REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, BOATS, and COMMUNICATIONS => Build Threads => Topic started by: KensAuto on December 07, 2014, 10:44:29 PM

Title: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:44:29 PM
Note: As with Part 1 and Part 2, all posts from KensAuto, here forward, are from Flyin6 unless noted and highlighted.
Ken

Look what showed up in the mail!
(http://i.imgur.com/21eEboM.jpg)
(http://i.imgur.com/Xwvpdbt.jpg)

Yepper, that's 57 gallons of diesel fuel fun!
The last pic says it all
First it is the correct tank
and most importantly, Made in the good ole semi-commie U-S, of A!
No cheapo chinaman or nippan crap in that beauty!
(http://i.imgur.com/aPuKSQu.jpg)
(http://i.imgur.com/d3niatb.jpg)
(http://i.imgur.com/ACIpaq2.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:46:27 PM
OK, lets get busy with another project. Actually two projects intertwined. I'll be installing a Titan 57 gallon fuel tank and relocating the AD165 fuel lift pump.
I started with draining the fuel tank. I ran it to below empty so I didn't think there was much diesel left. Wrong! I drained nearly 5 gallons, and managed to save enough inside to pour all over my head, chest, well everything sometime later

Here's the start, blast shield off and things comin' on out. I noted about 20" ground clearance with the near factory setup with the Alligator Diesel sump.
(http://i.imgur.com/FUTnlF0.jpg)
(http://i.imgur.com/3xixSVu.jpg)
(http://i.imgur.com/YgNBtAk.jpg)

I drained the water separator filter to see how much water was caught up in there after 15,000 miles
I couldn't find a single drop!
(http://i.imgur.com/i70b5gZ.jpg)

Here's the AD-165 fuel pump/filter assembly where I mounted it some time ago. The new fuel tank will soon occupy that space so that is the other part of this project, moving the assembly.
I will place it on the outside of the frame rail about where it currently is. I shouldn't have to extend any lines except possibly the fuel return
(http://i.imgur.com/SQamzpA.jpg)
(http://i.imgur.com/TbAnIHR.jpg)
(http://i.imgur.com/rzIVVqu.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:49:14 PM
The Air Dog came out easily
After removing it, I pulled off the shield, then cleaned it thourghly
(http://i.imgur.com/SAA6Gkt.jpg)
(http://i.imgur.com/2GRZk0z.jpg)
(http://i.imgur.com/l5WDOPj.jpg)

I'll be using the Cat primary fuel filter and a Balwin water seperator with drain when it all goes back together.
(http://i.imgur.com/PSHakrQ.jpg)
(http://i.imgur.com/RKXILyA.jpg)

Next the factory fuel tank came out for the very first time.
It was not difficult, except to pick out the two retaining clips on the tank return line.
(http://i.imgur.com/K5bgZOL.jpg)
(http://i.imgur.com/fyv0Ggc.jpg)
(http://i.imgur.com/4kMfAiV.jpg)
(http://i.imgur.com/5x4SA32.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:52:01 PM
The Titan fuel tank is a lot bigger!
(http://i.imgur.com/d2YQgWK.jpg)
(http://i.imgur.com/K74zLJK.jpg)
(http://i.imgur.com/7j6okso.jpg)
(http://i.imgur.com/rfs49pq.jpg)
(http://i.imgur.com/QejZ9mQ.jpg)

This is what is inside the factory fuel tank. Mine, of course had the Alligator sump which appears to be in excellent condition.
(http://i.imgur.com/7XYORxy.jpg)
(http://i.imgur.com/qTzwQwx.jpg)
(http://i.imgur.com/krNiFhZ.jpg)
(http://i.imgur.com/BbTUUnc.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:54:15 PM
Using a 2.75" hole saw, I drilled in the hole for the new sump. Titan provides a nice sump exactly for that purpose.
(http://i.imgur.com/h9Aqzui.jpg)
(http://i.imgur.com/aujGvj3.jpg)
(http://i.imgur.com/dAuZOoj.jpg)

Oh forgot to mention that Titan fuel tank is a full .260" thick! Not bad!

Then I drilled all the mounting holes and screwed the alignment studs into the inside the tank mounting flanges.
(http://i.imgur.com/ctmggCz.jpg)
(http://i.imgur.com/ZtPjyZS.jpg)

 like using axle grease to hold things in place, so I packed some into the slots for the two "O" rings and worked them into the recesses in the sump housing.
(http://i.imgur.com/cGBS4ir.jpg)
(http://i.imgur.com/tjxrKVW.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:56:29 PM
Then carefully installed all that onto the new Titan fuel cell.
(http://i.imgur.com/or18DAG.jpg)
(http://i.imgur.com/LuKJNys.jpg)

I also applied a fresh coat of paint to the filter guards. Then I discovered the Cat filter is larger in diameter requiring me to saw a slit onto it's cover so it will slip over again.
(http://i.imgur.com/fKgnIRB.jpg)

A motorcycle jack is perfect to lower and raise the tank into position
(http://i.imgur.com/8xtfVYc.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 10:58:59 PM
Looks sort of lonely under there doesn't it?

All that fluid on the ground, well before I had to wash everything out, is not diesel!
Yea...
After removing the Air Dog, I went about cutting my earlier fabbed mount off the frame. While cutting through, fluid started running all over all at once. Water?? Diesel??
No, neither? And it sure smelled a lot like brake fluid...
Somehow I managed to saw into the main brake line running aft which was well out of the way on top of the frame! I still don't know how I got into that, but I ripped right into it and ruined it. I'll have to cut out a section and splice in another section to repair it tomorrow.
(http://i.imgur.com/WVeJlHh.jpg)
(http://i.imgur.com/w2oGPsu.jpg)

I also picked up a cheapo 5 gallon pail of OptiLube. I figured I needed a bunch since I now have the tractor and Big Red sucking diesel as well, and that ULSD will foul those engine fuel injection pumps as well. THe Case has a Bosch inline P7100 and the J Deere 4720 is a common rail 4 cyl.
(http://i.imgur.com/faVbde7.jpg)

I also threw the Dewalt together in anticipation of starting the tac-topper project again. That means. of course, it will serve as the "DeWalt welding table for some time until I actually start to employ it with cutting something!
(http://i.imgur.com/4s4BPUr.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:00:06 PM
Quote:
Originally Posted by Armalite
"Don, one thing I've been wondering, and apparently its not an issue, is the off set added weight. Anyone calculated how much more extra weight will now be on that side of the truck, and I'm assuming it wont affect anything to drastically, while climbing over the top of off center kias? Just a thought, but you will probably be countering that added weight of fuel/tank by adding products to the other side opposite the tank, hence the clearing of the path on the exhaust pipe...
Just thinking out loud here, and should already know the answer." ...


I did think about it some
The Titan tank carries 21 extra gallons
a gallon weighs 6.8 pounds 21 X 6.8 = 142.8 lbs
The extra area of the tank probably adds in what feels like an additional 20 pounds. So we're looking at an additional 163 odd pounds, which isn't a big number.
You can already adjust for lateral weight bias through adjusting the torsion bar screws. I specificially set up my rear air springs to adjust independently.

