standards for runout.

Starting with one of the centers I previously cut out, I welded 4 ea. 6.5" long 1/2" grade 8 bolts
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:00:56 PM
I selected a piece of flat 1/4" plate steel 22" X 22"
Marked the center, aligned the hub/bolt fixture and welded that together
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:01:50 PM
Then I measured where I wanted the backspacing to be with a wheel and a center and recorded those measurements. I decided to use the shortest distance. Note that just dropping these centers in place gets them pretty close
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:02:46 PM
With the caliper set to 5.760" and the outside resting on the plate, I adjusted the nylock bolts and single stainless washer to that exact height.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:03:27 PM
That all ended up looking like this
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:04:17 PM
The technique goes something like this:

Place the cleaned up wheel over the fixture, then drop the center onto the studs, tapping it into place with a plastic mallet until it bottoms out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:04:54 PM
Then tighten the top nuts to hold it all in place
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:05:28 PM
Then tack the center to the wheel in 4 places, remove and bolt it onto the front hub of the truck
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:06:28 PM
The gig got me to within .070 of dead flat

Using a heavy section of pipe 9" long, I would determine the high spot, then place the pipe over a stud, and give the wheel a healthy whack. Using a 3-5lb. hammer and assuming the tack welds are not too heavy, you can move the wheel a few thousands.

Just repeat this process until you get the run-out that you seek. For off road only, I'd just weld it up and be done. For highway usage, I'm sticking with the industry standard of .030"

I was able to get the first wheel to .025" and the second to .035, which was a bit over, but close. It will take you hours of this trial and error method, but you can get to where you need to be.

After straightening the wheel, I removed it and remounted it into the jig, tightening the bolts to around 75 ft. lbs. I then welded the inside of the spokes with a high heat setting, permanizing the assembly
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:07:06 PM
And here it is welded up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:08:25 PM
Quote:
Originally Posted by stlaser View Post
Just for the record & not sure that it matters (but depending on how they cut centers out it may matter). I set bolt height to backspacing desired and drop wheel with inner side of rim down on to metal. My thinking is A) you won't have a cut edge throwing you off. & B) runout is measured off inside where outside of wheel can be distorted due to tightening halves together. Just some food for thought. Good job using steel instead of processed wood though!!!


Excellent point, and good technique.

Techniques are ah-plenty, we will soon see if my chosen one works.

I thought about pulling down against the back of the wheel, but with the flange that holds the studs all in the way of a decent weld access, I opted for my method. I will say I am measuring some local warpage in and around the studs in a couple of areas, so your point is valid, but when I tighten those clamp bolts, all 12 studs are touching the plate, so the thing is flat the plane axis.

The bolts wouldn't weld to the OSB...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:09:04 PM
Quote:
Originally Posted by stlaser View Post
Also why balancing beads work well for this application.

I'm definitely going with internal balance media

I plan to use a bag of the trans Siberian double helix titanium matrix poly fluoride, carbonated substrate mixed with a few tablespoons of those plastic pellets I use to shoot at my boys with.

That should be enough to git it all balancin' like a Korean waiter on roller skates.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:11:17 PM
Quote:
Originally Posted by Anthony24x View Post
Don,
Thanks for linking this over on expo (my normal hangout) I just powered through all 383 pages in like 3 days. I like the way you change fluids ( by changing the entire truck around them). The only thing I can contribute is to ask if you have considered a shackle flip for the rear axle? The you could eliminate the rear block all together and get a better ride!


Welcome aboard!

You'd call it a fluid change gone wild, or over the top tune up, or truck detailing to the infinite degree, or...

I did consider it, and I actually have a WFO customs Shackle flip kit available sitting on my work bench. Too much work and the block isn't so big, plus this truck has had 2 blocks in the back end for 22 years already, so I actually made it better.

finally when I got to playing with the inverted shackle, I was amazed at how much droop-out it allows. It's a good system, so since this is not a dedicated off roader, but a "Get out of Dodge" vehicle. (Sorry for the pun) (Well, not really)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:12:35 PM
Well, I see everyone has been entertained in my brief absence.

I finally got all the wheels done, welded on both sides.

This is what I started with today:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:13:23 PM
You'll notice the outsides are welded as well as the insides. Here's the more difficult to access outward facing welds:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:13:57 PM
But the day yielded the rest of the operation of building the new centers and wheels up.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:14:18 PM
Even with the welding fixture, that represents many hours of setup, grinding, cleaning, checking, double checking, corrections, and then final welding. Not an afternoon task. I have my jig now producing duplicatable wheels which are coming out about .040 out which is just outside industry standards.

So here's what I am going to do. I'm taking them to a machine shop, to have the mounting surface trued up in relation to the wheel itself. Might as well just go for perfect with these heavy steelies
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:14:55 PM
Today I started cutting the new tread into the MTR's. Man, that is just plain a good workout.

Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:15:36 PM
I set the blade, a #5 up to cut about even with the bottim of the existing tread grooves, although that is hard to get exact.

Mere's the MTR just before I started:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:16:22 PM
I think the best thing to do is to start with something simple and expand from there. So, initially, I'll split all the center lugs on all the tires and then maybe get in and sipe the outside lugs. I don't think I want to regroove those outside lugs just yet.

Here's the first couple cuts:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:16:58 PM
And done:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:18:42 PM
Wheel Paint:

I think I'm going to do something cool here. Sort of let the old Square D make a cameo appearance of sorts. The base color of my truck is a darker silver. I just happen to have 1 quart of that paint here.

Be ashamed to waste it, wouldn't you agree?

The inside part of the wheel will be that base Dodge silver, to remember from wince it came. Then the ring the later camo color, the color you saw on the Allison oil.
I was thinking of making the wheel outers and the chrome part of the grill that color along with the engine.

The overall color scheme would be based around the two OD greens and the JD Blitz black, which are all semi gloss paints, and all enamels. The only other colors would be the inside of the wheels which would be the Dodge dark silver, and the Lycoming gray underpinnings.
Simple, understated, function along with the style I am looking for.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:19:41 PM
Quote:
Originally Posted by Armalite View Post
I would say local machine shop can handle that. I know when I had a set of custom spacers built, 10" wide spacers, so I could run duals on my Honda Foreman, they welded them up, then put them on a lathe, and trued them up. I could run 45 mph down the hwy, with all 8 wheels and tires bolted up, and there was no wobble.

But we are talking about comparing an atv to your truck. But I would still assume that a machine shop could come up with a way to lathe them true for you.

That would be my first spot to check. 

We're on it (Duane and I) His buddy, and becoming mine, Dan, knows a machinist who has a nice home operation and he himself (Dan) has a growing machine shop himself I think. So we ought to be able to handle this, and yes, Ash, same deal as your spacers. Just a simple milling operation we now thing instead of a lathe.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:22:08 PM
Salt covered brown truck showed up and brought this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:22:50 PM
Those boxes contain 6, brandly new Bosch injectors which have been extrude honed and balanced within a millimeter of infinity to make a WHOLE bunch more power. I am still asking what the specs on them are, but haven't learned yet.

Gillette Diesel in Bluffdale Utah built them as +120HP units to sync up well with the twin turbos I will be adding.

You Have a Quality Engine: Now You Want Quality Gillett Diesel Service

Additionally, here is a rebuild kit for the stock H1C Holset turbo which came on my truck
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:23:24 PM
They also sent these clamps and flanges to help me assemble and create this home-made twin setup that is coming to a SquareD project truck you and I both know.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:24:52 PM
That stock Holset will not be staying stock, Nossir not at all.

The stock air squeezer has a 56mm compressor wheel. Here is the 60mm compressor that the stock center section will be getting:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:25:26 PM
Everybody like playing parts?

Isn't this fun??
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:26:20 PM
OK, let's continue...

The stocker and rebuilt center section of the Cummins turbo will also get a much mo-better exhaust housing. The stock junk takes this afternoon to spool up. But this Purdy thing here will spool in 13 micro seconds, producing well over 1000psi of boost!

Really!

Well, I might have exaggerated a little...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:26:58 PM
It wouldn't be a compound turbo system unless something compounds the factory turbo.

This should do:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:27:49 PM
And that my young padiwans is what they call a new turbocharger!

It is a Borg-Warner S300 unit which is not too big, but plenty big enough to build a great towing motor which isn't reaching for ultimate horsepower. I'm not sure exactly where the horsepower will fall, but a twin setup and injectors like these should supply enough stuff for power creations well north of 500 and torque well over the thousand mark.

Keep in mind that Square D has one ton less heft to move around than the D-max trucks we drive, and we already know how fast the LML and modified earlier D-maxes are...

So this little Dodge will certainly be no slouch and should achieve north of 20mpg.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:29:14 PM
Don't forget the gaskets!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:30:07 PM
Hey, remember we were talking and kidding around about using a chain saw on those tire inserts?

Remember how we thought it was dangerous (Probably is) and sort of a joke?

Well, I have to say it actually works quite well!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:31:01 PM
It's quite controllable and manageable and makes a 3 minute job out of pulling those huge pieces of rubber out of the tire

Makes a mess as well!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:31:36 PM
The tire is a whole bunch lighter now without this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:32:22 PM
I made a major discovery today

Hot tires are easier to carve on than cold ones!

Really!

Yesterday, I would brush the snow off the tread block, then push like I was benching 275 to get the tire iron blade through the super hard rubber.

Today, I didn't want to work on a cold tire and get all wet like yesterday, so I placed the tire in front of that torpedo heater for awhile and let physics have it's way.

Well I lined up the tire iron and pushed it through the rubber like a hot knife (Which it is) through oatmeal (Thinking of something thicker than butter)

Anyway, it went much easier
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:37:13 PM
Just thought I'd interrupt for a moment to talk about building a 12 valve truck...Sorry to barge in!

DOTs...

Well, with the severe cold, stuff just gets slowed down. I have been seeking machine shop services for the wheels and I found the guy. Lives something like 2 miles from Casa Don!
We will get into the wheel thing on Saturday provided my snow tunnel boring device hooked to the front of Combat Max can get through the next blizzard approaching from the west!

So I am going through a process of getting a mil tire, heating it, then chain sawing the run flat thing out of it, then heating some more with Mr. Torpedo heater, then firing up the grooving iron.

Today I heated the tires up a bunch more and it made carving those blocks a lot easier.

Got all but one tire done, so that should fall tomorrow. I'll be mission complete on tire conversion and basically waiting on the wheels to process, then I'll get to being done with them as well. I am anxious to see what I end up after all this effort.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:38:00 PM
OK, got the wheels in at the machine shop for a couple of operations designed to make them even cooler!

So at the casa garage I chain sawed the final tire thing up and grooved the tire to off road perfection, then I started to put those poly centers into the tire.

Then I invented a tool, then I used a press to oblong the PVC thing, then a strap, some nylon webbing, some soap suds, about 55% of all the patience I have remaining in my life.

SO what we are left with is one insert stuck in the tire sideways and I can't get it out, (Just gave up)
I have another sitting near another tire which has seen me try to insert that thing every which way I could think of, but no cigar.

So

Asking the Brain trust out there...How does one stuff those things into the tires anyway?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:38:56 PM
Take a look at what I'm talking about.

Here's the bead lock that somehow has to get inside that tire. And those sidewalls are pretty stiff around the beads
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:39:43 PM
I soaped this one up and pried on it with a variety of steel bars and managed to get it this far. Now even with me kicking it as hard as I can. it won't budge. I'll be able to pry it out but this just illustrates just how tight everything is
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:41:34 PM
How to install PVC inserts for Hummer rims, the easy way.





How to install PVC inserts for Hummer rims, the easy way.



Alright. This is a how-to that probably had its place 5 years ago, but some of us cheap bastards are still running H1's. And when you do, you'll want to ditch the stock runflats: the radial tires(12bolt rims) were all supposed to have rubber inserts, with the bias tires(8bolt rims) getting magnesium-ally, bolt-together deals.

Click image for larger version. Name: DSCI1501.jpg Views: 6 Size: 261.5 KB ID: 71850

This is what you're starting with: an insert, and a tire to put it into. I'm using PVC inserts from TrailWorthy Fab, they are rounded over, chamfered, and have a nice space for the valve stem to sit into and it ensures that air will get past the the insert. Available at Trail Worthy Fab.


Click image for larger version. Name: DSCI1502.jpg Views: 8 Size: 231.4 KB ID: 71851

Take the tire, and smush it on top of the insert. The idea is to get the insert wedged in there; the next step does all the work.


Click image for larger version. Name: DSCI1503.jpg Views: 7 Size: 244.6 KB ID: 71852

This is most of the magic: Stuff the whole deal under your engine hoist. This is also the easy way to remove rubber runflats: chain them up and yank them out.


Click image for larger version. Name: DSCI1504.jpg Views: 7 Size: 222.8 KB ID: 71853

Pull the insert up until it kind of pops in there. At this point, you can put your foot inside the tire and kind of press the beads down over the insert a little more. It helps with the next step, just gets a little more work done while it's easy. When you're done, remove the hoist and chain.


Click image for larger version. Name: DSCI1505.jpg Views: 7 Size: 259.4 KB ID: 71854

If you've got a tire iron, that's best, but any suitably strong pipe/walking stick/crowbar will do. First, push the insert over inside the tire, it won't go all the way but it will lean over like you see in the pic. Next, I used a tire iron's "spoon" side, not the side with the hook, and pried the bead over the insert. The insert slides right down into the tire. The other side will be much easier to do but needs the same thing done. You're just about done.


Click image for larger version. Name: DSCI1506.jpg Views: 8 Size: 253.1 KB ID: 71855

Adjust the insert inside the tire with your heel, and that's it! Takes about 5 minutes per wheel. Super easy, very low stress.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:43:15 PM
Quote:
Originally Posted by Cudakidd53 View Post
As a matter of practicality, give the monumental headache the things have caused, how well do the run-flats really work? I fully grasp the tactical reasoning behind it, but performance wise, what's their drivability?


drivability: No difference locked or not.

The big difference shows up if you get stuck. With a standard tire, you can air down a little to increase tire footprint and maybe get unstuck, all the while risking the tire popping off the rim bead, since air is all that keeps it seated. That happens and you're done.

If the tire bead is mechanically locked to the wheel, it needs no air what so ever. So you could air down to say 5psi and have this big floppy tire getting double or more the traction of an inflated tire which would help you self recover quickly.
That happens to be part of my vehicle mission statement: Self recovery

Afterward, take a moment to air back up and proceed along your merry way. Beadlocks will go unnoticed until you need them, the all of a sudden captain America showed up at the party to help!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:43:48 PM
I just realized something.............this is the adult version of texting. Being ashamed, I'm going to do something constructive! Off to the gun store and range!

Don, I'm betting you'll have those fenders and doors off in no time, engine pulled or some other useful part of your fluid change procedures.

Ken, you better go to the store and get bread and milk, split some wood and hunker down! 

I'll check back in on you this evening to make sure all is well; news show said to check in on friends and neighbors in this weather!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:44:25 PM
Quote:
Originally Posted by Cudakidd53 View Post
I just realized something.............this is the adult version of texting. Being ashamed, I'm going to do something constructive! Off to the gun store and range!

Don, I'm betting you'll have those fenders and doors off in no time, engine pulled or some other useful part of your fluid change procedures.

Ken, you better go to the store and get bread and milk, split some wood and hunker down! 

I'll check back in on you this evening to make sure all is well; news show said to check in on friends and neighbors in this weather!

I discovered a new technique for getting those beadlock centers installed:

Drop the whole mess off at the tire store!

Yup, with a minimum of effort, while I ate a Subway Philly steak and went to get a haircut, those boys got two of them done and were werkin' on a third. Probably all done right now!

That's the way to get it done!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:45:58 PM
Quote:
Originally Posted by m715 View Post
Well I saw your link over on Expedition Portal and thought I would take a look as I'm a fan of the simplicity of the 1st gen dodge diesels...

I must say this is an impressive build, awesome attention to detail and great documentation and pictures

You've given me a number of ideas that are running through my head for when I finally get around to putting a 12v Cummins in my 1968 M715 truck...

Keep up the good work 

Love those 715's.

Have an opportunity to pick one up, but I'm knee deep in these two projects plus the farm and Real Man and...

The 1st gen diesels are so rock solid...it's nearly impossible to dismiss them as THE go to power plant

Welcome aboard!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:47:02 PM
I can post some pics now, but I have to leave shortly for my evening of suffering at the gym!

Today I ripped the fenders and hood off and did some other tear down.

I started with the retrieval of the tires, now sporting their permanent double bead locks
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:48:22 PM
One trick I learned many moons ago was when removing body parts that are already fitted, Drill a couple 1/8" holes through the parts where they attach. When reassembling I insert Clecos into the holes which temporarily hold everything just right while I snug up the bolts once again.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:49:47 PM
Lets get some more truck ripped to shreds!

So. a few bolts later and the hood was off.
Talk about timing, about the time I was going to drop the hood onto the floor by way of the windshield, the shelf with the polish, my forehead and chin, my tall blonde daughter walks in.

"Katz, grab that hood" She bailed me out and we got the thing onto the rear frame area without further complications.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:50:50 PM
The hood, like everything else is in great shape. It will really only require a light scuff, primer and paint. I think I'll glue some sound mat stuff to the underside to keep that clakin' to a minimum

I removed the factory mat, discarded it, then vacuumed the debris from a couple decades up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:51:43 PM
One of the pre-rangers who was playing the bad guy during todays mock battles left in a hurry, leaving his weapon to be vacuumed up and disposed of like all the other toyz he leaves layin' around...

I drilled the reference holes in the hinge just like the fender, then removed it. It. too, was lickin' clean
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:52:46 PM
I pulled the remaining fender bolts and yanked that sucker off and placed it on the back for temp storage
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:53:32 PM
These old square bodies pretty much all suffer from cracking in the cowl area. Mine is no exception:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:54:35 PM
The cowl box is, however completely rust free. THis truck is a real survivor!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:55:11 PM
Everything else is only dirty and otherwise in very good condition
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:56:28 PM
Next I removed the other fender and found some cracking over there as well
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:57:42 PM
The right cowl box was as perfect as the left one was
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 04:58:34 PM
And that's where she sits after build day 92
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:00:13 PM
I got a bit more of the teardown and clean up completed today Starting with the removal of the wheel wells
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:01:01 PM
Found this jack mount down near the air filter. I think I'll retask it for a jack mount on the gator
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:01:54 PM
This will inaugurate the start of the coil spring/radius arm suspension. I consider this the tear down phase and here the shocks and shock mounts have been removed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:02:34 PM
Here's the start of the accumulation of parts that will be painted/renewed, processed, plated/who knows
I believe those shocks are destined for Duane's crew cab along with the front 6" springs
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:03:31 PM
Remember the HMMV wheel centers?

I am turning two of them into a jack stand of sorts.

My plan is to bolt these to the hubs which have the axle resting an inch or so lower than it will in final assembly

I then plan to clamp the front axle, with some big muffler clamps to a steel bar which will be actually welded to that huge hillbilly front bumper. I will finally extend legs down from the front bumper which will hold everything in place, while I remove stuff and build up the new suspension around it. At some point it will be connected to the new suspension and no longer in need of the positioning struts
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:05:07 PM
Then I went to scrubbing in all the areas I could not get into earlier. Using hot water and simple green along with judicious use of a brush, the thing came out clean enough to just paint.

Look at these pics and realize this is a 23 year old truck that lived in salt infested Kentucky. The condition of this vehicle gives little hint to it's earlier life if that life was a hard one
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:06:06 PM
Quote:
Originally Posted by tjZ06 View Post
Quick question, not trying to rain on your parade. But at this point, with as much as you've torn down, restored and reassembled and with hindsight being 20/20 would you just do a true frame-off restoration from the ground up, every nut 'n bolt if you had it all to do again?

-TJ


I absolutely would have

The oil change just got out of hand and evolved

Ya know...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:22:17 PM
OK, SBHTP (Super Bowl half time postin')

Sort of looks like I developed a problem on the right side of the rebuilt Sterling axle
That is an oil leak!
Grrrr...

Guess I get to see the inside of all that once again!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:23:04 PM
Well, that wasn't much of a game...Denver can say they showed up...
I'm a Manning fan ever since he went 13-0 in his senior year at Tennessee. Too bad his record year ends like this...
Congrats to Seattle and a brilliantly played game!

The new jack stands are working out well
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:23:40 PM
The object of today was to get the front end firmly secured for the surgery that starts this week
I went with the 6 X 6 stand assembly I build and used on the rear.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:24:22 PM
After pulling the stops off and trimming it to size, and adding a 2 X 6 to the top it fit and worked perfectly
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:26:43 PM
In my continuing search for rust, I am still not finding much if any!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:27:29 PM
This drag link, and the early Dodge push-pull steering will not be reused. Even though I replaced this part earlier, crossover steering completely renews the steering and pretty much removes the factory installed bump-steer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:28:44 PM
Update:

I got the cab partially unbolted and jacked up on one side. That is so I can get to all the recessed areas underneath and prep and paint them. Once I get the drivers side, I'll get the pass side, then I'll be ready to remount the bed. I want to get the bed on before I get too hot and heavy into the front suspension change up.
I only have a few pics, so I'll add them to tomorrow night's pics and post them up then.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:29:53 PM
Lets get some more done here:

The objective right now will be to get the cab up and off the frame so all of that can be cleaned and coated, then fastened back down using brandly new hardware

Just before unbolting:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:31:04 PM
As you can see, things are really not too bad, so the plan will be to remove the bolts from one side, loosen the bolts on the other side, then jack one side up and do the repairs, then reverse the procedure.

Since the rocker has a nice seam, to lift it, I simply cut a matching groove into a 2 X 6, and notched the other end to fit the jack, then let hydraulics do the rest
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:31:40 PM
Just to keep everything safe, I precut some blocking to slide in between the body and frame as we went up, so if anything slipped, it would only fall maybe 2"
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:33:39 PM
Then inserted them into the body mount pocket as the cab went higher
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:34:33 PM
The jack was supported by blocking as well so it could not roll around on the
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:35:16 PM
Then when it was at the desired height, I placed two more slotted 2 X 6 pieces under the rocker seam
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:36:33 PM
This is not looking bad at all. A couple hours with the wire cup and it will be looking pretty good
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:41:42 PM
The old body bushings had seen better days
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:42:35 PM
They get replaced with the poly stuff
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:43:15 PM
The steering disassembly continued with the shaft removal
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:44:20 PM
I had the chance to go over to the machine shop to watch James mill the things true

He was using a big computerized Bridgeport
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:45:38 PM
He is working to half a thousandth, and he was so meticulous, that he stoned the bench, and took some time getting the machine and the wheels clamped and square before making the first cut
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:46:37 PM
The first pass was only a couple thousandths and it nearly touched the whole mounting surface. That means the jig I used to weld them up is pretty true and only a minimum of material should have to be removed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:47:31 PM
He set the mill to make two passes and in total he only removed .008" from the nearly 3/8" steel to true them perfectly. These wheels are now way better than industry standard, which is a max of .030" out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:48:40 PM
He made one more clean up pass which left a shiny and smooth surface.

Had here's the proud father, Mr. James with his great craftsmanship.

Seriously, if he takes as much time with other things as he did with a simple wheel truing operation like this, I think I found my machinist for all future projects
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:51:09 PM
Quote:
Originally Posted by duramaxdarren View Post
lets not forget this is a dmax site...we all can appreiceate the 12v mechanical dodge and its simplicity but this was just to get a reliable runner to the combat max and give don something to drive while he did the sas conversion......please dont distrcact don any further. he's about to turn the corner from disassembly to reassembly lol!

So true Darren!

But I guess sometime during the teardown (Oil change) I saw the light.

That light being that in the survival context, this old Dodge could be everything the Duramax could be. And even go it one better. The D-Max will not survive an EMP, whereas the Dodge will wake up and ask, "Hey where is everybody?"

So I decided that instead of tearing into the dodge, then doing it all again later, I would just do it all one time and slide the timeline for that Chevy SAS.

I am also using the Dodge for the suspension dryrun for the chebby. This is the first coil spring suspension conversion I have done, so I plan to get it cyphered out on Square D, then it will just be a repeat operation on Combat-Max
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:52:44 PM
Quote:
Originally Posted by Echo30 View Post
Having been watching this thread for a while but not contributing, it would seem to me that reliability should be your main focus with this truck. 600 HP is great and all, but adding a twin turbo setup introduces a lot more things that can fail. I would think dead simple and 100% uptime running whatever fuel you throw at it would be the goal of this project, but hey, it's not my truck 


I'm directly addressing some known shortcomings with the 1st gen Cummins. That being high EGT's
Two ways I know of doing that is more air and water. So I have both going on. This setup I purchased parts for is far below the threshold of what twins can do. THe S-300 is about the size of some later diesel stock units, so it's not really for HP. What it will do is under a long pull, provide about 4 times the air and drop EGT's about 150 degrees.
By building the injectors to match and adding a redundant water/methanol injection, I figure the head gaskets will live when pulling a big load up a long grade as speed while trying to distance myself from trouble. At the top of that grade I would like my pistons and head gasket to still be viable, so that's why I build such a huge safety factor into the engine design.
It just so happens that a lot of extra horsepower will also result.

Edit: These Cummins mechanical injection motors are really nothing like out electronically controlled D-MAxes. SO you really can't think about them in the same way. You get to B30 and you're out of bounds with our Duramax. But the cummins will eat a tank half full of old motor oil and fuel! Big time different. In my view the Cummins design is vastly superior with regard to simplicity and reliability.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:54:14 PM
Quote:
Originally Posted by Armalite View Post
Hey, tell ya'll what... In light of my story telling skills, or lack there of, I will defer this story over to Don himself. He set it up, lured me in, and I took it. I mean, swallowed the hook, and all. Must admit, I got a great laugh out of it after the fact, but, I think the author himself can give a lot better description and layout of how it all went down, since he masterminded the whole debacle himself...


So, at the humiliation of me, for the entertainment of everyone else, Don, feel free to embellish all those reading on the events that transpired last week...

Feel free to make it as detailed as you wish.


Im used to everyone getting a laugh out of my expense anyhow!


Ash, I certainly wouldn't do anything to humiliate you, certainly not

But get a good laugh at your expense...Why Not?

Ash recently installed 4.10 gears and a Tate supplied grizzly rear locker into his truck. He drives away from the shop, then shortyl thereafter (I think) texts me.
"Don, this rear seems to be staying locked up a lot, is that normal?"

Right away, like immediately, I test him, "Ash, your mechanics did add the grizzly grease didn't they...It's important"

Well, ole Ash, trusting his old friend in a moment of vunerability texts back, "I'll have to check if they added it, I have no idea!"

Got him I'm thinking, live one on and the drag is set low, so I'll let him pay out some line while I work him some.

I text him to ask Tate if he included the grizzly grease in the shipment

Meanwhile, I PM Tate right away, telling him this fish is headed his way.

Before Tate opens my PM, he gets the call from Ash asking him if he had indeed sent the necessary "Grizzly-Grease!"

Well, Tate, being confused and puzzled, tries to figure out what Ash is talking about and also tell him there is no such thing as "Grizzly Grease."

Tate opened my PM up right after the confusing conversation...

So Ash texts me and I call him back and we laughed so hard my sides split...Grizzly Grease!!!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:55:04 PM
Quote:
Originally Posted by Armalite View Post
Hey, tell ya'll what... In light of my story telling skills, or lack there of, I will defer this story over to Don himself. He set it up, lured me in, and I took it. I mean, swallowed the hook, and all. Must admit, I got a great laugh out of it after the fact, but, I think the author himself can give a lot better description and layout of how it all went down, since he masterminded the whole debacle himself...


So, at the humiliation of me, for the entertainment of everyone else, Don, feel free to embellish all those reading on the events that transpired last week...

Feel free to make it as detailed as you wish.


Im used to everyone getting a laugh out of my expense anyhow! 

Ash, I certainly wouldn't do anything to humiliate you, certainly not

But get a good laugh at your expense...Why Not?

Ash recently installed 4.10 gears and a Tate supplied grizzly rear locker into his truck. He drives away from the shop, then shortyl thereafter (I think) texts me.
"Don, this rear seems to be staying locked up a lot, is that normal?"

Right away, like immediately, I test him, "Ash, your mechanics did add the grizzly grease didn't they...It's important"

Well, ole Ash, trusting his old friend in a moment of vunerability texts back, "I'll have to check if they added it, I have no idea!"

Got him I'm thinking, live one on and the drag is set low, so I'll let him pay out some line while I work him some.

I text him to ask Tate if he included the grizzly grease in the shipment

Meanwhile, I PM Tate right away, telling him this fish is headed his way.

Before Tate opens my PM, he gets the call from Ash asking him if he had indeed sent the necessary "Grizzly-Grease!"

Well, Tate, being confused and puzzled, tries to figure out what Ash is talking about and also tell him there is no such thing as "Grizzly Grease."

Tate opened my PM up right after the confusing conversation...