Adjustment plan: After filling and measuring I think I'll see what (If any) difference in side to side height I have. Then measure the exact air pressure side to side. Then fill the low side bag until I'm level (side to side) again. say that is an additional 4 pounds of air. I'll take half of that and run the bag at that pressure. I'll also give the left torsion bar screw about a quarter to half a turn and leave it.
That should dial it in to be a decent base setting until I start adding the topper and loading it up as well...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:04:49 PM
OK, another day, well about half of it, working on the titan fuel tank.
If I hadn't cut through that brake line, I would have finished by tonight, but that single mistake is really costing me.
I fussed around with this and that for a couple hours, then around noon went off to the auto parts store to pick up some 1/4" brake lines and fittings to make a repair. I picked up some DOT 3/4 fluid, had lunch then returned to the task at hand.
First I had to remove the coating on the factory brake line to even be able to slide on the male flare fitting.
Next I double flared the ends, screwed that into female union fitting and connected that to the replacement section.
That's where the fun started. After getting it tight, and never expecting a leak, I filled the MC, then while bleeding the rear brake, noticed the leak on one of the flares.
Well, I drained the fluid capturing about half of it to reuse, then cut off the defective end and did it all again. Filled the MC again and went to bleeding the right rear bleeder, the brake that line services. Well WHile getting a lot of air out, I wnet too far, and my son pumped the MC empty.
That little mistake caused me to have to pull both lines off the side of the MC and re-prime the piston(s). So I did that losing another quart of fluid and making a pretty big mess. While bleeding the brakes again, I noticed the leak reappeared at the same fitting! Damm!!!
So I corrected and tightened that, but not after losing most of the fluid again. At the present time I have a spongy pedal, but at least it does not go to the floor, and I am leak free! All of that cost me most of the day and made a mess too large to even think of remounting that fuel tank.
So I then decided to concentrate on getting the pump remounted, which I did. Here's the start of that process:
(http://i.imgur.com/R7pOLfX.jpg)
(http://i.imgur.com/Saaq79I.jpg)
(http://i.imgur.com/RqQyZRM.jpg)

Actually, here's the brake line repair which is not seated and stowed in these photos. It all gets a lot neater...
(http://i.imgur.com/Ji2eW7u.jpg)
(http://i.imgur.com/JPb4gAL.jpg)
(http://i.imgur.com/9KGyg39.jpg)
(http://i.imgur.com/E9Q013J.jpg)
(http://i.imgur.com/I9LSaQ6.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:09:12 PM
The fuel pump will now reside outside of the frame rail about a foot aft of where it mounted before. I fabbed up a top and bottom frame bracket. The one shown sets on the top of the frame and has two studs to capture the top filter mount. It wraps around the top of the frame, then will weld to the inside of the frame and is constructed of 3/16" steel.
(http://i.imgur.com/7MEsagb.jpg)
(http://i.imgur.com/DvFSprK.jpg)
(http://i.imgur.com/w5iyGle.jpg)
(http://i.imgur.com/QkHASTq.jpg)

Here is the part that holds the fuel pump, upper mount. THis part got welded to the frame capture bracket.
(http://i.imgur.com/iYKcnmx.jpg)
(http://i.imgur.com/LYpYY4L.jpg)
(http://i.imgur.com/FPBEM1O.jpg)
(http://i.imgur.com/owKbY6p.jpg)

Here's the spot, and the upper mount welded in place with the filter hanging for bottom bracket alignment fitting
(http://i.imgur.com/7sZpXZQ.jpg)
(http://i.imgur.com/LQUn5DY.jpg)
(http://i.imgur.com/3LpyKCS.jpg)
(http://i.imgur.com/52VtRCn.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:12:00 PM
I welded in the lower mount, but forgot to get pics. It needed final grinding before it is presentable.
Anyway I screwed on the old filters once again to seal it all up against the grinding dust. Here's how it sits with the steps stowed in the travel position:
(http://i.imgur.com/4LeprsA.jpg)
(http://i.imgur.com/gI4hQvR.jpg)
(http://i.imgur.com/HSkLaOA.jpg)
(http://i.imgur.com/YWNrKWi.jpg)

And with the steps down:
(http://i.imgur.com/2aVjFnH.jpg)
(http://i.imgur.com/VEKK8zo.jpg)

Here you can see the difference between the AD and the CAT filters and the phenolic tabs which made the CAT filter unhappy:
(http://i.imgur.com/yDRRYk1.jpg)
(http://i.imgur.com/mcIQykr.jpg)
(http://i.imgur.com/4XHqLHt.jpg)
(http://i.imgur.com/BoMZVdf.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:13:03 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:16:01 PM
The Titan fuel tank project is now complete along with the Air Dog relocation.

And

Surprisingly

Thanks to Nick, and Willie, and Holton

It all works!

So's eyes started with the modification of the Air dog pump, removing the two plastic blocks and grinding of the bracket as Willie advised. I shortened the bolts and ground away the inside corners of the pump bracket for clearance on the larger diameter CAT 2 micron filter.
(http://i.imgur.com/nT4PZXh.jpg)
(http://i.imgur.com/Bxr9L8F.jpg)
(http://i.imgur.com/9NBbrTT.jpg)

Again, the focus of my now failing camera is set to make things clearer for me, which is blurry for the rest of the world...In fact I'm having trouble hitting the right "F" key, since when I look down between the space between my two hands, I see two "F" keys in stead of the one I am accustomes to seeing! I have learned if I aim at the right "F" key it usually works out for me!

Here's what the filter mount looks like after grinding, cleaning, and painting:

Note: I ground away all of the bracket where something used to mount in front of the tank. Titan says to leave some of it to support the fuel lines, but Big Don says to hay with all that nonsense, get dem sharp hole in tank grindin' edges outta' there!
(http://i.imgur.com/ubMI65p.jpg)
(http://i.imgur.com/PhmJ9z7.jpg)
(http://i.imgur.com/IJguIyc.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:16:12 PM
If you're wondering if the emergency brake cable catches on the Air Dog mount, well, it does. In fact I rigged a neat little toggle switch that fits into the cup of that cable so that when I set the brake, the cable snags the switch throwing it off. That switch controls the fuel pump circut, so the pump is automatically off when the vehicle is parked over night!















Anyone buy all that?
Whoever did, you just validated the low quality and standards of our failing education system!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:17:52 PM
Then the Air Dog was perminized at it's new address! Pretty colored filters were added, and blue lines were plugged into various holes.
Lines were not secured at this point...
(http://i.imgur.com/CAtuFyt.jpg)
(http://i.imgur.com/ggH33rS.jpg)
(http://i.imgur.com/C6zQcvN.jpg)
(http://i.imgur.com/YvaZL7K.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:20:05 PM
I almost left the one line hanging in the loop there, sort of like the tailhook of a B52.
Oh, a B52 doesn't have a tailhook?
Well it should!
Problem with that was the tank was going to get into my nifty emergency stopping device, so I abandoned that idea and pressed on.

I zip tied everything together, even things that didn't need it to include my newest dog which was coming in doing vicious attacks on me. You see when I'd be in some akward position on my back with one hand balancing something and the other hand working a tool, that little devil would run if and start viciously licking my face. I'd yell, squirm and eventually drop the nut or wrench I was holding, and lash out at the dog that was by then about 1inch outside my swing...she's smart like that.

Well, not to be out done with an animal with a brain the size of my thumb, I made a loop out of a long zip tie and assumed the position. I watched her take up station keeping just beyond the old fuel tank, nest to the Dewalt welding table and chop saw. I started to utter my favorite blessings and grunt and just like clockwork she attacked>

HA! The game was afoot! I snatched her up much to her surprised and wipped that zip tie around that shout of hers and gave it a yank! Lassoed, garage project style she was and struggling like a prize marlin after 20 minutes of fight! While she was pawing and struggling with the thing on her shout I grabbed my handy air ratchet, stragetically placed it behind her and pulled the trigger. Yup, scared the living stuff) out of her. She departed straight out toward the light at about mach 2, peeing the whole way.

Mission accomplished, except that I had to hunt her for awhile to get that zip tie off. WOuldn't ya know it, she found refuge under the holly bush where I scratched my hands all up wrestling her through all thise briar like sticker things.

Not sure who won the day, but I'll call it a draw and I didn't get harassed anymore!

OK, I forgot about the build thread thing...
(http://i.imgur.com/RtuuyE4.jpg)
(http://i.imgur.com/lUwDyi6.jpg)
(http://i.imgur.com/T43BSm2.jpg)

Next the tank itself was prepped and again, I zip tied the lines together and gave them a couple wraps of electrical tape to hold it all in place for assembly
(http://i.imgur.com/jQEbzII.jpg)
(http://i.imgur.com/xccAOZN.jpg)
(http://i.imgur.com/yUbivIF.jpg)
(http://i.imgur.com/nSgT16B.jpg)
(http://i.imgur.com/1nkYtPA.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:21:42 PM
That tank then witnessed it's last couple minutes of daylight as it was slid under the vehicle to begin the connections.

That process is relatively easy although awkward and hard to get into position to hook up the vent, filler, and sending unit

But as with all things, it yielded and with the help of my handy motorcycle jack, also slid home

THe Titan straps seem adequate, although I would perfer something a little more robust. I placed the rubber isolator straps between the steel straps and the tank and secured it in place.