So Ash texts me and I call him back and we laughed so hard my sides split...Grizzly Grease!!!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:56:36 PM
From Tate (who sells the grizzly locker)

And if I had read the PM first I might have given him a heart attack if I carried through with the suggested mission. I wanted to tell him he could source the grease locally behind the ear of any brown bear species, shouldn't be too tough since they're hibernating and all right now. I'm not quick witted enough like Big D here however and would have flubbed on the gag I'm sure. Way to take it on the chin Ash.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:58:09 PM
Quote:
Originally Posted by Tedram View Post
Left handed bacon grease strainer, I was at scout camp and checked four different sites before I figured it out..... ( I was 12)... Well anyway, thanks for the great build thread and listening to like minded folks having a good time...


Welcome to the fray! Hang out and beat up on Ash, Shawn, Bobby, Ken, JR, whomever you want.
We are like minded here. God, Guns ,Country, trucks, things to shoot, and a healthy helpin' of kiddin' around are the essential ingredients!

If I were you, I'd avoid hanging out with the DOTs. They're a lowly lot, those folks! Their feet stink, their momma doesn't like em' and they are no count, as we say in the 'Tucky
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:58:33 PM
In the Armee, it was:
1. Canned Muzzle blast
2. Flight line
3. A bag of Emory sparks
4. Squelch oil
5. Rotor wash
6. Track Tensioner
and a few more...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 05:59:37 PM
Quote:
Originally Posted by flyin6 View Post
Welcome to the fray! Hang out and beat up on Ash, Shawn, Bobby, Ken, JR, whomever you want.
We are like minded here. God, Guns ,Country, trucks, things to shoot, and a healthy helpin' of kiddin' around are the essential ingredients!


If I were you, I'd avoid hanging out with the DOTs. They're a lowly lot, those folks! Their feet stink, their momma doesn't like em' and they are no count, as we say in the 'Tucky

From Tedram
Thanks for the warm welcome Don!!!! I have been a lurker on this thread and on your "My Build Thread" along with the Coffee Induced Early Morning Rant thread--- great theme throughout all of them, God, Family, Country.... Thanks for sharing your talent and experiences----
I am new (relative) to the thread and enjoy learning through your mistakes (tactical camper top)-- I plan on making a few myself.....
Hope i don't screw up the install of my B&W Goose neck and Companion Fifth Wheel Hitch tomorrow- the only real mistake I can make is to cut the hole in wrong place---- Like a former teacher once told me "measure twice and cut once"---
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:03:32 PM
Quote:
Originally Posted by ChrisLib View Post
Well thanks for such an awesome welcome! And for the record I used (key word USED) to actually work on Kia`s for a living(a rather meager one lol), been an Auto Tech for almost 30 yrs now. ...I get a kick outta the references to them, own one myself a Sorento (it was cheap...a deal I could not refuse lol).


Kia

You own a Kia

Get off this thread

You're banished

Well

Wait just a minute

Maybe I was harsh

Good thing you weren't standing here

I would have shot ya

Not anything bad

Just nicked the shoulder or earlobe or something like that

To let you know you're close to crossing the line

Well, Shawn here owns one of those scrap metal things

and

we (barely) tolerate him

So you can stay

But you're on probation!

I want to see abundant patriotic references to our great Nation

Not the hippie part of it mind you, only for the good "Real American" part of it

I want to see positive references to guns, Mom, apple pie, and the like

and

No joke here,

Praise for our king in heaven!

Carry on...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:04:25 PM
Own a 12 valve?

I just came across this on Willie's Amsoil site (Mr. Manners)


LUBRICANTS & FLUIDS:

Engine Oil
Grade 1......CF-4
SAE 15W-40 Synthetic Heavy Duty Diesel and Marine Motor Oil (AMEQT)

Synthetic 15W-40 Diesel Oil (DMEQT)

Synthetic 15W40 OE Diesel Oil (OEDQT)
-9 To 10 F......10W-30 [1]
Above 10 F......15W-40
Below 0 F......5W-30, 10W-30
Manual Transmission,G360 (5-SPD)......SJ
All TEMPS......5W-30
SAE 5W-30 Signature Series 100% Synthetic Motor Oil (ASLQT)
XL 5W-30 Synthetic Motor Oil (XLFQT)
OE 5W30 Synthetic Motor Oil (OEFQT)
Automatic Transmission,A500......AP4
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Automatic Transmission,A999(32RH)......AP4
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Automatic Transmission,A998(31RH)......AP4
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Automatic Transmission,A518(46RH)......AP4
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Differential, Front Spicer 44......GL-5
All TEMPS......80W-140, 85W-140, 80W-90
SEVERE GEAR 75W-140 Synthetic EP Lubricant (SVOQT)
80W-140 Synthetic Long Life Gear Lube (FGO05)
Differential, Front Spicer 60......GL-5
All TEMPS......80W-140, 85W-140, 80W-90
SEVERE GEAR 75W-140 Synthetic EP Lubricant (SVOQT)
80W-140 Synthetic Long Life Gear Lube (FGO05)
Limited Slip Differential, Rear Dana 60......GL-5*
All TEMPS......80W-90 [2] [3]
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Chrysler......GL-5*
All TEMPS......80W-90 [2] [3]
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Dana 70......GL-5*
All TEMPS......80W-90 [2] [3]
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Transfer Case,NP241LD......AF2
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Transfer Case,NP208......AF2
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Transfer Case,NP208......AF3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Transfer Case,NP208......AP3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Transfer Case,NP241HD......AF2
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Transfer Case,NP241HD......AP3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Transfer Case,NP241LD......AP3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Transfer Case,NP241HD......AF3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Transfer Case,NP241LD......AF3
Signature Series Multi-Vehicle Synthetic Automatic Transmission Fluid (ATF) (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
OE Multi-Vehicle Synthetic Automatic Transmission Fluid (OTFQT)
Transfer Case,NP205......GL-5
Above -9 F......90
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Transfer Case,NP205......SJ
Above 32 F......50
Synthetic Powershift Transmission Fluid SAE 50 (CTL05)
Transfer Case,NP205......GL-5
Above 90 F......140
No AMSOIL Product Recommendation
Transfer Case,NP205......GL-5
Below -9 F......80W
No AMSOIL Product Recommendation
Transfer Case,NP205......SJ
Below 32 F......30
Formula 4-Stroke® 10W-30/SAE 30 Small Engine Oil (ASEQT)
Fluids
Clutch Fluid......HB
AMSOIL Brake Fluid DOT-3 (BF3SN) [4]
Power Steering Fluid......PS
Power Steering Fluid (PSFCN) [5]
Brake Fluid......HB
AMSOIL Brake Fluid DOT-3 (BF3SN) [4]

[1] SAE 10W-30 recommended below -18 C (0 F) with block
heater only.
[2] Limited Slip Identification: Lift both rear wheels,
turn a wheel and other will rotate in same direction.
[3] With controlled slip, add 6.5%
Mopar Trac-loc additive or equivalent
[4] Hydraulic Brake Fluid, DOT 3
P/N 04318080AB or 04318081AB, meeting MS-4574
[5] Mopar P/N 4883077, Spec No. MS5931


FILTERS:

Oil Filter 25,000-Mile Ea Oil Filter (EAO80)
Oil Filter WIX 51607 Oil Filter
Fuel Filter WIX 33379 Fuel Filter
Transmission Filter WIX 58707 Trans Filter


WIPER BLADES:

Blade Class

Driver

Passenger

ExactFit T181
ExactFit T182 T182
ExactFit T181
NeoForm T16180 T16180
Winter T37180 T37180


CHASSIS LUBRICATION:


CAPACITIES:

Engine, with filter..........13 quarts [1]
Cooling System, AT Initial Fill..........17.4 quarts
AMSOIL Antifreeze and Engine Coolant
Cooling System, MT Initial Fill..........16.4 quarts
AMSOIL Antifreeze and Engine Coolant
Automatic Transmission, A500 Initial Fill..........4 quarts
Automatic Transmission, A518(46RH) Initial Fill..........4 quarts
Automatic Transmission, A998(31RH) Initial Fill..........4 quarts
Automatic Transmission, A999(32RH) Initial Fill..........4 quarts
Automatic Transmission, Total Fill
4 speed A518(46RH)..........10.1 quarts
3 speed A999(32RH)..........8.6 quarts
4 speed A500..........10.1 quarts
3 speed A998(31RH)..........8.6 quarts
Manual Transmission, G360 (5-SPD)..........7 pints
Differential, Spicer 44 Front..........5.7 pints
Differential, Spicer 60 Front..........6.6 pints
Differential, Chrysler Rear..........4.4 pints
Differential, Dana 60 Rear..........5.9 pints
Differential, Dana 70 Rear..........7 pints
Transfer Case, NP241HD..........5.9 pints
Transfer Case, NP205..........4.4 pints
Transfer Case, NP208..........5.9 pints
Transfer Case, NP241LD..........4.6 pints

[1] After refill check oil level.

TORQUES:

Oil Drain Plug.....44 ft/lbs
Manual Transmission G360 5-SPD
Fill Plug NA ft/lbs
Drain Plug NA ft/lbs
Manual Transmission
Fill Plug NA ft/lbs
Drain Plug NA ft/lbs
Manual Transmission 5-SPD
Fill Plug 30 ft/lbs
Drain Plug 30 ft/lbs
Manual Transmission A833 4-SPD
Fill Plug 15 ft/lbs
Drain Plug 35 ft/lbs
Manual Transmission NP435 4-SPD
Fill Plug 35 ft/lbs
Drain Plug 35 ft/lbs
Transfer Case NP205/241
Fill Plug 40 ft/lbs
Drain Plug 40 ft/lbs

Transfer Case NP208
Fill Plug 18 ft/lbs
Drain Plug 18 ft/lbs
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:08:47 PM
I worked all day on the wheels with the objective of getting them painted today. I had to start with some serious scrubbing.

I had to use some heavy duty cleaner which requires you use rubber gloves
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:09:17 PM
It was in the mid 20's outside where I cleaned them, so after rinsing them with hot water, I placed them one by one in front of the torpedo heater to prevent rust
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:10:16 PM
They came out pretty clean but that was only the first step of what was a lengthy process
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:11:38 PM
Next, I used a combination of a 60 grit sanding flap wheel and a wire cup grinder to work out the gouges that occurred during the demounting of the tires
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:12:33 PM
Then I feathered the other areas with the grinder and brush
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:13:15 PM
Next came sanding with both 180 grit and the abrasive pad to sand every inch of the powder-coat, welds, and new steel.
Then the wheels were scrubbed with a brush and lacquer thinner, and finally the studs were taped up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:14:02 PM
The first coat was with the acid etching primer which I only sprayed over the bare areas
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:15:03 PM
After that dried, next was a complete coat of the two part epoxy primer/sealer. The wheels looked good enough at this point to actually stop and bolt them on if I had wanted a black finish
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:15:45 PM
The detail painting took a long time. Each spoke has all sorts of recesses that need a different spray angle to get to. Then the front is partially obscured by the double flange, so it's just not a dust and run...although I seem to get some runs!

I decided to commemorate the original Chrysler paint scheme by using the trucks dark silver primary coat as the wheel color
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:16:39 PM
Here's the first medium coat
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:17:27 PM
And here they are after the third and final coat:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:18:16 PM
I started sometime after 10 AM and walked back in to shower at 1942. That was a bunch of work.
Tomorrow will tell the story if it was worth the effort
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:20:16 PM
Posting up early tonight
Going to the guy in a bit, so I'll put this stuff up now instead of later.

The wheels came out a solid 7 out of 10. I give them the lower score because of the runs, and knowing that I was trying not go get any.

Anyway, they look OK, and since looks are not all that important, I'm calling them done, runs and all!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:21:11 PM
ZI think I am going to paint the wheels on the D-Max the same color. It will tone down the flash some while still looking street worthy and make them more corrosion resistant.

Remember the fuel filler system I fabbed up for the bed?

There are the rings which retain the aircraft style fuel cap
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:21:58 PM
I got to thinking if I did a few things here and there in that color, like the grill surround, the mirrors and maybe the door handles, it would look finished without getting too flashy and would tie the thing all together so it looks like it was built as a total system and not just appear as a bunch of cobbled together parts.

There is how that will look
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:22:57 PM
The tailgate handle is done. It will likely be the only piece of chrome on the entire truck when it is installed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:23:54 PM
The outer rings on the wheels were the subject of attention today.

You can see how James milled the center, but did not go too far, just to clean up plasma torch marks. These areas will get cleaned, but not enlarged much
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:24:36 PM
After some cleaning this is what I was left with
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:25:22 PM
After all the grinding and flap wheel work, this time I wet scrubbed the parts with the abrasive pad using the purple degreaser to completely rid the parts of grease and scuff up the surface for the paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:26:00 PM
THe 2 part Epoxy is a 2:1 mixture and I cut that with 10% of reducer to help the thick stuff spray our better at lower HVLP equipment

It helps to mark your measuring cup with masking tape to be sure
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:26:47 PM
The 1st coat of two
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:27:30 PM
And here is after the second coat, where the Epoxy is setting up
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:30:22 PM
Darned computer failing slowed me down a bunch. This is computer #2. That means these build threads have seen two computers and three cameras...sort of taxing on electronics I guess

Here is how I set up to build up the tires/wheels:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:31:14 PM
That stand was a recent gift to me from Dan who custom built it, one for Duane and one for me...I like it!

Here is the all important O-Ring that must be installed into the groove of the wheel
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:32:48 PM
I am using a mixture of air-soft pellets and copper clad BB's as internal balance media

THis should be enough (or not)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:33:26 PM
Next I hefted the tire into place and dropped it on the wheel bottom
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:34:18 PM
Next I squeezed some Silicone into the recess. I tried to match the stuff that was in there from the "Factory" and this seemed to match the color at least
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:35:10 PM
Next up the outer bead "Clamp" ring was slid into place and some anti seize was then applied to the 1/2 X 20 threaded stud
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:35:55 PM
Note how proud the clamp ring sits on the studs...about an inch. THat will soon change.

I deviated a little from the Armee specified hardware. They just use a shouldered nut. I elected to use a grade 8 SAE washer and then the nut so that the back side of the nut would not gall the parent metal of the lock ring providing a nice place for rust to start
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:36:43 PM
Yep, I didn't buy enough for all 5 wheels... I was thinking 4 wheels, 12 studs each for a grand total of 48...so a pack of 50 worked just fine. Well, now I get to buy another couple packs for plenty of spare nuts!

Hardware stacked on
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:37:52 PM
Fuzzy pics...I guess this new jap camera is malfunctioning...and why not? it's a couple years old, jap made and planned obsolescence and all that.

What ever happened to American quality goods?

There is a whole lot of tightening going on...probably taking the most time of all the processes here. I kept tightening a little then going opposite, back and forth many times until that outer ring collapsed all the way down onto the inner flange
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:38:48 PM
It actually held air!

Man was I surprised!

And here it is mounted up to Square D
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:39:30 PM
My compliments to John Staz at Stazworks for building the centers and creating the double beadlock plastic spacer, and to James Sweet for doing the machine work.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:46:33 PM
From Ashley:

So, whats the next plan of attack for the Dodge? Tires are mounted. Wheels are done. What is the next POA ?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:46:54 PM
Bones...

Gotta follow the bones

The front suspension is next, of course (sort of).

But the cab needs to get lowered back, and that means first I need to finish the underside (tomorrow??). Now we know that the cab bone is connected to the bed bone.

I need to get the bed back on so I can check out alignment of body parts whilst I remake the front suspension bones. But before I put the bed back on, the cab bone which is connected to the cab paint bone needs to get done. I am doing something to the cab top (Classified) and something to the cab right front (Classified) which requires me to weld in some fabbed up hard points, so those (New) bones will need to be added before the paint bone is connected to the cab bone.

Of course the same paint bone is connected to bed bone, so those bones need to be properly connected before the bed bone is reconnected to the frame bone. At that time the fuel filler neck and tailgate bones will get reconnected.

And

That

is

how

you

install

a new front suspension!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 07, 2014, 06:48:16 PM
Quote:
Originally Posted by Cudakidd53 View Post
Prediction of Don's cab projects:

Right front- snorkel intake prep.

Rest of cab- Either Roof Rack or exit hatch/gun turret option. 

Spooky!

Right pillar: hard point for 6" snorkel tube

Roof: 4 hard points for roof rack mount, R/F for rack plus top capture for snorkel
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:47:22 PM
Let's 1. Get some stuff built, and 2 Post it up with poor quality pictures

With me?

I had to trash the old lap top...It died!

The new one has that abortion called Windows 8

I hate it

Just discovered Microsoft removed their handy little office photo manager tool.
It was a great little program I used to crop the raw stuff so you couldn't see my hairy toes and stuff like that

I could also adjust the lighting so the pictures looked more natural.

None of that is present for duty

So here goes anyway

Today, the focus was on more rust processing so I can get that cab back in place.

Here's what I started with:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:48:38 PM
I reduced a wire cup to stubble while doing the frame and the bottom of the cab
It turned out OK, and no new rust was found!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:50:15 PM
I pulled out the always reliable rust converter. I discovered it will also convert a dog, that is if the dog holds still long enough. Haven't tried it on a cat yet!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:51:21 PM
The frame top and the underside of the cab simply got a heavy coat of rubberized undercoating. The frame would be painted like the rest of the frame with the Blitz black
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:52:33 PM
I had already prepped the cowl area, so that got coated with undercoating since it is hidden and can not be seen. I wanted a lifetime of protection on all of that area:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:54:04 PM
The underside of the cab:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:55:23 PM
The cab bones were connected to the door hinge bones it would seem.
The drivers door had some droop from an elongated hole in the hinges. Since I needed to get into that area, I decided to pull the door and install new bushings and pins
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:56:08 PM
The old pins were in pretty good condition, but I opted for new ones anyway
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:57:07 PM
With the door off the truck, it is a simple matter to drill the pin holes out to .50" and install the new bushings
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:58:26 PM
The new 1/2" drill went through the hinge steel like a hot knife through butter
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 05:59:37 PM
The new bushings slide right in
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:47:48 PM
With the door pulled, it is a good time to do all the recess detailed painting before putting it back on

First was a lot of sanding and degreasing
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:48:32 PM
Gillespie paints specialized in historical military paints. I chose a WW2 OD green in synthetic enamel. They will sell gallons or load some of the same paint up in spray rattle cans perfect for a job like this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:49:32 PM
The first of three coats:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:50:16 PM
And still wet after the third coat
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:51:52 PM
Well I coated myself again today with various products, and even managed to get some of it on the truck.

First a closer look at the door we painted yestertag

Here's what happened:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:52:32 PM
The paint turned out smooth, but it scratches very easily. I might have to bite the bullet and add some hardener. That will unfortunately add some gloss...

Since I have a new temporary work bench in the shape of a door, I got to work, working on things on top of it

Here's the body mounts getting sorted for installation
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:53:23 PM
Since there are poly bushings, I coated all wear surfaces with the special poly grease to prevent squeaking, then they were set in place
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:54:22 PM
Then with the body lowered back into place, the bolts were tightened down, but not snugged up yet
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:55:00 PM
Next up, it was time to paint the door jamb.

It was taped off, scuffed off and cleaned
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:55:43 PM
There were a few areas of bare metal that needed some primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:56:41 PM
Then came 3 coats of color
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:57:24 PM
While that was drying, the opposite side was unbolted and jacked into position
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 06:58:23 PM
The rust, which I could not get to before was little more than some surface scale
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:05:36 PM
With a brand new cup wire wheel in hand, the grinder made quick work of the bad stuff and had the frame shining like new 
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:08:07 PM
Rust converter:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:09:18 PM
Then just like the other side, on went the paint and undercoating
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:10:05 PM
If you're wondering about that transmission...It is coming out to get the full treatment. I see no sense in cleaning it all up right now when it is going to be overhauled, built and painted. Before the truck rolls again, it and the transfer case will be refreshed.

So here is the SOB (State of the build) tonight, the end of build day 100
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:11:15 PM
Kicked the can down the road a bit farther today.

The focus is on getting the cab done so I can reinstall the bed and put that one in the finished column.

The door is dry enough to reinstall. Too bad, it made a pretty good work bench
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:12:06 PM
Ran across this early on. One of the body mount bolts was buggered up.

Not sure what thread it was, but I guessed 1/2-20
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:13:21 PM
So I tapped the nut in the body and ran a die down the thread...It was not 1/2-20, but it was when I finished!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:14:13 PM
With that done, I greased up the poly bushings and reinstalled them, lowering the cab back down for good
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:15:09 PM
Then I rehung that door all by my lonesome.
Well if the truth be told, I got some help from my trash can. It turned out to be the perfect height to temporarily hold stuff up while I wiggled and fished and giggled those bushings and pins back into place.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:19:24 PM
The force was with me and I had been living right apparently because all that worked out! I roughly set the hinge position and darned if it didn't fall into just about the perfect position.
With no slop at all in the door, the striker pin needed to get replaced
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:22:26 PM
I needed another work bench so I grabbed one from the right side:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:23:01 PM
I yanked the old felts out of it in prep for sanding
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:23:59 PM
Setting up the new work bench created a big hole in the right side of the truck!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:24:43 PM
 started the sanding and managed to get the door done before time ran out and I turned back into a pumpkin!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:25:23 PM
I must have been really at it, rockin away listening to my Christian Rock station and sanding up a small dust storm, because the red dog came in a' sheakin and scored my new big screwdriver. By the time I figured out that it was gone, she had reduced the handle length by nearly 2"

I thought I take a picture of what the dog looks like without a 9mm hole in it:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:26:43 PM
Tried to chop off some more body parts today, but didn't succeed. I did, however get some more stuff done on Square D

First up was the prep for paint of the door jamb and door
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:27:36 PM
Then the painting just like the opposite side.

We've seen this in detail for the other side so I won't press here, just show the results for those who may be tracking the project
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:29:03 PM
OK, paint done...needs to dry, so on to item next.
Still concentrating on getting the cab box done so I can set the bed back on, I started fabbing up the hard points for future additions.

As always, I started with a paper pattern
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:30:06 PM
The concept here is to beef up the roof so I can later mount up a hefty roof rack with loads of dead spotted owl, which taste really good! Right up there with pileated wood peckers...tastes like chicken.

So this pattern will become a piece of thicker steel to which I will construct a strong anchor point.

Here's the shape of things to come:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 09, 2014, 07:31:36 PM
I know what you're thinkin'...Did he fire five times or six...What about it, punk, feel lucky?
Sorry drifted some there...Dirty Harry...
No, you're thinkin the plywood is flat, but the hood is rounded...Or you're brain dead and not thinkin' at all.
Know what, I don't care, and neither does anyone else.

Anyway the plywood got clamped up and turned into steel
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 12:54:58 PM
pics aren't fuzzy are they? Didn't think so...

So next I drilled a whole bunch of holes in them just because I felt like drilling a bunch of holes. Then cleaned that mess up again

And started forming the curves with my handy red dog taming device
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 12:57:31 PM
I got them to fit pretty well, but taking my time and forming a little at a time
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 12:58:27 PM
Here's a before and after on the right aft hard point
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 12:59:53 PM
Then after marking the position and location of the holes, I ground away some primer, leaving most of it in place
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:00:35 PM
Next I applied the sparky electric glue
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:01:27 PM
I used some more sparks on the welds and came up with this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:02:16 PM
While all that was happening, the paint dried and happiness was achieved!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:03:03 PM
Quote:
Originally Posted by Cudakidd53 View Post
What's the planned edge treatment for the hard anchor points, sparky glue or fiberglass from Tac Topper?

It would seem I should use automotive seam sealer after the rest of it gets welded on. THis is only the base
You will see square steel tubing pylons grow out of this base with some nut plates to act as the base for the foot(s) of the RR.
Had a dream...Weird. First I was in Australia...Wife was an oil executive and we had to go there to follow her. That has nothing to do with anything, but just thought I'd mention it...
So I saw the transmission cooler residing up there in that roof rack, and I sez to meself,
"Self, I ought to place the transmission oil cooler up there, I sez!"
Then I started in thinkin'
Two things
1. That always costs me money
2. Sometimes it works
So I got a little past startin in thinkin, to the actual thinkin part
I sez, ya know, I ought to convert all those flexible lines into that hydraulic hose you see on back hoes, tractors and the like.
I continue this dreamin'/thinkin' state and in it, I see two hard lines running up the back of the cab all anchored in pretty like, then they terminate into two flex hoses that lead to a PDB (Pretty darn big) oil cooler, jest like the Armee does on its HMMVs.
And then the wife work me up and I went and ground up some quoffee beans, which leads me to this very moment in time
Wasn't that a nice story?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:04:20 PM
OK, Ken, cool...glad to supply a laugh

I can post up some but I have a date with a lobster tail in about 1.5 hours and that is moistest important.

Anywho, I did the one armed paper hangar thing again today, putting that lead filled door back on by me lonesome
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:24:26 PM
Now this is the weird part. I simply pulled the two pins to yank the door a couple of days ago. Just prior to reinstalling it, I installed new bushings just to be sure, although the old bushings were tight.

So I go to close the door and I discovered a tear in the space time continuum right in my garage. The door didn't fit. Since no physical explanation fit, it must have had something to do with aliens (Not Mexican types) and the fabric of space and time.

I know for sure that door was taking up some space, and it darned sure cost me more time than I had planned to readjust all those hinge bolts.

But just like any well fought battle, I won the day and the door shut!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:25:35 PM
OK, diner didn't work out too well.
Went for Red Lobster...But with a hour plus wait, we opted for something fast.
That was Chinaman's food, which was not good...Well so much for stories, let's get back to building

Remember those hard points?
Well they grew

Here's the extensions which will serve as a nut plate and the actual station the roof rack bolts to
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:27:09 PM
Here's how they will fit
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:27:58 PM
There is a 3/8" nut welded to the inside of the top side. The hole in the bottom is to use to roseweld the mount to the base plate if needed.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:28:37 PM
First a good cleanup with the flap wheel
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:30:18 PM
Then each one was welded to the top plates
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:31:21 PM
Along with the inside
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:32:35 PM
Next up, I attached the two upper snorkel mounts
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:33:14 PM
Both mounts
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:33:56 PM
Here is a piece of 3" tubing showing alignment of future snorkel tube. The actual tube will likely be a section of 5" or possibly even 6" tubing, room and bulk dependent
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:34:41 PM
You can thank this horrible windows 8.1 for the problem and lower picture quality, as the photo editor I now have to use lacks many features and ease of use the old program had. Little things like turning photos is sometimes missed since the effort and time to edit has probably tripled

Time to seal up the mount with seam sealer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:35:15 PM
Using the Mark 1 eyeball and the nose probin' hand mounted digit, of which I still can use effectively to count to ten, I smeared the gooey stuff all over creation getting some of it on the actual part, but most on my Bengals sweat-shirt
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:36:41 PM
After that all cures, I'll sand then prime it, then the entire roof gets a coat of Bed Liner since once the expanded metal bottom of the roof rack gets bolted down, there won't be easy access to the roof anymore
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:37:16 PM
And the state of the build (SOB) as of close of business today:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:37:56 PM
Quote:
Originally Posted by Wantamax View Post
What is the plan for snorkel build? Steel, fiberglass? Filter on top or air box under the hood with filter them the snorkel feed a sealed air box? Kind of curious, I've wanted to build one for the Tahoe one day.

Edit: You posted the steel tubing as I was typing.


I plan to build a bulkhead isolating the air filter area from the engine bay. Then I'll close off the area between the fender and the wheel well with fiberglass which will make for a huge air channel and chamber. Finally I'll open the rear of the fender for a piece of tubing that will stub off to a point just below those mounts. I'll connect that stub to the actual snorkel tube with a piece of silicone hose and top it all off with a prefilter, centrifuge device, something like you'd see on a piece of heavy equipment
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:39:05 PM
Mo progress, unlike our congress

The emphasis remains the exterior finish of the cab because as we know the bed bone is connected to the cab bone, and therefore with no cab bone, no bed bone...which as we know eventually leads to the suspension change bone.

So, here's the start before much sanding:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:39:44 PM
And after some close and personal attention with the orbital and a 120 grit disc, here's what it ended up looking like:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:40:26 PM
This is the cheapo harbor freight sander I am using attached to another cheapo harbor freight vacuum.
I must admit, it sure kept the dust to a minimum
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:41:23 PM
Next I removed the mirrors
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:42:48 PM
Then I went to work on the pesky stripes and killed kias decals squared proudly wore...until today
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:44:13 PM
Then the heavy rubber side moldings were relegated to history
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:45:17 PM
A quick way of removing the glue is to hit it with the cup grinder, then work on what remains with a rag soaked with liqueur thinner
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:47:30 PM
A quick way of removing the glue is to hit it with the cup grinder, then work on what remains with a rag soaked with liqueur thinner
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:48:41 PM
Then both doors were sanded along with everything else, first with an #80 grit pad, then followed with a #120 grit pad. THen the back window was taped up ready for the primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:49:21 PM
Here's the primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:51:11 PM
For today, I only sprayed the roof and the back panel with that primer mixed 50/50 with thinner
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:52:07 PM
The paint is still a little wet in spots, therefore the strange shading
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:53:34 PM
After it dried:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:54:50 PM
Quote:
Originally Posted by Wantamax View Post
Is the paint finish going to be flat on it? Or are you clearing it? I know the Tahoe will be ready for paint in the next few years and have contemplated painting is a flat tan with black bed liner on the lower doors.