I found that by sourcing slightly longer M-whatever metric bolts the process is easier.
(http://i.imgur.com/M6QgWdU.jpg)
(http://i.imgur.com/1ocOLLX.jpg)
(http://i.imgur.com/lRg30cK.jpg)
(http://i.imgur.com/aAAT43N.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 07, 2014, 11:24:46 PM
Last on the to-do list was to make the sump connection.
You may recall I had angled the sump fitting on a 45 degree angle when I installed.

You may have noticed I did that with the tank on it's side
That makes everything sort of inverted in a parallel universe, or on layman's terms: Backwards

So I unbolted that, and clocked it the way I had intended in my universe and made the connection.

You probably can't see it well, but the line is actually bolted to the frame and tucked in tightly, although I plan to do a little bit more in a couple days to shield and protect (Sounds like something I read on the side of a police car!) the now exposed line.
(http://i.imgur.com/Hkcsk63.jpg)
(http://i.imgur.com/w5gLuvy.jpg)
(http://i.imgur.com/stZBM8u.jpg)
(http://i.imgur.com/unY2El4.jpg)

During the short test drive I used Nick's suggested procedure to clear the very spongy brake pedal. Acclerating then slamming on the brakes hard. THe anti lock engaged and Voila'!! Good brakes!
Thanks Mr. (Sergeant) Nick (And thanks for serving my brother!)

Then I did the leak test. I do that by parking my truck on a parch of clean driveway which is hard to find. I leave it overnight and check it in the morn'

Well, it rained around 0600, so I have no clue what leaked if anything except for the sky, but it seems OK.
Another indication is the sled dog. You see she licks anything that leaks or falls to the ground. If it is fuel, oil, antifreeze or the like she gets sick. SO by observing her you can tell if something leaked. Diesel gives her the runs, brake fluid, grease, gasket sealer, paint, and latex paint makes her sick, and I believe Anti freeze would kill her.
So, she is alive! Good, no antifreeze leak!
But she has the runs, so...???
(http://i.imgur.com/Q1oLLwN.jpg)
(http://i.imgur.com/dOxZvAX.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:25:04 PM
Today I decided to get the rear view camera working once again, or rather install another one that will feed into my GPS.
I decided to use an audiovox unit and custom mount it
Here's what I started with:
(http://i.imgur.com/PJcwznO.jpg)

Yes, that's a new OSB welding table...hope this one last longer than the old one and at least as long as the cardboard welding table!

Looking at the bumper as supplied by Travis at Road Armor, I noticed a hole which seemed unoccupied and in fact seemed purpose cut to mount a camera.

It measured just under an inch at .95" A quick check put the camera barrel at a very close .90"
How could this be, a no drilling, no welding, no nothing camera install???
See for yourself:
(http://i.imgur.com/uAwRIv7.jpg)
(http://i.imgur.com/UGWswbU.jpg)
(http://i.imgur.com/LjJyVyS.jpg)

And here it is just a couple minutes later:
(http://i.imgur.com/XpqLzB3.jpg)
(http://i.imgur.com/NubTm8A.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:27:40 PM
At this point, since I would be splicing into the back up light cirvut, I decided to install a couple of LED work lights I had purchased some time ago.
They are super high quality units boasting solid aluminum castings for housings and stainless hardware. I believe I'm going to be adding these gems elsewhere as this build progresses.
(http://i.imgur.com/KagX9j5.jpg)
(http://i.imgur.com/jwZlrE7.jpg)
(http://i.imgur.com/1U6yIpA.jpg)

To mount them mo-easily, I welded a 3/16" stainless screw to the bracket then bolted it all together.
When I installed them the first time, I immediately noticed the light mount placed the lamp way too high.
To somewhat alleviate this problem, I ground dowh the light housing and the top of the "U" bracket, the redrilled the hole through the housing, lowering the lamp a bit more than 1/2"
It's still too high, but it's the best I can do without cutting on the bumper.
(http://i.imgur.com/WlolDZy.jpg)
(http://i.imgur.com/P5c994l.jpg)
(http://i.imgur.com/rrM0ll3.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:33:29 PM
After fishing the green wire which supplies power to the BU lamps, I soldered in both power wires from the lights and the power cable for the camera

The initial test proved everything was working so far
(http://i.imgur.com/nXvKL0H.jpg)

in this pic I have just started to tidy up the loose wires. I am stuffing them inside various size looms, the zip tying them to other cables. It is starting to look like stock.
(http://i.imgur.com/PVgT6wX.jpg)
(http://i.imgur.com/cB75d7s.jpg)

I'm not done with lights on the rear bumper just yet. I never installed the lisence plate illuminators so that's next. I acid dipped the chrome housings then painted with primer and black paint. These will get soldered into the factory harness so the hookups will be same-same as chebby intended.
(http://i.imgur.com/Vmk13h7.jpg)
(http://i.imgur.com/TZzES2e.jpg)

Here's how I left it for the evening...We'll be back on it in the morrow...
(http://i.imgur.com/PXDXe8B.jpg)
(http://i.imgur.com/8cs8wax.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:35:33 PM
 just posted this on another thread. Regarding the Y-Bridge that Calvin at T-Rex is building, read below:

There is a plan afoot!
Talked with Calvin. He is going to modify your unit or someone else's. Someone just shipped one back, so I assume it is yours.
Anyway Calvin is going to mock it up and take a look at this interference issue. He is going to make a small bend for clearance. After that he is shipping the part to me. I am then going to do an evaluation, fit it up and all that and if necessary make adjustments. When both of us are happy that the thing fits, Calvin will use that part to make the new ones from.
So hold tight, this is going to be a 10 day to 2 week event to get it right, but when done, it will be right.
If the thing doesn't work, I'll say so and that will be that. I don't think that will be the case. I think Calvin has a good 75% part at the moment that just needs tweaking, not a redesign. So patience is the word, (As if there were any other choices)
Calvin feels remorse for getting the part out there a bit too soon. He responded to felt pressure to get a new part into the hands of people who really wanted it and perhaps (Don talking here) jumped the gun a bit. But I see it as a good thing. He jumped the gun because, sure he wants to be the first on a new part, but think about it. He DID produce the part. He does care enough to invest his personal time into building stuff for a small market. And for that he deserves credit, and he has my support. I'll support him as long as he does the right thing, and I think he is trying to do exactly that.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:43:29 PM
                                                                                      (5901)
I finished the back-up camera addition. I split the cables and have it running to both the Edge CTS and the Kenwood stereo/reciever/GPS.

I also fashioned up the stainless steel skid plate for the bottom of the fuel tank. It is just a partial plate which I feel only needs to protect the sump and lines which are secured however could possibly be snagged.
I am not settled on this as a final design, however just something I threw together to keep the brush out of there during my off road farm trip excursions.

I used a piece of .032 sheet stainless steel. You know the type which you can't drill through if you tried. By keeping it to .032" it remains somewhat flexible, but totally puncture resistant.
It covers most of the stuff under there and is held very securely in place with HVAC nylon zip ties.
(http://i.imgur.com/gp7Ea26.jpg)
(http://i.imgur.com/edNOstQ.jpg)
(http://i.imgur.com/Gf1mkqJ.jpg)

Installed:
(http://i.imgur.com/9KO3iA5.jpg)
(http://i.imgur.com/mfxzwQP.jpg)
(http://i.imgur.com/0Uy0n7k.jpg)
(http://i.imgur.com/gkwwQNO.jpg)



Here it is:
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:46:00 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:47:49 PM
On another subject, the Y-Bridge Calvin is making, I just posted this message on another so named thread:

Just got an email from Calvin.
(Edit: I am refereing to the gentleman who posted that he had returned his ill fitting Y-Bridge to Calvin)
I guess he got two back. Yours and another which he said was in three pieces. Not sure if it came back in that condition or Mr. Calvin cut it up himself.
Anyway, he is upset all this happened and is trying to make this good. He is modifying your part and shipping it to me on Tuesday. I'll have it in a week or less and have it on the next day so we'll be able to move this ball downfield to maybe a touchdown???