Just flip back a few pages...
All those photos already posted show OD green, WWII, semi flat.

That is the actual paint going on the outside as well.

The roof above that obvious seam will be bed liner in black. The rocker panel will be bed liner. The two fuel filler port-plates will be bed liner, and of course the bed will as well.

Of course I want the paint to look good, but paint in this case is more of a rust inhibiter than a "Look"

I am trying to achieve some low observable characteristics to the vehicle. That's why it will have very few shiny areas, it sports a quiet exhaust, and we have yet to see the forth coming sound absorbing mat going on everywhere.

What you're seeing is only primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:55:43 PM
Quote:
Originally Posted by Armalite View Post
Good looking truck there Don. I've started noticing more and more of these gen 1 trucks running around my neck of the woods. Kinda getting the itch to pick one up... Hmmmmm......


And you should!

Kinda like a old Ford 7N or 8N... not only do they still exist having left production half a century or more ago. people still use them and they still work!

These 12 valve mech injection Dodges are the stuff
They will always do the job any of our 2500/3500's can do and for a LOT less. They are dependable and in my case at least, they feel more like a proper MAN's truck. My Chebby, which I love feels like my wife's caddy only with some burliness. The Dodges make no apologies. The fit and finish of the body is simply no where near that of the new Chevy, and know what? I like that!

It rides rough, belches smoke, is noisy, rattles and at the end of the day is one hell of a hard working truck that ALWAYS starts, is devoid of electronics and is simply raw, naked truck DNA smashed together in some gigantic press into a bunch of ill fitting parts that work together like the Philadelphia symphony!

For the money, it's a magnificent truck. This is my first. I plan to acquire a crewcab and do the deal on it as well. These trucks are the ones I will use until the grave claims me and I go home for good!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:56:30 PM
Quote:
Originally Posted by Wantamax View Post
Ok. Wasn't sure it that was what the actual finish was going to be or if it was just a base. On the outside, will you be using a base/clear in one or a two stage base then clear?

Ken has it correct. Single stage run what ya brung stuff. No hardener, no base coats, no nothing. Add in a bit of reducer just so air can squeeze the stuff through a tiny little orifice and blast it out and yer done!

It's as simple as the rest of this brilliant truck. Repairing the paint will be as easy as whacking on a brush full of the stuff or scratching up the panel and respraying. Bugs in the paint will not hurt but actually help to break up the outline, aiding in camouflage, so it's all good.

And it's cheap. $35 or so a gallon!!!!!!!!!!!
I bought 4 gallons of it. Three for the actual truck and one to spray at wasps and that D!N$@<% Red Dog. spray paint kills wasps instantly, so does carb cleaner. I actually call the stuff "Spider Cleaner"

If I yell for one of the little rangers to get me a can of spider cleaner, they will show up ricky-tick with a can of carb cleaner. Now paint, when used as a weapon, has the added effect of blinding the critter before it suffocates it. So one second the thing is buzzin' around having happy bug thoughts, the next instant it enters IMC (Instrument meteorological conditions) a flying term we helo drivers don't like so much. Well the thing quickly realizes that there is something coating it's Mark 12 eyeballs when it experiences sudden stoppage against some wall.

Then as it's regaining control. it realizes ice or something has covered it's wings causing a catastrophic loss of lift, and the added weight of this sticky stuff wreaks havoc on its center of gravity. Losing lift, and over weight now, flying blind, it increases power which due to the fact that more paint is on one wing than the other causes an asymmetric increase/decrease of lift and the thing enters an unrecoverable spin. Sometimes the imbalance of lift can cause an inverted spin which is off the hook to behold, especially, me being an A-V-8-ER.

Well during this plunging out of control blind spin the bug suddenly needs a great deal more oxygen due to it's having increased power production to the redline. About one instant later it realizes it is not processing oxygen any longer due to the sticky ice like stuff covering it's streamline body. That's when it all starts to turn dark. The bug's last thought is probably something like, "Where did I go wrong, I never got to sting anyone," or something like that. Then unconscious, it's monocoque body hits the ground and someone like me walks over to examine the wreckage. Then with the final application of pressure, (In bug weights and measures) of about a trillion tons of force the landing gear from the big walking giant crunches the body of the dead bug producing what is actually its last sound ever heard, a crunch.

And that is why I bought the extra paint.

Well, almost. Red demon possessed dog...I figure that red dog is gonna come a sneakin in around the most critical part-painting time. I figure she will be looking for a screwdriver or pliers to snack on. She won't know it as she slows to half speed while approaching me from the "6" position that I have loaded the gun up with a little bit extra paint. As my aft facing extra-sensory hairs start to stir from the slight tremor in the force that red dog is creating, I plan to reel around and get one good pass across the head somewhere of that awful beast. In effect while painting it, although I will feel really good for a moment, all I will really be doing is to increase it's effectiveness. You see, having partially camouflaged it, the dog becomes all the more stealthy, a fact none of the cats are going to appreciate much. But in a small way, I'll feel like justice was finally done, and I'll sleep better that night!

And that's all I have to say about that!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:58:25 PM
Got a bit more done today

Started on the firewall
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 01:59:24 PM
The rubber almost looks green already.
Anyway the name of the game was to strip the firewall of everything, then prep it for paint.
Look what I found behind the sound proofing:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:00:30 PM
I think some critter took up housekeeping in there. Good thing I checked it out first

I thoroughly cleaned that, stripped the old felt and fiberglass, then repainted it with interior plastic paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:01:20 PM
Then the sanding began
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:02:30 PM
Next the master cylinder and brake booster were removed. They will not be reused as the truck will be converted to a full hydraulic brake system powered by a larger power steering pump
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:03:18 PM
With that gone, the firewall got pretty vacant and sanded up nicely
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:04:07 PM
Then everything was taped up and wiped down with solvent after the sanding
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:05:10 PM
Then it got two heavy coats of quality lacquer primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:06:01 PM
Just the doors remain to be primed and checked for straightness before the color coat
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:06:41 PM
Off subject, I seem to have a leak I can't find in this tire. It goes flat in 3-4 days
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:08:36 PM
this is where it sits at the end of build day 105
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:09:30 PM
Quote:
Originally Posted by kaslduramax View Post
This is exciting, you're getting closer and closer to the engine build! The part I am most anxious to see!

Also, wondering why you're doing all the paintwork first? I've always seen people attack the engine bay and other mechanical issues first before starting on paintwork.

I'm betting it was to give yourself time to think about how to change the oil? 

You eat an elephant one bite at a time...Right?

Same-Same

When I pulled the bed and this thing got serious, I entered a new game (Frame off full restoration/oil change), but I entered it at the wrong point in a normal build schedule. So the cab is happening now because I want to put the bed back on. I could have just painted the back of the cab, slid the painted bed on and called it done, then painted the cab later.
But I thought I might as well, just bag the cab painting all at once and be done with it.
So it all ends up getting done in this convoluted fashion. Linear??Hardly! But Done correctly? I think so...So I get to the same place but I started climbing Mt. Everest by helicopter on the third day ascent. Then I had to trek back down to base camp to get supplies to set up the second base camp so that I could make a descent run at where I am right now. But at some point all that will be laid out and I'll be making for the summit...

Motor? After the cab/bed I will pull the head and ship it off for mods. While that is gone you will see the front suspension going in, and near cylinder head return day, I will be pulling down the motor further to detail and rebuild each part except for the long block which is easily good for another quarter million miles or more. Then the head will go back on and then the twin setup
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:10:36 PM
OK, done with that
We did good and not so good today.
THe ball did get pushed downfield more so that was good

I started with pulling the old rubber trim off the door glass...I really should have done that earlier, but in the backwards sometimes sideways methods I am employing it all makes sense
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:11:42 PM
I wasn't sure if I had new rubber seals. Turned out I do, so I'll just repaint this area with the color coat
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:12:30 PM
Then I went taping everything and a few things nearby (Red Dog!)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:13:21 PM
And I remembered to pull off the last pieces of trim and sand behind them
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:13:58 PM
OOps forgot the sanded pic...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:14:57 PM
That's it for the silver except for the hood and the fenders and a few small parts. It all turns black in the next few frames.
I finished the taping inside and out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:15:54 PM
Yes, I'm painting the door handles on the truck. I sanded the snot and chrome out of them so they are needing something to coat them.
So I mixed up more of that cool black primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:17:44 PM
Then commenced spraying after wiping down everything with solvent
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:18:26 PM
better
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:19:07 PM
Next up: Windows, front and rear.
Here I am about to pull the rear glass.
I decided to do it this way to minimize the dust that would get into the interior, and because I did not suspect I had any major issue at all
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:20:19 PM
To pull the glass, find the rubber insert, pry it out, then pull it out completely
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:21:26 PM
Then starting at a corner, Slowly work the rubber gasket to the outside of the lip that retains it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:22:32 PM
Then even pressure will pop it right out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:23:53 PM
I soaked that old awful window tint with liqueur thinner for about an hour before going after it with a razor blade
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:24:31 PM
The rubber gasket was perfect so I'll reuse it.

While that was drying I wire-brushed the window flange, scuffed it down and painted it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:25:33 PM
Next up: The windshield

It comes out the same way, well, almost...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:26:17 PM
I was only worried about this one spot:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:27:04 PM
Then as I was GENTLY prying this happened
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:27:40 PM
Yep, that is a crack, actually a few of them.

So I made some more to match:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:28:26 PM
I started having a good time...I was thinking about the red dog and that d!MM#$! bird the whole time...

Well, to hell with prying, I beat the thing until it yielded in ten trillion little pieces
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:29:05 PM
Good news is no rust to speak of, bad news should be obvious!

So with the rear painted and after an hour of vacuuming all the glass shards up, I ran out of time!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:31:00 PM
Today after knocking it out at the gym it was like 1230 by the time I left there.

I had to buy some sanding discs in various grits and had to run to a number of stores before scoring what I needed (and cheap too) at HF.

Then I went gold shopping...I am, and you should be too...buying some bullion for the upcoming crash. it comes in ounces and tenth ounces, and for Nate, millionths of an ounce, and for Bobby, they will give you a picture of what it looks like! (Sorry Menses)

Then off on my quest for todays parts.

Made some great purchases. I decided to keep the brake system Dodge for the most part, so I purchased a brand new 1999 Dodge 2500/3500 hydro-brake booster. This gem runs off the power steering pump and provides nearly 300% more braking than the terrible stock vacuum setup.

After reading various swaps, I figured I can modify this one and make it fit in tight by fabbing up a mounting plate and adapting the too long push rod to the factory brake pedal. I also purchased a brand new 1999 master cylinder.

Next up was the quest for hydraulic hard line, 1/2" thank you very much. I ended up in a hydraulic shop with all sorts of stuff and purchased a 20' stick of hard line for $20!!!!!!!!!!

I will install compression fittings on either end and a hose fitting that will attach on one end to the factory cooler lines under the truck, and on the other end to a new roof mounted transmission cooler, uber-big in size. These hard lines will be mounted on the back of the cab on the right side in pillow blocks and give the truck a more pronounced "Back to the Future" look.

All that business had me arriving back at casa Don at 1712, far too late for any building shenanigans, so the real work will have to wait until tomorrow...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:32:22 PM
Sitting here chewing on some cashews and figuring out how to get the various paints, plastics, body sealer and dust out of my hair and off my skin...Gas?

Well this happened again
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:32:59 PM
So I bought these:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:33:53 PM
Lost the small one already...Threw it at the red dog and missed. She swooped in, snatched it up and carried it off...
How do you spell dead dog???

Anyway, with the heater blowing hot air on my leg I wrestled with the last tire/wheel...sort of a chores thing. But with this one I used different and better grade 8 hardware.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:34:30 PM
It came out just fine!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:35:27 PM
Someone asked me earlier just how much all that weighed,

Well, here's your answer:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:36:09 PM
That explains why I am having to work so hard moving these things around...so it's actually good news!

While rolling it back to the pile I noticed this!

When I pried it out, the whole screw was maybe 1/2" long, so no patchin' required...Yippee
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:37:22 PM
The planned major task for the day was the prep and primer of the windshield area.
Using the handy cup grinder I definitely got rid of all the old gooey sealer stuff. I also buffed the plastic trim on the inside of the cab into a billion pieces and sent part of my new headliner to an early grave.

I spent some time doing a litany of sailor blessings, then continued the mission
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:38:21 PM
The primer found it's new permanent residence and I put that one in the bag!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:39:18 PM
Next up is the final body work. There are a few small dents I will be repairing starting today, then after that the bed and the cab will be showin' some purdy OD Green color

TO help me along, I added this fine piece to the tool chest. Cost me all of $19 today at HF!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:40:32 PM
And it works:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:42:04 PM
Then Dr. Bondo paid a much anticipated visit
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:43:00 PM
After some coarse leveling with the file, it is about ready to sand
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:44:32 PM
The brake parts came in today:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:45:18 PM
The old vacuum booster dwarfs the new hydro-boost brake maker betterer thing
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:48:37 PM
Spent today ordering pieces parts including a Canik 9mm pistol. Got carried away on the fittings and hoses I guess...
Anyway $319 for a new 0mm plastic pistol with a couple 18 round mags, two holsters, a cleaning kit, storage case and something else...You kiddin'!!

OK anyway, after that I guess I continued to be carried away ordering some fresh Danish 5.56 ammo and another super cool Surefire 60 round magazine

Sorry...drifting

So finally I got out into casa garage and did mostly body work.

Even though 1. the roof can't be seen by most non mutant people, and 2. It is going to receive a thick coat of bed liner, I decided to smooth out those roof plates and hard points I welded in earlier
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:56:23 PM
After more sanding and more primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:57:19 PM
I got the fuel door openings done
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:58:12 PM
The other side of the bed required another skim coat of filler, so that got slapped on and left to dry

I am working the area with a long board and 80 grit so it is very laborious and time consuming
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 02:59:10 PM
Some of the smaller dents were completed all the way to 120 grit sanding and a coat of primer
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:00:13 PM
After the dents are finished, I'll scuff everything with 400 grit, then prep and paint with the epoxy sealer, and follow that in an hour with the color coat

The cab is coming around, nearing completion
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:02:05 PM
Welp, here is what the whole mess looks like tonight, the end of build day 108
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:05:15 PM
Quote:
Originally Posted by TexasRedNeck View Post
Welcome to middle age Bobby! I hate it when I walk the 12 ft from my office to my admins desk only to forget what I wanted by the time I get there....

Don, Trying to follow along at the home version...

I guess passing the tranny lines through the protected cab area and up the B pillar and to the roof using AN bulkhead fittings and braided high pressure line was not an option? I know you are very methodical and thoughtful about each detail, so was just curious.

Interior space is at an absolute premium. So much so that I decided to pull out the bench seat, mount it in the bed (Under a topper) and install something like thinner racing seats. Summit has a great selection and it looks like I will have no problem doing all that for less than a grand.

Transmission fluid lines get hot. That heat radiates...good for the winter, but not so much during our rather warm summers. Lines stay out of doors thank you berry much. The back of the cab is a tree branch, Kia "B" pillar, and 2 X 4 free area, so that's why they go there.
The roof is easy to armor up so that's a good spot for the cooler...that's how I got to all that.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:06:26 PM
Quote:
Originally Posted by FBJR View Post
Are you making your own Snorkel? (like you don't make everything else )

YESSIR I is.

Not my first by golly

Nossir, been down that road before.

It's easy and mine are always strong enough to serve as body protection as well for the occasional 99%er who is bouncing off precious body work

I built my last one on a supercharged gasser tundra. It turned out to be too small ID and cut boost by 3psi! EEK!

But it sure looked cool!

This one will be 5" 16 gage steel tubing with reinforcing, have a prefilter cap and be blended into the fender. I decided to just block off the inside of the fender to make that one big continuous air channel and install a suction activated (Spring loaded) flap valve in the system that would be pulled open by additional air demand. That way during normal operations and even under higher power demands all the air would come from high altitude. But if that Cummins started sucking the paint off the inside of the fender, then Mr. flapper does his thing and the rear tires continue to vulcanize state highways everywhere...perhaps long black stripes are coming to a street near you

Anyway, my last contraption:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:07:30 PM
Quote:
Originally Posted by Dustoff 35 View Post
That's a great idea.

Routing the lines between the bed front and the cab leaves them vulnerable to pinching and the frames on these 1st gens flex quite a bit when taken off-road.

Nope...

Plenty of room between the cab and bed for 1/2" lines

Besides box and cab don't get closer together, they just act in a sawing fashion, maintaining clearance.

This is my third square fender dodge. The others were off-roaded hard. the frame twist is there, about like the early PS Fords, but nothing ever comes of it. Frames do not fail. Large gaping holes are not rubbed into bodywork anywhere, in fact the flex is beneficial.
Unlike unit body big things like suburban's and Excursions, whose bodies have to cope with all that torsional goings-on, the Square trucks provide a great way to alleviate all of that. a joint of sorts..
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:08:17 PM
Nate, with all your cookin' going on, I thought of you when I saw this...

Sorry bro..

There was no danger, and all that...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:09:42 PM
Quote:
Originally Posted by Bobolallawa View Post
Don, I am with you on not having any oil lines any where inside the cab. If they were damaged at all and leak under any pressure the hot oil could be all over you and the windows. We had to remove all the hydraulic lines from the cabs of our snow and ice removal equipment.
Build an outside raceway for the oil lines and any other wires you might need for the roof mounted stuff like lights, cameras, electric switches and controls for well most anything.


And for others, Bob PM'd me this morning to tell me same, and I asked him to post up for everyone to see.

I shared a story with him.
A long, long time ago in a galaxy called Korea, I was in a "C" model chinook. Those things had roughly twice the hydraulic lines that the modern D, E, F, and G Model Chinooks have.
I was going along minding my own business. I was IFR, in a cloud directly over the airfield being vectored in for an approach and landing. Below me the pattern was hosting returning F-16's who were returning from playing around up north.
All of a sudden, and with no warning one of the 3000 psi lines severed, as in two, dumping and spraying hot oil and crap all over my helmet, neck, windshield, panel and the crewchief who was hanging around up front. I watched as the pressure quickly spun down to 0 and the #1 flight boost system shut itself off.
So, I've been there and done that, and had to get a new flight suit as oil kills the fire resistance of Nomex.
Nossir, no pressure lines in my cab...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:11:25 PM
Moving right along

While looking at an add from Midway shooting supplies, I noticed a single Beretta 92 left hand, Uncle Mikes, belt holster, closeout priced at $13...So I ordered it

Today it arrived. THe parts storage table is getting clogged up again, so to heck with it, I decided to bolt that sucker in and get some real world intent going for the square dodge

Here's the pieces parts:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:12:31 PM
I plan to mount it here:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:13:12 PM
Sort of like this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:14:00 PM
I was thinking that the well seasoned plastic could use a little help, so the plan to wrap the fuse cover panel with sheet aluminum was hatched.

Here's some .025 I had laying around (Amazing that the red dog hadn't eaten that as well as everything else!)
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:14:44 PM
I have a really good quality metal shear (Thanks Duane) which makes short work of anything that enters those jaws
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:15:29 PM
After some ninja like slices I had this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:16:08 PM
Next I got some help from my trusty harbor freight brake which I tuned up just for this operation
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:17:25 PM
Then the bendin' commenced
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:18:30 PM
Adjusted then voila' a aluminum clad old piece of plastic!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:19:39 PM
Next the holster was positioned and the 8/32 screw holes were drilled
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:20:35 PM
decent angle me thinks
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:21:45 PM
Three pop rivets permanized the assembly
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:22:27 PM
Next step: Cleaning, sanding, painting
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:23:10 PM
Then after drying, reassembly
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:24:25 PM
And mounting in the cab
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:26:04 PM
OK, we can call that project in the bag...

On to body work

About 75% of the dents have been smoothed and repaired, Only a couple remain and I am just going slow to bring them back to being perfect before final sealer and paint
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:27:11 PM
That took nearly 30 minutes of sanding with a long board to get to that point.

A technique body men sometimes use is to apply a "Guide coat" to check flatness. I like to spray on primer, then lightly sand with a board. All high surfaces are hit first. The flat areas which most of this is now all sands at the same time. Any unsanded area is a low spot needing more filler. I had a case of door #3 today:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:28:02 PM
It's nearing perfection at this point, but this final coat of body polyester should do it:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:28:48 PM
The lower passenger door had one small low spot:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:29:40 PM
The back end is done, but I decided to do a little more work on those roof rack mounts
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:30:17 PM
That slow leak is still there...Even after blessing it with choice drunken sailor language!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:30:59 PM
Well, I do!

THe brown truck did two things.

1. It delivered a bunch of view blockin' boxes

and

2. Nearly carried off the red dog.

Unbelievable, but while the kindly UPS man chatted for a moment and looked over the progress, that Da)(!@#!! red dog got into his truck and scored a box!

She was working on it when he got back...luckily in time before whatever was on the inside became dog poop in my back yard!

Anyway here's some boxes:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:32:29 PM
Here's some snorkel parts, clamps and a silicone hose, and those T-Clamps Mr. Texas suggested I purchase...Well, good call, I own them!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:33:29 PM
Here's the 5" sewer pipe, err, strike that, I meant snorkel tube
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:34:28 PM
That pipe will obviously be fitted on top of the hard points I built for it, and be trimmed down to size, so folks don't get crazy, "Yo, Don, did you notice it isn't centered and it's waaay too long", and "I'd suggest you reinstall the fender at some point and get a much better fit." You know stuff like that

If you do, I'll purposely leave it on there too long!

Here's a 45 I purchased to help with the transition up to the precleaner which will find refuge inside the roof rack
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:35:25 PM
This is Dynamat, an aluminum and rubber sound deadening self adhesive mat.

I purchased it now, because it is going onto parts of the firewall now right after painting and before the new brake stuff gets going.

The big box is for a custom piece made for the underside of the hood.

Part of the stealth technology will be the control of the volume/ amplitude, and intensity of the noise the truck will generate.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:36:15 PM
Anyway, that concludes another build day, number 109
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:37:08 PM
Just scored the top precleaner for the snorkel:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:38:01 PM
Quote:
Originally Posted by EL TATE View Post
I'm assuming that 800cfm is not sufficient? it looks like it pulls air from the sides, vortexing and allowing water to fall out the bottom while the air is pulled through the venturie, am I correct?


Incorrect!

Air enters from the bottom via some canted vanes which starts the swirl. as it continues upward toward the open Venturi and aided by spinning blades, heavy particles are centrifuged against the sides of the canister, eventually finding their way to the slits in the back

This is the way air is filtered in a great number of turbine powered helicopters...very effective
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:53:24 PM
Getting back into the project, I continued smoothing the body work, concentrating on the dented area of the bed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:54:46 PM
I finished the area on the top of the bed.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:55:33 PM
This camera is just not working for me very well. I think the projects is about to claim its next victim!

Anyway, the big dent in the rear was still just a tad low, so I pulled a very thin coat of filler over it again. This should be the last time I have to do that.

While that was setting up, I turned my attention to the roof stations...and the sanding continued
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:56:26 PM
I worked that with 50 grit, 80 grit, and 120 with the orbital. The idea was to get it smooth and nothing more since the bed liner will be pretty irregular in appearance and cover any deformities easily
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:57:13 PM
This primer coat finishes it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:58:23 PM
 like to keep a couple projects in queue on any given day. The other being a mechanical or fabrication project.
Today was no exception. I wanted to build the mount for that new Hydro-boost brake device.
To start, I pried the old gasket off the vacuum brake booster to use as a template
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 03:59:29 PM
Using that and a nearby can of paint, I sprayed the outline on some .125" plate steel and cut that out
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:00:34 PM
Next up, removal of the second gen factory standoff mount from the brake booster unit.

First the snap ring is removed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:01:23 PM
Then in the interest of saving time, I chop sawed off the mount to gain access to the unique square nut
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:02:31 PM
Then fussed with the nut until it yielded
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:03:33 PM
I bored a hole into the new mount and checked the fit...everything is a go so far
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:04:15 PM
Tracing around the existing hole in the firewall, I came up with this template which I used to locate the bolt holes in the plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:04:58 PM
I drilled holes small enough to be tapped to the 3/8-16 bolts I wanted to use
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:06:00 PM
After cleaning it up with a flap wheel, the 3/8" socket head stainless bolts screwed right in
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:07:40 PM
And the moment of truth...Does it fit?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:08:38 PM
Next test, does it work with the booster and does that fit?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:09:28 PM
So far, so good!

Now remember that 2nd gen standoff? That exists because the engine resides partially under the cowl, unlike the traditional 1st gen square truck. The old unit is 2 3/16" shorter than the new one
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:10:16 PM
The middle mark is approximately center of the rod, and the other two marks are the actual cut lines

Here's the rod after shortening
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:11:03 PM
While setting this up for the next procedure, I cleaned and primed the mount plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:13:07 PM
The plan is to tap either end then screw them together with a coupling nut which is a long nut used to join all thread if necessary. This was 1/2" so I cut 1/2-13 threads into either piece
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:14:39 PM
For simulation only, I joined the two pieces with a standard nut.

I'll search out a coupler tomorrow
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:27:35 PM
So now everything is the proper length, time for the paint!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:28:35 PM
The painting finished this operation and me for the day!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:29:42 PM
Quote:
Originally Posted by lutzjk913 View Post
Coming along nicely don.

When do you think you will be finished with this?


Finished is a relative term!

I hope to drive something this summer or fall, but I suspect I'll be doing things to it for years to come!

I have the SAS to do on the chebby

Then the tac-trailer project. The trailer/habitat is the only way all of this makes sense. Neither truck has sufficient room, so the trailer is a necessity.

I hope to drive the truck after the engine, twin turbos, coil spring suspension, front and rear bumpers and rock rails.

Then while I'm driving it and sorting it out, I'll start the exo-skeleton. With that complete, I'd have to call Square D effectively done with the occasional upgrade keeping it alive as a project for years...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:30:36 PM
Quote:
Originally Posted by BobbyB View Post
I think you should leave it the camo paint job you have on page 484. It's definitely a "hide in plain sight, broken down truck" paint job... 

Bobby, ya know...that isn't so bad of an idea.

Make it look so junky, how could it be anything...

I think you have something there...

You know I was painting it with OD Green and the bumpers and so forth in semi flat black

But as I mentioned some time before here is a great little home-made camo paint scheme which also looks half way OK:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:32:21 PM
Quote:
Originally Posted by duramaxdarren View Post
Yup she's my angel! Thanks guys. I'm afraid it's to late and I got axed. They weren't real men and I didn't drink the koolaide. Not to worry, god has his plan for my family and I will work as I was meant to ( in the field and running a crew) while I hunt for a new full time jig. Wife's not thrilled and she's right (as always) but I will provide for my family and god is with me


Sent from AutoGuide.com Free App


Darren, try this out...
You may have troubles, but Jesus told us we would have trouble in the world.
He also told us to rejoice in him and in times of trouble;

Faith in Christ is the foundation for joy and hope in life. Jesus' life on earth, his death and resurrection is the cornerstone of Christian faith. This faith is not based on the state of our emotion. That's why it is important to study the Scriptures to strengthen our faith and grow in our knowledge of the truth. The Bible teaches that Jesus came into the world, entered human suffering and conquered sin and death. Only through faith in Jesus Christ can we persevere and sustain our hope and joy. The Bible gives us reason to rejoice. We rejoice because God showed his love and grace to us. We have reason to celebrate because God is in control. We should rejoice because God is good and his love endures forever. We must learn to rejoice in the Lord always.
Feel free to use these verses for a Bible study or a short devotional. For more encouraging Bible verses check out the articles posted on the next page.

Philippians 4:4
Rejoice in the Lord always. I will say it again: Rejoice!

Psalm 13:5
But I trust in your unfailing love; my heart rejoices in your salvation.

1 Thessalonians 5:16-18
Be joyful always; pray continually; give thanks in all circumstances, for this is God's will for you in Christ Jesus.

Psalm 40:16
But may all who seek you rejoice and be glad in you; may those who love your salvation always say, "The LORD be exalted!"

James 1:2-4
Consider it pure joy, my brothers, whenever you face trials of many kinds, because you know that the testing of your faith develops perseverance. Perseverance must finish its work so that you may be mature and complete, not lacking anything.

Psalm 30:5
For his anger lasts only a moment, but his favor lasts a lifetime; weeping may remain for a night, but rejoicing comes in the morning.

Romans 5:1-4
Therefore, since we have been justified through faith, we have peace with God through our Lord Jesus Christ, through whom we have gained access by faith into this grace in which we now stand. And we rejoice in the hope of the glory of God. Not only so, but we also rejoice in our sufferings, because we know that suffering produces perseverance; perseverance, character; and character, hope.