Anyway, hang loose for a while longer and we'll close the loop on this Y-Bridge issue.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 08:59:12 PM
OK, fellow Y-bridge watchers:

I just got the modified unit in from Calvin at T-Rex for a fit check.
Evaluating it with my Mark-1 eyeballs which are finely calibrated instruments of combat diaster and burned meals (As of late) I can see a rather obvious dent hammered into the thing by way of a acetylene torch and a ball-peen hammer.
Hopefully this is not production quality stuff, but pre-production only and sent to me for the purposes of checking clearance from the CP4A fuel line that has caused all the flap.

With this pre-production concept in mind, I will say the area which is not all bammered and burned up looks good, consistient with Calvin's quality.

I'd say we have to make this dent uniform and address a flap of steel protruding in the inside and if the part fits, we'd have a keeper.

Here's what I am seeing:
(http://i.imgur.com/2zf4Xg2.jpg)
(http://i.imgur.com/YzCwrDX.jpg)
(http://i.imgur.com/DUFzxaZ.jpg)

Some more shots
(http://i.imgur.com/abgfDMo.jpg)
(http://i.imgur.com/NhLh3hp.jpg)
(http://i.imgur.com/I4JIQtA.jpg)
(http://i.imgur.com/QzXNC5h.jpg)

And the part I'm not liking so much, the interior flap. I think there will need to be some additional grinding on the production unit to get rid of this piece, which I'm sure we can work out.
(http://i.imgur.com/CjgiWEv.jpg)
(http://i.imgur.com/WNa96EN.jpg)
(http://i.imgur.com/OHLktXW.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:02:52 PM
I got the test fit of the Y-bridge done today.

It is a total no go! OK, Lets go through this thing.

I had a whole writeup on disassembly and so forth detailing the tools required and steps necessary, but that's a waste since this piece will not be manufactured and is now only a test piece.

I'll show the Y-bridge details for those who have never seen or explored one. It is fairly restrictive and needs to be replaced.
Here it is:
(http://i.imgur.com/A1EUVhW.jpg)
(http://i.imgur.com/iEsDQJm.jpg)
(http://i.imgur.com/mvI1TtE.jpg)

Interior view:
(http://i.imgur.com/5cniMN7.jpg)
(http://i.imgur.com/Ut8GuWU.jpg)
(http://i.imgur.com/1By76mJ.jpg)

And for those who have never seen the right and left manifolds, here they are:
(http://i.imgur.com/IRncqfj.jpg)
(http://i.imgur.com/up0CTr5.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:04:20 PM
Here is the T-Rex Y-pipe about as close as this guy can get it:

You can clearly see the Y-pipe resting on the fuel supply line!
(http://i.imgur.com/cniaZEG.jpg)
(http://i.imgur.com/FhuPSUt.jpg)
(http://i.imgur.com/F2DLeiO.jpg)

This is how far at the top side that gap from below translate into!
(http://i.imgur.com/iEB1RTn.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:06:28 PM
I think we need to revisit this process again.

With that said

This part was known not to fit. It was sold to 4-5 people. This particuliar part was modified and "Fixed" and sent to me to make sure it was all good before release to the GP.

Next we are going to look at the T-Rex upper cold side intercooler pipe that I just removed...There is rust forming on the inside
(http://i.imgur.com/ypOXdyb.jpg)
(http://i.imgur.com/REBIWPo.jpg)

I wire brushed the living heck out of the pipe, washed it with laquer thinner, then painted it up with blitz black to try to corrosion proof it.
(http://i.imgur.com/ltOPEt8.jpg)
(http://i.imgur.com/kALijEB.jpg)
(http://i.imgur.com/ao0wzww.jpg)
(http://i.imgur.com/D8b2ImG.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:08:20 PM

BTW. I did some experimentation with moving that line. Here is some shots of it unbolted.

Note: Even with it unbolted it could not be bent, IT is formed os some high strength stainless and I feared something that strong will also be brittle. With 10,000 psi inside, you don't want to intro a stress riser (Pre-crack)
(http://i.imgur.com/Bsd7wkG.jpg)
(http://i.imgur.com/v6wFEba.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:08:40 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:12:40 PM
More Y-Bridge news
Calvin and I just had a marathon phone conversation.
I was hanging over the fender of my truck while he asked me all sorts of questions to give him a better idea of what's going on in there.

Together we came up with a great idea that just might work.

Instead of running a round 3" pipe down to the bridge, why not run a oval made from 3" pipe. Then instead of angling it over toward the cold side, stand it more straight up and lean it forward.

That should clear everything and get it to fit.
Here's the best part...While hilding and looking at the very poor factory design, and understanding a thing or two about transonic airflow, it occurred to me this thing could prevent boundary layer air seperation and the resultant turbulence if we just built an angled fence on the short side of the bottom of the bridge

W O W

That will make a huge difference in airflow, or at least getting that high speed column of air to make the turn.
Good news is Calvin is up for it, and with another set of flanges he has is going to start on the redesign tomorrow. We will work together closely and see if version #2 can be all that we want it to be!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:15:45 PM
So Mr. Kory, you are obviously a turbo guru to be sure...What say ye about a single built turbo unit vs a compound setup for daily use on these LML's?


Response by bluessmax (kory willis):
For 600 and still have stock spool just do a 475 over stock setup... It was very fun on the one I rode in.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:17:41 PM
Quote:
Originally Posted by Armalite
Kory, if you don't mind, where would you see the compounds be the most versatile option to go with?


Kory:
Everywhere... That compound setup is AWESOME up to roughly 685-700hp. Past that point the stock turbo becomes much like a kink in the air system. H&S made 750hp fuel only, but the limiting factor to it being 750hp was by far the stock turbo. Pretend you have a straw (air system on the engine) that flows great, now lets take that straw and add small coffee straw (stock turbo) at the end and try to blow. What happens is the stock turbo opens the vanes all it can to not overspin itself, however, it has A TON of air trying to get though it and it can only physically move so much. At this point we have a ton a back pressure which creates EGTS and is stressful on components.

So up to 650-700hp that setup is very fun all around and still very efficient. Much better for towing as well as long as everything is in its efficiency range.

Hope that makes a little sense on turbochargers.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:36:38 PM
OK Y-Bridge stuff

Calvin will have this thing done today I think and in the mail to me ricky-tick.

The plan is for me to bolt it up again and see if we do any better than last time.

Here's the pics of the redesign:
(http://i.imgur.com/nwTYpTF.jpg)
(http://i.imgur.com/NA1DWn5.jpg)
(http://i.imgur.com/4yiUq6j.jpg)
(http://i.imgur.com/RHBrUWt.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:47:45 PM
I remember this list, put together by Armalite, one of the times we took over Don's build thread:

Future Install Recommendations, or FIR's, for Don's truck...


1. Armalite - Exterior Snorkel

2. stlaser - 4 link w/ coil overs

3. Barnett performance - roof rack

4. Camaroz2866 - hidden lock box for ammo/guns

5. KensAuto - 5 link w/ coil overs

6. BobbyB - spare fuel cell under bed

7. Cruizing - communications center including Ham Radio, HiGain CB, Cellular WiFi, SatPhone

8. Cudakidd53 - on board compressor w/ impact & bumper jack
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 09:55:28 PM
                                                                                                    (6846)
I'm going to use my thread here to conduct a small survey.
How many folks out there would like to investigate a solid axle conversion for the LML HD trucks?

I am currently talking to off road unlimited about such a project.
My vision is to keep it simple and rugged

Long and flexy leaf springs with dual shocks or a 2.5" or 3" front shock.
Dana 60 high steer with a traction device and of course one of those really cool GLO diff covers and a not too tall 6"-7" lift height.

Murice over at Off road unlimited does not make a LML kit, so I may be interested in adapting his existing stuff and figuring it out for the rest of the folks out there.

Now, the truck already has an excellent, well sorted out front suspension. It does most things well, but does not have a great deal of flex for more aggressive off road situations such as my survival truck build would encounter.

I estimate I really need about 36" suspension flex, front to rear to adequately crawl over most Hyundais and Kias since those flimsy pieces of junk all crush down to the size of their poorly designed motors anyway. Since Americans have seen fit to clog up our by-ways with those things along with a healthy supply of Dodge Neons, I want a suspension capable of crawling over that junk on my way to freedom.