Psalm 28:7
The LORD is my strength and my shield; my heart trusts in him, and I am helped. My heart leaps for joy and I will give thanks to him in song.

Romans 15:13
May the God of hope fill you with all joy and peace as you trust in him, so that you may overflow with hope by the power of the Holy Spirit.

Psalm 64:9-10
All mankind will fear; they will proclaim the works of God and ponder what he has done. Let the righteous rejoice in the LORD and take refuge in him; let all the upright in heart praise him!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:33:13 PM
Quote:
Originally Posted by BobbyB View Post
Wasn't it your intention (the mother of all evils') with D2 to keep it looking as you got it on the outside, as to not attract too much unwanted attention, yet still have the ability to scoot cross country if needbe? I do remember things, I just don't let on to the powers that be.
 

Yes, that is my intention, to keep it low observable and low keyed.

Now going down the road, this truck is going to attract enormous attention, just because it will look so "Rad" if that is a word.

So no hiding the "intent" part.

When you design and build something favoring function over looks, it will get all creepy looking pdq.

So I figure the best I can do is to break up the pattern with some strategic blending of colors, all muted of course.

Look at that Hmmv with it's OD and black swatches.

It sort of stands out because of the fact that it's a H1 hummer and looks like it came of a Mad-Max set.

Now consider our HMMV's and my helicopters after we have been operating them for a few days in the bush.

They start to look all muted and that base color only helps blend it all together.

I say you take my truck, drive it through a field with a mud hole and you'll be approaching "good to go"

Then take that same truck and drive it partially into a wall with maybe one tire resting comfortably on the neighbors Taurus and I think it will look like a wreck, someone abandoned.

That's how I plan to play this one out. I am just building in the ability to punch into that wall without doing any more than scratching some paint...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:33:51 PM
Today, was a work out (Takes hours) and parts collection day. I did manage to score all the material for the roof rack. Total cost on all that steel was $88! Not too bad me thinks.
I also got more stuff for the snorkel, but the most important part, the precleaned did not show up. After three days, the warehouse just told us that even though they show one they had zero balance. So it has been ordered from the factory and I believe is 3 days out.

I got a late start so I spend some time cleaning the place since I will be painting most of the truck in a few days to a week. As far as what's next, I was thinking, I ought to fab up that rack and snorkel before the fresh paint so that that purdy green stuff does not get all sparky when I tack this or that together. Right now it matters not. So tomorrow, hopefully I have set a lofty goal of getting the snorkel and the roof rack put together.

I'll post todays progress along with tomorrows Friday evening
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:35:45 PM
I was working on the snorkel. This flat bar is the snorkel base mount that attaches to the hard points
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:36:37 PM
It was painted with the weld through copper primer from U-Pol
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:37:24 PM
In this photo(s) I temporarily reattached the fender so I could sort out the snorkel position before permanizing it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:38:07 PM
This junky Sony/jap camera is failing, and why not?? It's over a year old, why should it continue to function?
So apologies for the out of focus pics I purposely took that way to hide my poor workmanship!

I butt welded the 5" 45 to the main tube
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:38:44 PM
Then shortened up the top part
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:39:42 PM
Then I chopped off the excess from the bottom
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:40:46 PM
The pipe is big enough to screw on with bolts from the inside, so that became the simplest concept. Since my wife tells me I am simple minded, I went with it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:41:30 PM
And lookey there, it fits!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:42:12 PM
It even works with the opening and closing of the door!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:43:16 PM
I'll fab up the bottom piece in a few days after I get a couple more 45's from summit

Side view:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:44:10 PM
With that fitting nicely, I removed it, the welded up all those rose-weld holes making that permanent
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:45:11 PM
After selecting some shorter hardware, I snugged the snorkel up, but not tightened all the way down
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:49:26 PM
So have you heard of the flying Wallendes?

They are the most famous trapeze family alive, that are mostly, still alive

Why do I mention them?

Well I seem to have something in common with them

They get completely horzintal well off the ground...

Yep

Apparently, so do I

I think the difference between them and I is that safety net.

At least in my case There was a flat 8" thick layer of safety concrete to stop my fall.

I was traversing around from work stand to frame. Apparently the comforter I have laying in the frame is not permanently attached, and it moves.

The good thing is that when it moved displacing my foot, it did not scratch the paint. When I got horizontal at least there were no tricky air currents to set up the spin. When I hit the safety concrete with a perfect three point landing, those points being my buttock protrusions and the back of my skull, I didn't damage it either.
It didn't hurt because it knocked me out. Then I was happy when I awoke to discover my toes and legs still worked, and that the D_)!(&*!! red dog hadn't eaten any of me.

So it's all good. I'm sitting here doped up on aspirin if one can actually do that and for some reason the only thing I am angry about or with is that D)!&*!! Red dog and she was absent from the festivities for once.

Oh, then a few moments later my mind got the slow traveling pain signals. I was in such a state a moment after waking up from the fall and figuring out how much I was hurting to weld a little on the roof rack. I must not have been thinking straight or perhaps at all. because when I tried to stand up and the lower back said, HEY, I'm hurt here, How's bout a little help, then gave way to gravity, on the way back down, I reached out and grabbed onto the roof rack...TO the exact spot which had been molten 10 seconds before...Yea...Not my day at all

The last couple pics are normal welding battle damage...nothing to lose any sleep over...
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:51:24 PM
OK folks, no aspirin.
I started the day with them, but said to heck with it about mid day. I'll only live for just so long and the day was ah' wastin' so I donned the old work clothes and hobbled out to the garage to get a couple hours in.

I really think it's only bruising kind of injury, nothing more. I have very little functioning brain, so injuring that wouldn't hurt...
The foot was because instead of putting on my trusty combat boots to weld like I usually do, I went at it with some mid tops...mid tops act like bug funnels for sparks and hot metal...nuff said

No headache, just a really sore butt and lower back. I think I fell just about perfectly, except I forgot the PLF at the point of impact.

OK on to work...Back to the snorkel. The brown truck showed up again so I concentrated on getting the lower pipe section created
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:52:04 PM
The lower section starts with a length of pipe to get the bend in about the right spot

The camera is going to fail again, so bear with me prudy please
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:53:22 PM
The pipe needs to turn in closer to the fender. To do that I cut several wedge shaped sections from the pipe then fit them to get the radius going in the direction I need it to
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:54:42 PM
I was able to turn this pipe inward to the correct angle with just three sections
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:55:54 PM
I welded these sections from the inside, then made a pass around the outside, then ground off the excess on the outside. Once I get it all fitted, I will finish it with body filler and it will get all "One piece lookin'
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:57:02 PM
Here it is temporarily assembled to the upper pipe
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:57:54 PM
Three paint paddles supply the needed clearance from the fender I will need to build in a base plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 04:58:52 PM
Here is more of the lower section, but more still to come
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:00:03 PM
The piece that will turn into the fender is another 45 pipe section with some additional wedges welded onto the end to make the complete transition into the inner realms of the fender world
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:00:53 PM
It will fit something like this:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:03:05 PM
I'm not super impressed with my "turnmanship" with respect to that pipe, but it still isn't done, so I'll withhold my judgment until after I get it done
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:05:12 PM
Quote:
Originally Posted by Cudakidd53 View Post
Glad you're moving around and all- now go rebuild grey matter! 

Thank all of you for the out-pouring of concern. It was just a silly fall, and didn't hurt much more than my butt and ego, really, not so much the ego.

I want to take a moment to thank all you wonderful people for showing a genuine concern. Although the fall was not a big deal, you all treated it as though it was a potential end of life possibility, and to be analytically correct, perhaps it might have been.

That made me think. It could have suddenly ended my life. One moment, I'm blissfully tacking in a weld, the next I'm asking Saint Peter "What's with the beautiful Pearly gate?

Isn't that the way life goes for some of us? You hear about this person or that who suddenly died in a violent car crash or dropped dead from a heart attack? In my line of business, I remember Sonny, a fellow pilot. He flew little bird guns. One day in Panama during Just Cause, I went out to refuel some other aircraft with my huge gas filled chinook, and he off to support the Seals we inserted, well, I inserted, the night before. I came back all tired, hot and sweaty into that packed hangar on Howard air for base in Panama city to find the mood changed. When I asked what's up, a fellow aviator told me Sonny's dead. Just like that! No, hey, Don, I have something to tell you. Nope, Just Sonny's dead, and so is Lieutenant Hunter...

I had my own moment. Happened in Baghdad in 2005. Well I guess I had more than one. Some missiles trying to turn my chinook into burning scrap metal in Desert Storm, and others. But for those of you who read my book, you would probably agree, Baghdad was a moment in time when God could easily have snatched me off the earth and that would have seemed like the natural result for what was going on at the time. But he didn't, and in some crazy way, I consider my time since then "Extra credit."

What it makes me think about is what if we die? We all do you know. Man, I hope I'm not breaking the news to anyone here, sure hate to mess up your day. But this IS THE POINT. If you are playing around with the concept of maybe getting to know God, say a few weeks, months before the date you imagine, or when the doctor marks your forehead with a capital "C," then let me tell you, you're really taking a huge chance.

Heaven is for real. Hell is for real. There is a God who created all of this and there is a devil waiting in the shadows. And he is hoping you don't get a message such as this...Just an old guy pointing out the obvious, devoid of PC or reservation. I have earned the right and now I get to tell the truth all the time, and I don't and really never have cared what anyone thinks about it and I don't now. You don't like what Don is saying, flip the channel. But if you want one guy for once to look you in the eyeball from 3 inches and tell you the spittin' truth, well, I guess I'd be your man.

That fall could have killed me. And that would have been a great thing for me! Not for my sons, or wife, but for me, no more hell to deal with on earth. No more wars. No more young men dying on board my aircraft, no more horrible stories of little girls forced into prostitution, no heroin, no disease, no bad weather or old coffee...heaven.

But God gave me (and that helicopter) more time. I plan to use it for him. He is what matters to me. I hate to burst anyone's bubble, but this truck here means very little if the truth be known. It is only important in that it provides this forum, this arena where we come to know one another and share the truth and build up each other. We get to introduce some of our readership to the creator of the universe and for that simple fact alone, I am overjoyed to the point of tears, than my Father and his son Jesus the Christ gave me the breath needed to write and post this.

Think about it...Get it done before you fall...

The Peace of God be with you my friends!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:15:19 PM
I see you all have been busy! Good, that kept you out of trouble for a while longer.

OK here's what I think of my snorkel work so far:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:16:05 PM
My "dislocated shoulder lookin' thing got deep 6'ed. and I started anew with a new idea I had right after the entry I posted this morning.

I'm going to bring a short section of pipe down into a steel box, welded to a "Fender plate" and run a steel rectangle section forward to a hole in the fender where it will dump into the inner fender cavity

Here's the fender plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:17:50 PM
Cleco's will hold it all in place while it gets assembled piece by custom fit piece
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:19:14 PM
I used 16 gage for the fender mount and 11 and 12 gage for the air chamber parts. That stuff is about 1/8" thick and will be pretty strong

The next thing was to fit a square section to the pipe and tack it up to the fender plate
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:20:16 PM
No rocket science yet, just simple cutting of plate steel.

Next I welded up that assembly and trimmed it to the shape I wanted
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:21:44 PM
The voids will bet filled in later. Here is the trimmed panel home where it will live in harmony with lots of other parts:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:23:07 PM
Where the pipe enters this chamber will be a collection spot for water sucked in from above. I wanted a means of evacuating that water, so I used this cool land-rover part from the British military Rovers. Suction pinches the rubber together, but the weight of water easily blows through and drips onto the ground, and out of the intake air
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:24:16 PM
That gets welded to the bottom panel of the collection-plenum
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:25:07 PM
Now the laborious process of closing in the "Box" begins, adding piece by piece
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:25:55 PM
Then the outside
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:26:35 PM
Next the transition tunnel bottom
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:27:37 PM
Then the top, and a triangle section
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:28:20 PM
And slowly the process of tracing out a piece from cardboard, then tracing that part onto the steel, cutting the steel, then finally welding it into place.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:29:09 PM
And more triangles
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:30:02 PM
I ran out of time at this point, but I think you are getting the idea.

So what was the better choice, the convoluted steel box thing from hades, or the dislocated shoulder?
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:32:43 PM
Duane came over and installed the nut-serts into the body for the hydraulic cooler (Transmission) and I worked on the beautiful Cinderella like snorkel.
Why Cinderella? Well she turned ordinary things into masterpieces of beauty, same-same with the Cinderella snorkel!

Duane wanted to complete the Frankenstein look here, so we found him a bolt!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:33:24 PM
He worked out the trans cooler line stuff. The lines will run from under the body on the left side, up the back of the left side of the cab, then across the top of the back of the cab then turn into rubber and make the connection to the cooler which needs to get mounted on the right side of the roof rack
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:34:19 PM
He used his handy-dandy nut-sert tool which collapses a steel threaded insert inside a hole, both providing a point for threads and creating a nice secure finished look
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:35:02 PM
When the tool and Duane have done their thing, this is what you have left:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:36:20 PM
The threads are for a 10-32 screw

Several more mount points are installed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:37:45 PM
That all makes for a nice, secure, simple, and low clearance mounting of those coming steel lines.

I'm happy with that!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:38:51 PM
OK back to the snorkel construction

Using a #40 grit flap wheel I smoothed out the welds first
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:40:03 PM
Same as before, adding piece by piece
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:41:29 PM
Then the long run is covered
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:43:17 PM
Now for the transition pieces:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:44:18 PM
I tapered the front in both axes to reduce the "bulky effect" and help it plow through branches and 2 X 4's more easily
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:45:45 PM
The outside panel is thick 11 gage and a single piece which I relief cut, then bent to shape before welding it in
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:47:17 PM
Here's some views after the welding:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:48:47 PM
A couple more:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:50:42 PM
Quote:
Originally Posted by FBJR View Post
Just be sure t add a bolt to the other side so you can jump start it

Why run the lines up and around the back vs just up the side for the cooler? Wouldn't that protect them more?

The intake does look better built up some, but why not build it into the fender vs right on top?


It's easier to fix this way. Easier to replace the fender if I need to someday. Mostly, I was thinking that if one had to diddy-mau (Vietnamese I think, but think: Get out of dodge quick!) then thinking out of the box, why not just drive through a building? Ya know, some gang bangers or similar bonehead, future stationary target tries to jack your vehicle in an alley. Conventional thinking has you going forward and backward, right? Well, why just not drive through the warehouse or residential house beside you?