So, what say ye about this?
I'll post up on another thread to get some coverage...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 10:03:39 PM
Posted by A****:
Don. Why do u wanna run leafs instead of a 4link. Wouldn't u get more flex from a parallel 4link then leafs? And you can dial in the suspension better than with leafs

...by KensAuto:
Yeah Don, why not a 4 link? front and rear ? rofl


Don replies:
The last SAS I did was a 5-link.
4-Link Plus a panhard
Fellas, that's a lot of work. Angles are critical and easily messed up. Not as easy as it may appear. There is a ton of fab in there doing that and it really changes the vehicle.
The end links/uniballs are expensive and so are the coil-overs. Then there's all that messing with spring rates, length of stroke, valving and so forth. If you haven't done it, there is a book worth of information you are not considering. It is not as simple as just tossing a coin.
When I did my Tundra, I was the only one in the world who attempted it. 8 other guys went with leaves. All got their SAS done quickly and the best of them could do 80% of what I could do. It took me a year to get it installed, cut out, reinstalled and working correctly.

Leaves are strong. They are simple. They give you a ton of travel. They are much stronger than those link arms. Lots and lots of parts in a full link setup. All those parts are constantly corroding, wearing, needing grease, squeaking, rusting, needing maintenance, and so forth.
Springs...Not so much.

If you want to go uber cool, and cost, time, don't matter, then link it up and make sure you powder coat it up some pretty color...Show stuff.
If you want it to work 6 years down the road, leaf spring it and forget it.


Quote:
Originally Posted by KensAuto
Easy there Big D ! All kidding aside, I would leave it stock. An SAS front end build would be uber (yes I said uber) cool and all but you could do 20 other projects in the time it would take to make it up to your standards and to work the bugs out. plus these LMLs ride pretty darn good considering how much stouter they are compared to the past generations. Just my humble opinion.


Special K

All true. There is a strong argument for staying with a stock style suspension. It needs scads of work, to, well, work
It needs that UCA droop stop removed
That necessitates a mo-better and longerer shock. Might just as well make it larger diameter and cut some steel out of the way to get it in there.
I think the tie rod ends I have accommodate more angle, but that would have to get looked into
The sway bar would have to be a disconnectable. and finally the axle shafts would have to be changed to some of those RCD units made of core stellar matter (Anti matter forged in Mt. Doom)
All that gets a suspension capable of flexing maybe 2"-3" more at best.
OK, I can work with that
But it won't ever (Even in leap year) out wiggle a SAS.
Then with the SAS you get to pick stronger everything and even add a locker whichins we kant do nutin bout at the present time!
So, all that spawned the question I raised with Murice at ORU some time ago which has led us to this point.
Nothing has been decided, and nothing may come of it. but I am definitely asking the question.
In the end I could opt to refine the IFS like I did on my Hummer H2. It worked fine as long as you don't mind a wheel hanging 5 feet in the air sometimes!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 10:08:33 PM
Posted by KensAuto:
have you measured your current amount of flex? Can't remember if you posted it or not. I just finished rebuilding my forklift and guess what the first thing I did with it was.....yes, I lifted a front tire to check flex.....got exactly 19". Not to sure what I expected to see, but at least I can say my forklift works. [color]

Ken,

The 19", that was front to rear, correct?
If it is like most IFS vehicles, then 70% of that flex is in the rear springs
Doing a bit of cipherin' I come up with 5.7" flex in the front which sounds about right.
Pitiful isn't it?
But that's what engineers do these days. They design around their road courses. They measure the largest impact reaction and build something to accommodate that plus a small margin.
By comparison, I got 40" of travel out of my SAS Tundra after I loosened up everything on it!

...KensAuto:
[color]].....yes, just lifting a front tire 'til the rear tire started to break contact with Earth. I didn't have time to measure in detail what was flexing. I had customers showing up and looking at me like I lost my mind so I dropped the truck and went back to work as if I always lift vehicles that way to check for leaks.[color]

 Yepper!
That is about right!
Less than 6" suspension travel in the whole front end!
Most guys don't realize just how little they get
When I measured the Tundra I got a tad over 3"
That made me sick enough to cut the front suspension completely off the following day to force me to change it to a SAS!
That's why I haven't measured mine yet...You see, I have a better plasma than I had before!!!!!!!!!!!!!!!!!!!





Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 09, 2014, 10:13:02 PM
Special K
How about doing it all again and take a bunch of measurements
That way we can see exactly what is going on
Of course if you want to see Don leave his stock suspension intact,
Then
Disregard this message!


...KensAuto:
I'll get right on it! Gonna try to do it on concrete this time to be more accurate ......3" on a tundy is just wrong any way you slice it.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 10, 2014, 10:05:18 PM
Posted by KensAuto:
Checking articulation :
First, I checked from top of tires to bottom of fenders, front and rear. I had 11" in the front and 11 and 3/4" in the rear (average, rounded to nearest 1/8"). Lifted it with the forklift and remeasured all corners.....
 (http://i.imgur.com/kQy231i.jpg)
(http://i.imgur.com/w4KPC2X.jpg)
(http://i.imgur.com/BTostpO.jpg)

.....I was surprised to see only 1" of compression in the front left and 2 1/4" of extension in the front right (it was still partially loaded) for a total of 3 1/4" travel. And the last pic shows one of the reasons why....she's hard into the bump stop. Part of this issue is because of the 4-6" lift that is set at 4". And as Don predicted, the rear was very flexy. The rt. rear compressed 6" and the left dropped 7 3/4 for a total of 13 3/4" of travel. The front tire was also 19" off of the ground.

Note: I went back and got a true drop on the front using a floor jack and ended up with 6 1/4".
(http://i.imgur.com/LKZ7vkV.jpg)
(http://i.imgur.com/SSP2wrk.jpg)
(http://i.imgur.com/yfBzJRL.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 10, 2014, 10:06:14 PM
...And that is why we look to SAS!
Factory suspensions ride very well on roads and smoothness sells vehicles. Get 6 feet off a dirt road and you're in trouble.
The reason we need more suspension travel off road is that the act of lifting a tire or lessening its ground pressure reduces traction dramatically.
With the tundra, I was off roading it when it had a "lift" and the factory junk suspension. I drove over a rock about the size of a football. (No kidding, not making this up) The truck stopped. I set the brake, put it in park and investigated. That tiny front suspension travel was taking weight off the rear tires. One lost traction and began to spin. With an open diff, I was cooked!

For serious off roading you need to keep your tires planted and the only way to do that is to keep the tires not only planted, but firmly planted. Then you take advantage of all the terrain and not just three patches of it.

The difference of my stock Tundra vs the flexy one was dramatic, just take a look at what I was doing with it:
(http://i.imgur.com/OmFC2Uq.jpg)
(http://i.imgur.com/5Beqinr.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 10, 2014, 10:09:25 PM
Quote:
Originally Posted by C**********
Would you say trimming the uca stop a little to give it a little more travel would be beneficial as long as not giving it too much to break anything? Is their room to allow the axles, sway bar etc. to allow the stops to be trimmed some without having to switch out parts etc.?

                   
I would say DEFINATELY DON'T DO IT unless you are ready to replace the newly stressed parts before driving the truck again.
Think about it. If you now allow the arm to droop out to a point where the maximum tie rod angle is exceeded, you could crack it or pull the ball out of the socket. Then you drive away only to have your steering completely fail while on the road somewhere. My luck I would be adjacent a rocket fuel plant and go careening into a storage tank!

The travel of our front ends as just shown by Ken on this thread is pitifully inadequate. He was getting closer to 3" total travel than the 5.1" he thought he had. That's just a little more than nothing.

The more I think about it, the stock stuff is not worth fooling with. I mean you monkey with it and introduce a whole host of issues you now need to solve. You buy parts, get alignments, and fuss with things and after it's all said and done you have a suspension which can flex, what? Six inches tops?

See where I'm going with this. The benefit definitely does not outweigh the effort nor the cost, so I think maybe it is a big no-go.

I think I just decided to do a SAS on my truck and stop playing around with this nice ridin' factory stuff. After all my truck is a focused survival vehicle. If it can't survive leaving the road at speed, then what do I really have? Seems it's more of "I hope it will make it" and not a "I've got this in the bag!"
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 10, 2014, 10:14:05 PM
Quote:
Originally Posted by stlaser View Post
Oh NOooooooooooo! The dreaded coil overs and link suspension!