I learned that stuff in Baghdad during the war there. Going down the highway, we would "Go reverse" which meant getting into the lanes of opposing traffic, or get up on either sidewalk, or going through a warehouse or park or parking lot ;-))

The last was cool, and very good for the BMW factory!
So if one wants to drive through things like houses, the vehicle needs to be somewhat hardened. I figured I'd get dust free air to the engine and harden up the fender with one modification

and because that's just the way I decided to do it
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:51:28 PM
Quote:
Originally Posted by Higher Caliber View Post
something went awry when you whacked the hole in the plate where the tube inserts Don! Are you sure your head is alright? that's not your normal "attention to detail"... Think you oughta square that, or rather round it, away there chief!

That was freehand
It gets a plate welded on top. I figured I'd strengthen that area up anyway since the right angle transition takes place there, so I'm not sweating the slop so much
Plus, it's crap or get off the pot time. THis truck has been quite a while now in production. I need to see some results.

Hey, gun guy, Duane wants me to get this: Dammed near has me talked into buying one:

Ruger SR 762
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:52:37 PM
Quote:
Originally Posted by KensAuto View Post
Gotta love those threadserts, I've been using those forever.....very professional. The intake on the other hand...........
jk Big D, definitely one of a kind and that's why I like it!


BK, comment on your comment

You really made a cultural reference and didn't know it.

You were saying my snorkel is a one of a kind, and of course you are correct. More to the point, there was a time when every snorkel was a one of a kind.

These days, a build is nothing more than adding parts that one purchases. After bantying it about on some forum the builder purchases his well thought out star mags. He never once considered taking a "Lincoln 18" wheel, and welding in a chevy truck center to make something unique. Nope, today's kids, and they are mostly that, simply buy parts.

One climbs up the social ladder as it were based on how many of these parts he can purchase. SO the measure of a build and to the extent his peers give him credit, his personal esteem is based on nothing deeper than his pockets.

See where I'm going with this?

After WW2 Hot rodding took off in a big way and out of California, the home of these big dry lake beds. There, car crafters would take aircraft drop tanks and build them into a car. Stuffing in anything from flathead ford V8's to more exotic stuff. They would create suspensions and drive systems from parts that had seen no such connection before the incredibly inventive car nut got a sewer pipe and turned it into a drive shaft.

We have lost that as a culture and all the proof you need is to read backwards here on this thread about the snorkel I just built.
Folks find it unfamiliar. It doesn't exist in any parts catalog. I didn't take an ARB Safari land cruiser snorkel and adapt it.
Get what I'm saying here. This current 20's-40's generation has lost a LOT of creativity. Normal truck building amounts to little more than what one can purchase or by painting a Chevy emblem black. Inventive is little more than a creative or clever recombination of parts.

Guys now cover their M4 carbines up with parts they looked all over the internet to find. Does anyone get a lathe and a mill and create a new barrel, or other accessory?

It seems to me that someone who gets to bolt on the first of a new part such as the second injection pump is thought of as some sort of an oracle. He is nothing more than a guy who happened to have the cash to buy something.

Car crafting, and the imaginative forces that drive it in America is nearly dead. I can see a manifold change having lived nearly 60 years. (Turn that magic number in April). I see imagination nearly gone from what I knew from my youth. Men of half my age have seen less than half that change so it is not as pronounced.

Franken snorkel was a product of my imagination and inventiveness. I thought of a purpose, well more of a problem actually, and just crafted up something to solve the problem.

Does that make me something special? Here's the scary part...I know me pretty well. And knowing me, I can say, I am a pretty average guy. I am not special...I am the middle ground. Folks should be distributed up and down from me trending upward toward brilliant and downward toward moron.

We have lost so-so much and we don't even realize it!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:53:46 PM
Quote:
Originally Posted by flyin6 View Post
BK, comment on your comment

You really made a cultural reference and didn't know it.

You were saying my snorkel is a one of a kind, and of course you are correct. More to the point, there was a time when every snorkel was a one of a kind.

These days, a build is nothing more than adding parts that one purchases. After bantying it about on some forum the builder purchases his well thought out star mags. He never once considered taking a "Lincoln 18" wheel, and welding in a chevy truck center to make something unique. Nope, today's kids, and they are mostly that, simply buy parts.

One climbs up the social ladder as it were based on how many of these parts he can purchase. SO the measure of a build and to the extent his peers give him credit, his personal esteem is based on nothing deeper than his pockets.

See where I'm going with this?

After WW2 Hot rodding took off in a big way and out of California, the home of these big dry lake beds. There, car crafters would take aircraft drop tanks and build them into a car. Stuffing in anything from flathead ford V8's to more exotic stuff. They would create suspensions and drive systems from parts that had seen no such connection before the incredibly inventive car nut got a sewer pipe and turned it into a drive shaft.

We have lost that as a culture and all the proof you need is to read backwards here on this thread about the snorkel I just built.
Folks find it unfamiliar. It doesn't exist in any parts catalog. I didn't take an ARB Safari land cruiser snorkel and adapt it.
Get what I'm saying here. This current 20's-40's generation has lost a LOT of creativity. Normal truck building amounts to little more than what one can purchase or by painting a Chevy emblem black. Inventive is little more than a creative or clever recombination of parts.

Guys now cover their M4 carbines up with parts they looked all over the internet to find. Does anyone get a lathe and a mill and create a new barrel, or other accessory?

It seems to me that someone who gets to bolt on the first of a new part such as the second injection pump is thought of as some sort of an oracle. He is nothing more than a guy who happened to have the cash to buy something.

Car crafting, and the imaginative forces that drive it in America is nearly dead. I can see a manifold change having lived nearly 60 years. (Turn that magic number in April). I see imagination nearly gone from what I knew from my youth. Men of half my age have seen less than half that change so it is not as pronounced.

Franken snorkel was a product of my imagination and inventiveness. I thought of a purpose, well more of a problem actually, and just crafted up something to solve the problem.

Does that make me something special? Here's the scary part...I know me pretty well. And knowing me, I can say, I am a pretty average guy. I am not special...I am the middle ground. Folks should be distributed up and down from me trending upward toward brilliant and downward toward moron.

We have lost so-so much and we don't even realize it!


It's sad, but very true. Most people now would rather sit inside and play on an iphone than go out into the garage and make/build something. This build is unique because its not just a bunch of premade parts bought out of a JEGS catolog. I think in some applications, today's technology is a good thing but i really think it is ruining america, especially the younger generation.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:55:08 PM
Quote:
Originally Posted by Armalite View Post
Don, let's think about something...


Snorkel....

It's made out of metal. So it the snorkel "suction" tube...

Metal does not react well to hot/cold sways in temperature. Starts to "sweat" internally and externally. That large intake box, to me, would be a haven for moisture collection, internally. Have you considered this? Summer, Winter, no problem. Fall, maybe. Spring, definite.

Now, I would have to enlist the expertise of Duane into this situation, but, the size of that intake box should produce a lot of "sweat". How much? Internally, without insulation, how much water will it produce, that could possibly be sucked into the breather? Hopefully, and probably most definitely, the filter will catch the small amounts of liquid. I know you are running the drain, but I'm not so sure the amount of water displaced internally will filter to that drain plug, and run out.

Another issue, unless you coat the interior of that pipe, there is a potential for rust correct?

Just thinking outside the "box" if you will. I know if your humidity is anything like ours down here, that metal sauna is going to create a lot of moisture... Have you considered it?


The snorkel itself is aluminized steel...
The transfer tube/box I created is going to get the full treatment
The plenum chamber is also well protected.
Some water ingestion is good
I don't see it as being an issue.

Turbine engines have plenum chambers in some cases many times larger. They go on and on for years...no issues

It won't be any sort of a problem
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:56:14 PM
From ElTate

never could afford the expensive stuff, so I invested in benders, and welders (not great quality but got me by). my buddy and I made the lift kit, drop pittman arm, steering link, shock mounts, spring over axle conversion and mounts for my 72 wagoneer. Headers weren't available commercially so we dimpled some GM ones off a 396, worked great. had to have a plasma guy cut a mounting flange for them but I just didn't have the tools. got a lot of ridicule for the way the 74 springs sat on the 72 frame, so we cut off the perches, moved them back down to the horizontal portion of the frame and re-attached them. found f250 shocks that fit just right with the lift, fabricated seat mounts for VW Recaro buckets up front, cut diamond plate door and tailgate panels for the interior and made a spare mount inside the bed w/a fuel cell where the spare used to be.

I know they say necessity is the mother of invention, but poverty is a pretty good motivator to get creative too. That was one of the major things that drew me to this guy in the first place, ingenuity, can do attitude, make it work kind of stuff, and then I got to know him. If you have a copy of Distant thunder, go back to the section that talks about his time on the german fella's farm with a welder and the shock and awe of the farmer compared to the "this is just how it's done" demeanor of Don and his cohorts and you'll see a great example of this American spirit. I'm not holding you up on some pillar here now Don, don't worry, but I use this and you all as motivation for my boy and my daughter, and my neighbors and family, and we are almost at movement status here. Rebuilding, re-purposing, growing and farming. Sorry, that got off on a CIEMR tangent there, but where we may have lost some of "that" we have started to find more of it here, and creating more interest as well.
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:57:50 PM
Let's get this snorkel in the bag...sort of

Looking at it, I was sitting at about 75% on the design. Something about it wasn't making me happy. I think it's the big edge sticking way out. At first I thought it was OK because a triangle is very strong and that edge would be the edge that would catch everything.

THen I thought it might be better with some of that edge taken off, and perhaps even a rub strip of sorts bolted on.

So for the first order of business, I cut off a section of that edge
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 05:59:14 PM
I like this flat edge much better
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 10, 2014, 06:00:30 PM
With the fender removed, I made the hole through which all the air will pass
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:15:16 AM
After removing the clecos I made a discovery...

Turns out I welded more than just 11 gage, and you can say the weld penetration was at the least very, very good

Yup...I welded the snorkel to the fender without even knowing it!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:17:32 AM
Well... no worries, I guess the fender/snorkel is now permanent!

So, with that, next I drilled a whole bunch more holes and welded the snorkel from the back side all over the place

But first I did some grinding to smooth the metal and remove contamination from weld points
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:18:33 AM
Well, good time to finish the inside of the fender...So the sanding, wire brush and flap wheel started ah' smokin'
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:19:52 AM
First layer was some rubberized undercoating in all the areas I thought would be stressed with corrosion
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:21:00 AM
A bit more smoothing and it was time for some body filler.

I'm thinking this part will get sprayed with bed liner as well due to it's potential to get banged up, so All I am looking for is smooth
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:21:38 AM
Carving away excess before it completely hardens makes for a lot less work!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:22:47 AM
Then comes what seems like forever sanding all that plastic into the shape you desire
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:23:26 AM
And just like that, it was ready for several very wet primer coats
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:24:15 AM
And that is it for another build day, number 115
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:29:23 AM
Leaving for church in a few so I post up a bit, then come back and finish
BTW anyone ever needs prayer, our prayer team meets Tuesday nights, I'm on it and we'll lift up anyone with a need or concern.

OK the focus this week is paint. I need to get this thing in paint before Saturday as a personal goal, so full speed ahead on the prep.
First up: Finish the body work

I finished this spot, although forgot to shoot a pic of the work
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:31:05 AM
Then I moved to the opposite side and did a through sanding and then a heavy primer coat
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:32:32 AM
Then the front of the bed
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:33:32 AM
I finished this spot of body work next
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:34:39 AM
Next up was the right door
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:36:54 AM
And that my fine furry friends finished the bodywork!

Now I only need to lightly sand it, clean it like the dickens, then on goes the epoxy sealer followed by Mr. Paint!
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:38:27 AM
And we can see Combat Max still lives and perhaps, even...thrives???
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:39:41 AM
Let's play parts for a moment

Speaking of the roof rack thing, here's some of the lights:
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:40:35 AM
Those round things are dirt floor simple. Old school 100W halogen lights made from nothing special. But after an EMP effect, they will still be working, unlike these units which I selected to be "Scene illumination" flood lights.

The flood lights which will face in all directions are LED because I wanted a very low amp draw if I was down to a battery alone
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:41:30 AM
Here's the one over the world view of the parts situation. Dunno, but I think I am winning...you may differ in opinion, and that's fine as long as you don't ever publically disagree!
Bad news is that I had to start a parts room in the basement, so I'm sorta cheatin'
Ya see, the leaves on that jap maple I like so much are about to show themselves once again, and I want to gaze upon them between sparks, torquin' and assemblin'
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:43:33 AM
It was a long laborious day, but I have the body work completed and the whole vehicle minus the tailgate is all sanded

While sanding the primer coat with 320 grit, I found a whole bunch of new minor divets, so all of them had to be corrected as well.

Before we look at all that, let's play "tools" first.
Went to Harbor Freight and picked up this cool metal saw which I am going to use to cur an access in the bed floor for the electrical panel located below for servicing.
I also picked up another orbital sander. Now I have one set up with 240 grit and another with #40 grit for knocking down the body filler quickly
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:44:24 AM
Now is the time to really pay attention to what's going on with the body work. Deep scratches need to be filled with something such as this skimming putty
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:45:03 AM
During all that hand sanding (Hours) I found some dents that didn't show up before, but I certainly felt then, so back to the body filler
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:45:38 AM
And more putty
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:46:17 AM
And in between waiting for the various materials to set or dry, more detail sanding. THe firewall took forever
Title: Re: SquareD Part 5: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:46:51 AM
The back end went pretty fast. That is all done by hand. I did save some time by using the orbital on the roof since it is going to get thick bed liner anyway
Title: Re: SquareD Part 5: Body work, paint prep, Snorkel, and farther off course ...
Post by: Flyin6 on October 11, 2014, 09:48:21 AM
I found another large shallow dent while sanding around the previous repair. That got a coat of filler, then careful sanding with a 12" board.
Afterward, I sprayed on a "Guide coat of real paint which was meant to be sanded on and show up the low areas for a second pull of body plastic
Title: Re: SquareD Part 3: Body work, paint, roof rack, and farther off course ...
Post by: stlaser on October 15, 2015, 10:00:40 PM
Jeez, thought you would have this done by now! What happened you break a leg or something?  ???
Title: Re: SquareD Part 3: Body work, paint, roof rack, and farther off course ...
Post by: KensAuto on October 15, 2015, 10:49:27 PM
If you're going to DOT in a (locked) section, at least do it in the right one....the most current one. PART 7 !! haha
Title: Re: SquareD Part 3: Body work, paint, roof rack, and farther off course ...
Post by: Flyin6 on October 16, 2015, 11:44:25 AM
Ken, we might want to ban him again.... ;)
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