Gets worse young Sky-Walker

                                                                                                      (6896)
Talking to WFO Concepts today about SAS and my truck, they think because of the bend in the frame it might get too tall if I use leaf springs. The young man there was all over getting me to try out a 4-link, or a 3-link old bronco style setup. Actually, I'd be much more in favor of the latter. Keeping with my KISS principle way of approaching this project.
He advised that the only axle to consider was a 78-79 HPD-60 out of a Fard F250, F350.

...Contacted WFO Concepts today
We talked about the SAS project for some time
Seems like they have it going on, think like me and have a lot of great parts I can use.
So I believe I am deciding to press forward with the SAS.
They did advise me to only go with a 78-79 F250 HPD60.
He was thinking that is the only axle that was HD enough and actually had room for the 32" spring perch pads if I went with leaves.
They were pushing a 4-link or old Bronco three link style hard. That would be a lot easier to fit in there and we all know from experience just how well that all works.
SO that will be the plan for now:
3-Link, Panhard 78-79 high pinion Dana 60, and coil overs. I think I might go wild and crazy on that count and source a 12" travel 3" shock and add in a 2.5" X 14" travel rear shock. I could drive over single axle dump trucks with that setup and still have junior sleepin' like a kitten in the backseat. I am also going to add a front selectable locker, stay with 4.56 gears and step up to 37's and possibly 38's.
I guess it's time to start gathering parts, so who has that axle???????

 
Wouldn't happen to have one would ya???
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:08:34 AM
Quote:
Originally Posted by KensAuto
Can't wait to watch this pan out. I have also decided to modify mine in a way to get more action up front....1" before she bottoms out, mmmm, maybe that's why it's so rough down washboards and so darn smooth on the street. My problem is, I take offroading/hunting pretty serious, but where I'm located I have to drive 120-240 miles to get to the offroad part (and I drive faster than posted...always). Got to try and balance high speed driveability with at least some offroad prowless.

Ken,
If you pay attention to spring rates and shock valving and keep the shocks big in diameter, you can drive it just like you do now. I drove my Tundra just like a car. Folks were amazed at how it drove. One time a Taco guy told me my SAS Tundy drove better than his near stock Taco.
Working with a heavy truck should actually make it all work better. It's when you get little to no weight and you're trying to get that to act on big shocks that is more of a problem.

Well, this thing won't happen overnight, but as soon as I get it more cyphered out, I'll get some parts rolling in.
My plan of attack will be to acquire the axle first. No sense in pressing on if I don't have an axle. Once I get that I'll get the whole thing completely built to include the steering (High steer of course)
Then I'll get the shocks. I'm partial to King, but Fox makes some good stuff. I'll talk to the smart guys and have some good data (Corner weights) and so forth to go by. Only when I have all the parts on station will I commence teardown.

I'll probably build a total custom sheet metal shock tower and get that 12" shock in there. Now, for those who don't know shocks, that 12" referes to the stroke, not the length of the shock. a 12" coilover is more like 30" long fully extended. Not small stuff at all! No real need to go to a 14" shock as that would produce 28" difference right to left not counting any rear flex.

I'll probably build in a 60% rear to 40% front travel bias. That means loosening things up in the back and some longer 16" shocks back there along with some flexier springs residing in the back.

Anyway, It's time to find that axle and gather information and some parts, so let's go. Find me that axle!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:11:00 AM
Quote:
Originally Posted by stlaser
Yes, but it's been narrowed & is currently residing under an EB.....

I say build it from scratch, I can help you acquire parts as you know. The ford axle probably wouldn't have the pinion in the exact spot you want anyhow. Plenty of companies making those after market ford arms & I have track bar frame mount drop brackets sitting in my shop that have not been listed on the site yet....

I think I'll use the concept, but not the Bronco parts. I was thinking of tabing it just like I was doing a 4-link, but then just run the lower arm, then the upper length adjustable link (For caster adjustments) from the lower bar to the upper tab.
I'm sure you have seen all that before.
I think I'll keep the arm relatively long to keep movement down and lessen impacts from the whoops...
So you want to build the HPD60?
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:15:27 AM
Here's the cap I am considering to replace the tac topper project with:
(http://i.imgur.com/SX6pwiu.jpg)
(http://i.imgur.com/rV7Qc1v.jpg)
(http://i.imgur.com/GIedEuZ.jpg)


Posted by Armalite:
Don, I like the new progression. The tac topper was a neat idea, nothing wrong with that. But there is always something better suited out there, most of the time. I feel you are making the right decision by scrapping it and going with one pre-built, so all you have to do is modify it some to fit your needs.

I honestly feel you will look back in a years time, and think "man, what was I thinking on that tac topper?? Cool concept, but a lot of invested time/money for a sub par over weight project."

That new commercial topper will be ALOT sturdier as well, by utilizing the contours of the bed and bed floor for support, and not just the side rails like the tac topper was going to use...

Push forward...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:15:57 AM
Yea, it's starting to feel like I need to buy the ARE unit and modify to suit.

Afterall, I'll be in fab city for a while with this SAS project!

BTW, if Me and Shawn get that sorted out, you going to go for one as well?
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:17:00 AM
Talking to El Tate over at Randy's Ring and Pinion. I will be getting all the moving parts from them. Great shop with friendly people. Same ones that helped me with the locker and 4.56's last year.

Found a shop in PA. that has some F350 High pinion D60 cores. Will be contacting them and getting started on that.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:17:36 AM
About two hours ago I purchased, well ordered an ARE DCU aluminum commercial topper. It is very much like the one pictured on that F350 a few posts back.
That one was a 26" unit, I ordered a 29" model. The roof is at 23" so I will have a 6" rise above the roofline.
I ordered it with double barn style rear doors with glass in each and a security screen, a swing up door on each side with double windows in each, interior carpet, 4 interior lights and a foot massager.
OK one of those I just threw in there so any democrats reading this will have something to be angry about.
It takes 3-4 weeks to build so I'm looking at nearly September to get it bolted on.
No worries, I'll have the corner piled up with lights, hooks, gun rack, tractor beam and other stuff before it even arrives!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:18:28 AM
Posted by Dustoff35:
Well that didn't take long... about 24 hours from our discussion to pulling the trigger on the ARE top???

BTW, I saw the new Miller Syncrowave TIG at the NSRA show today...

They have a show special through Welders Supply...

Nice setup...

You may need it for the upcoming SAS project...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:19:36 AM
Buddy, you have a way of making me look at things objectively. When I did after we manhandled that top, I had a "What the heck am I doing" moment.

Yea, I ordered the new all aluminum commercial top already. It's just a matter of time until it gets here.

OK so, if anyone wants the tac topper it's free to a good home, just come and get it!
If you want to pay for it, then send what you would like to pay to wounded warrior and we're good


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:20:24 AM
 was just about to post something related to the words "Build" and "Thread"
But
Instead
Got instantly mired in the sticky going nowhere conversation between a couple of DOTs!
With my advanced age, no scratch that, with all my experience, you'd think I'd see that mine field and steer clear.
DOTs are clever
One must be ever mindful of the trap!

OK, movin' on.

I did some measuring up of the front axle and put together this scaled and highly detailed drawing of the existing measurements. I couldn't find any paper so I pulled a panel off the tac topper. Seems it serves still in my shop
These highly accurate (To within one ten thousanth of an inch...give or take an inch or two) this will serve to track down that ever elusive HPD60 F350 Fard part.
(http://i.imgur.com/Z3RV9ID.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:21:31 AM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:23:08 AM
Well I got the good news I was anxious about.
I will be working with Randy's Ring and Pinion and mr. Tate up there to put the Dana 60 axle together.
I am going to showcase a who bunch of Randys parts.
Currently the thinking is to run one of their air operated Zip lockers, their Yukon gears, Randy's Forged axles, forged outers, super duty U-joints and their new severe duty manual locking hubs.
I haven't secured it yet, but i will be sourcing a 78-79 Ford F350 High Pinion Dana 60 housing and make the magic happen from there.
Shawn and I have been talking about the suspension. He is suggesting and there is good reason to run coil springs and a 4-link, although I like the simplicity of a two arm setup.
I want to run a big shock, a 3" if I can do it and make it a 12" stroke unit. COnsidering that the shock mounts well inboard of the tire, the total travel seen at the wheel should exceed 14". I should be looking at nearly 30" travel from right to left when it's done without even considering the rear axle travel. I already know I will set up that shock for about 4"-5" of stuff and 7"-8" of droop out.
Anyway, that's my update for this evening. The top is ordered and that order has been received at the plant so that's going forward as well.
It's all looking good so far.


Quote:
Originally Posted by stlaser 
Lets be clear, I like the ford radius arms. Couple things should noted though.

First, stock radius arms will not clear those big tires. Now they do make fabricated after market units that have a bend in them that will clear larger tires. Which is great and they work well.

Second, the original style rubber that slides in between the arms and the axle are the best & allow for the most flex. However, they have been known to pop out while driving over cheap imports & flexing their stuff. You can buy aftermarket poly units but they are stiff & as such limit flex.


We'll have plenty of time to decide while I source and assemble the axle. I would think about the time I drive the last nail in that project and sand down the last coat of joint compound, I would like to have a corner stacked full of the suspension pieces parts. Otherwise you get P.S.S. (Project Stall Syndrome) which leads to STTFNGR (Sellin the truck for no good reason).
So to prevent all that
I need all you good patriotic Americans to prod, remind, push, cajole, harass, and otherwise force Shawn into coming up with some decent idea. Whatever that idea is, I will probably throw out the window, but I would still like to see the harassment to take place.
So what about it folks
You want this project to proceed or not?
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:23:58 AM
Aside from the desired harassment (toward a two timed banned guy BTW) I do like the toughness of a 4-link.
Looking under there, I would have some pretty long arms for the lowers. but not feeling it yet for the uppers.
The upper arm mounts are always the hardest anyway.
Which brings me back to the wristed two link with panhard.
But
If I can figure out the 4 linkey, I could triangulate the thing and eliminate the panhard.
The last one I did I used a panhard.
Everything the truck front end bounces up and down, the panhard exerts a side to side force on the truck so you get this wierd kuboki shimmy-shuffle which I grew to not like so much.
So the leaders seem to be wristed 2 linkey
and
opposing triangle 4-link
I think I will go with coil springs as per Shawn's suggestion. Dirt simple just like him, (and me) hard to break (like my distaste for the ugly blackhawk), found everywhere (Like OB lovin mexicans) inexpensive (unlike anything my wife buys) and easy to figure out (like the reasons this presidency does not work...literally)
I think I need to pay attention (and some big $$$$) for some biggin shocks. maybe some bypass crazy stuff, and the initial setup of this 4 link.
Hmmm, there I just went and said it
4 link
Hmmm, did that without knucklehead (Shawn) or bonehead (Ash) or even Special K or without gettin' Nate to kill anything.
Another decision made????


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:25:46 AM
I think the axle will come together pretty quick
There are only a couple complicated issues to deal with. Those being getting the anti skid...oops, not in the jet, err, anti-lock working and the factory brakes in there.
Not with standing the suspension could be just as simple.
We could have this thing rockin in a week from go time by using the democrat principle: Keep it simple because I'm not very bright!
Ya know, just tell me what I want to hear and what you think I need to hear!

On the suspension thing, look at how simple the early bronco suspension is:
(http://i.imgur.com/7j5al41.jpg)
(http://i.imgur.com/pMCRIKJ.jpg)
(http://i.imgur.com/2R7KePd.jpg)

Look how well it works:

And how much clearance I can build in for the tire.
The Dana 60 will be capable of 40 degrees of steering.
That means if I can keep the suspension arms out of the way, then my turning radius will be inside that of my zero turn mower!
(http://i.imgur.com/6vcS2N3.jpg)
(http://i.imgur.com/6vcS2N3.jpg)

You weld these things onto the D60 axle tubes, install the bushings, and install the arms!
Voila'
You's all linked up!

Second pic is that wristed link arm thing, although I'd add an adjustable upper arm bolted to tabs on the lower
(http://i.imgur.com/NaDCwh0.jpg)
(http://i.imgur.com/eqaa1YI.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:27:28 AM
 plan to build the suspension all the way to making it driveable. Get it aligned, then drive it over to Cincy to a custom drive shaft shop and dropping off said truck. Come back several gallons of artificially sweetened sweet tea and drive the completed thing away.
The shaft will probably have double cardan joints and a L-o-n-g slip shaft in the drive shaft itself
I'm just not up to building driveshafts, although, I could be talked into it for sake of showing people that Piluts and argumentative people can build it!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:29:18 AM
Quote:
Originally Posted by flyin6
Hmmm, did that without knucklehead (Shawn) or bonehead (Ash) or even Special K or without gettin' Nate to kill anything.
Another decision made????


Posted by BobbyB:
All 3 pages of comments I catch up on and this stands out, I'm free of the shackles of non-killing clause or am I relegated to iffin' no one else can, I can't either?? Just seeking clarification from my (apparent) Build Thread chain of command.... oh crap I was supposed to ask Nate first... so all this was directed at him... yea thats it.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:29:49 AM
It was a test
To see if you were paying attention
I leave you out then post it and hit the timer
6:37 later and you finally respond
Not very quick there Sergeant!

But now that you mention it, you should have checked with Nate first!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:32:42 AM
Quote:
Originally Posted by nmeyer414
so whats the status of the sas don ?

I found a company in Pennsylvania who supplies used Dana 60's
Together we figured out what to get.
I will be getting an early 78-79 High Pinion Dana 60 from a F350 with high steer knuckles and a ford spindle and hub.
I will be adapting the Duramax brakes to the ford stuff by way of some cool custom machining by WFO Concepts. They do things like that with cutting edge off road stuff.
Anyway the axle should ship tomorrow or Wednesday.
Once I get it, I can pull the BOW (Build number) from the axle which Randy's will use to select all the cool parts going into it.
I think this will be the best way to handle this build and keep it super strong while not going overboard and over priced.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:36:07 AM
Here's some of the parts coming from Randys Ring and Pinion
(http://i.imgur.com/v7fvFh7.jpg)
(http://i.imgur.com/auUdBOV.jpg)
(http://i.imgur.com/F4ZvM8T.jpg)
(http://i.imgur.com/GqAggW7.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:38:45 AM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 12, 2014, 09:44:33 AM
                                                                                     (7119)
Since I have all the drive line parts already coming in, I am taking some time focusing on the suspension setup.
I have something like a cold today, so sitting around on the computer researching all this stuff is about all i feel like doing.

The control arms are going to look something like these

And the suspension something like this me thinks.

There are variables afoot here such as driveshaft interference but this design keeps me from having to build a panhard.

As simple as the Panhard or track bar seems, and I might very well end up doing it, you sometimes run into problems trying to get the steering link and the track (panhard) parallel.

It must be parallel or you get bump steer, which is the same is bum steerin' !

Also, this about what the high steer will look like. The good thing is that all the important parts are well up and out of the way.
(http://i.imgur.com/mDYGmzd.jpg)
(http://i.imgur.com/NwoC1ky.jpg)
(http://i.imgur.com/eFzu9aj.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:04:20 PM
Not a lot of pics, because not a lot of building going on, but progress is definately happening.

Parts are still tracking in like a hellfire on a hajii hoot-nanny and will start blocking the view of that maple tree on Monday.

I plan a marathon day of weeding and gluing stones back onto the front of my house where they fell from, one narrowly missing me! That is so that maybe on Tuesday I can get on that welding table.

The 450 lbs of Dana 60 beauty will arrive sometime this week, and I'll need the place functional and ready to accept that monster so that werkin can begin.

I'm settling in on that suspension I showed in the last, well, suspension pic. Shawn's good with it, and he is smarter than me, so I must have guessed right! (Or he used some of my own military reverse psychology on me!)

I am about to select the company to manufacture and sell me all the tubing, brackets, end links, steering arms, bolts, do-dads, thing-ah-ma-gigs and what-cha-ma-call-its I will be using. My goal is to organize those boxes into stacks laid out on my storage and work table on the west side of the garage.

Normally, my goal would be to remove enough of the boxes, through actually installing all that stuff, to be able to see the leaves on that jap maple tree turning fall colors, but the colors don't change on it, so I may get a little break in that area.

On my very short list of companies to supply the stuff is of course
Great Lakes Off road for the cover
WFO Concepts for the bulk of the stuff
Blue Torch Fab
XXX Fabrication
and Ruff Stuff fabrication.

I needs peoples who speak my language and don't sell "Rock Star Mags" and exhaust tips, Nope, definately not my crowd. Sorry if I offended anyone, well, actually, I don't actually care if someone with Rock Star "Hey look at me" wheels is offended...no great impact or loss
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:06:49 PM
......I'm fairly excited about the SAS as well. THis truck deserves the complete heavy duty drivetrain, no excuses suspension, that I plan to add.
Not that the IFS is bad, it's fine for 99% of the time, but for that other 1% nothing else than a gool old live axle will do.

What I'm going to do here is to show everyone just how easy it is to do themselves, and the trememdous results they will enjoy when it's done.

This is a good time in history to do something like this. Instead of blowing thousands on rock star mags and 20's that will never do anything to include impress anyone other than other thin thinkers, a live axle will increase your capability to do everything manifold.

You'll likely improve economy, since there will no longer be parasitic drag caused by spinning axles, you'll be able to install a traction device in the front, A dana 60 is probably twice as strong as a stocker, wheel articulation will go from a paltry 8"-10" to around 30", and on and on

Apologies again to the rock star crowd, not trying to insult you directly, but wheels for the sake of "hey look at me" are pretty stupid, I think you'll privately agree.
Never the less, I apologize.


 
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:10:39 PM
I learned about IFS off roading with my H2 Hummer. Pic below.
I lifted it, but not with a kit, but by inventing all manner of parts to give it more suspension travel. That resulted in it being taller, which I didn't mind. It had the E-locker rear and a ton of good parts and was reasonably acceptable at off roading.
But, you had to get used to the idea that when going over irregularly shaped obstacles which only occur in 95% of off roading situations, that one wheel and tire would be actually off the ground! Sometimes that front wheel would be 4 feet off the ground! Not a great feeling when you reach the roll-over point and the weight shifts to place that tire onto the ground. Big-Big changes in roll angle...Used to scare the knickers off me and the family!

When wheeling like that you have to learn a technique called BTM (Brake Torque Modulation) When you want more traction you would actually lightly depress and hold the brake while pressing on the gas. That would keep the airborne wheel from spinning and give you some more traction.
You see if you just had that wheel planted you could just drive normally. And of course with going to a 60 I can actually add in a locker, which, of course I am!
(http://i.imgur.com/7TwRa2K.jpg)
(http://i.imgur.com/3qdAvo1.jpg)
(http://i.imgur.com/6LF35KQ.jpg)
(http://i.imgur.com/Ofx28yf.jpg)
(http://i.imgur.com/RP935h1.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:12:30 PM
Quote:
Originally Posted by stlaser
Is there a knuckle upgrade coming for this d-60?

No
I already spent money on the factory Ford stuff
In my assessment, that stuff is plenty strong enough for what I plan and hope not to use the truck for. In the meantime, mall speed bumps will only get about 2% into the capability of the stock D60 stuff.
Sorry Bro
Your Psychology didn't push me over the edge on that decision!

Quote:
Originally Posted by BobbyB 
What locker you going to put in the front? I probably skimmed over it, logged it in the brain and pushed it into the non-important compartment, which I periodically use later on. Its a process....


I'll be using the Yukon Zip locker which is a new offering, an air locker made in the US and sold through Randy's Ring and pinion.
It will be here Monday or Wednesday
(http://i.imgur.com/cuXcdJd.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:18:33 PM
Tate over at Randy's Ring and Pinion just helped me figure out how to connect the transfer case to the new Dana 60. HE suggested I use a companion flange so that I could mount a double cardan to either end of the driveshaft (Both ends??)
This will be replacing a standard 1350 yoke:
(http://i.imgur.com/5PKofdM.jpg)

Look what just happened
(http://i.imgur.com/MUuPEsk.jpg)

Lets take a look at the shiny things!
Those are Yukon Super Joints which are amongst the very best available anywhere on earth
(http://i.imgur.com/g6VI0ej.jpg)
(http://i.imgur.com/Qv8tOZ0.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:21:18 PM
They get special grease and a grease gun
(http://i.imgur.com/opj7tUf.jpg)
(http://i.imgur.com/yXNUEn9.jpg)
(http://i.imgur.com/rk3yCJz.jpg)

Then all 4 4320 forged steel axles, again about the very best 35 spline axle you can buy
This stuff is way bigger and a whole lot stronger than the stock axles as to make comparison silly. No kidding these Yukon axles are many times stronger than stock stuff!
(http://i.imgur.com/TexOe1L.jpg)
 (http://i.imgur.com/UAEaTlv.jpg)

Some of the decals already found new homes!
(http://i.imgur.com/e99Zqqa.jpg)
(http://i.imgur.com/yPy89XE.jpg)

Some bed time reading
(http://i.imgur.com/F03fu6J.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:25:01 PM
There's that new Yukon Zip (air) selectable locker
That thing is 40-50 pounds!
(http://i.imgur.com/sziwf5L.jpg)
(http://i.imgur.com/8rQ9VB5.jpg)
(http://i.imgur.com/w6j9uHg.jpg)

Bearings and seals
(http://i.imgur.com/unaUwSk.jpg)
(http://i.imgur.com/KYy2DDd.jpg)
(http://i.imgur.com/SMHD7Mr.jpg)

King Pin rebuild kits
(http://i.imgur.com/4iApnFx.jpg)
(http://i.imgur.com/L5mcSr2.jpg)

ARB air compressor for the air locker. I'll probably run a line off it to an air tank then I can plumb it to the air bags by way of a valve to allow me to regulate what pressure I am carrying out back
(http://i.imgur.com/X9044ZP.jpg)

Some super heavy duty Yukon manual locking hubs
(http://i.imgur.com/s0Ox3y6.jpg)

And an axle rebuild parts kit
(http://i.imgur.com/oE7G5d4.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:26:30 PM
Remember how the boxes in the past obscured my view of that Jap maple
Well
It's started again!
(http://i.imgur.com/fco4b2B.jpg)
(http://i.imgur.com/AfNzhnx.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:28:02 PM
On the build thing, it's definately shaping up nicely.

Got off the phone from talking with Bo or is it Beau? Dunno, but he's one of the guys over at WFO Concepts. I tell you, he really knows this business of SAS. He was very familiar with the Axle and the Chevy chassis.

He has some really trick stuff to make my job a lot easier getting the axle in there.

He makes a trick, bent radius arm that will clear big tires at full lock. That means the turning radius will tighten up even more than I had hoped for. Since he knew this axle and the chassis well enough he was able to let me know PDQ that coil springs will not fit!

Yep, this particuliar HPD60 has the diff moved over to the drivers side even more than normal which reduces room to swueeze in a coil spring big enough to handle over a ton of weight each.

So that means I will be switching up to coil-overs.
I can still do what I want with the coil-overs with the valving and a lot of fluid bu building a 3" shock. Again, that will yield more damping than 2-2" shocks and both take up less room and be simpler to set up. Now, all I'll have to do, essentially is weld a shock tower up to the frame and drop the coilover in and bolt it to the axle with a single bolt. How much simplier could it be?

They have some frame plates he thinks will fit, so after I trim the brackets off the factory frame I'll weld these on and it will look all factory pretty once again and get stronger as well.

This thing is going to come together well indeed!


Quote:
Originally Posted by Dustoff 35
Santa delivers in August!

You gotta come over and see this stuff!
You're gonna want to SAS that Cobra!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:32:02 PM
Posted by KensAuto:
Wow Shawn, 4 link AND coilovers! the world is truly ending .

...stlaser:
Lol, yeah it's been a tough sell that's for sure.

...Flyin6:
Special K
Not 4 link, 2 link radius arm with panhard/track bar
Shawn won like 3 outta 4, but not a clean sweep!

..stlaser:
Yeah & last week it was "like 2 outta 4" but that axle still ain't slung under that rig so only time will tell!

..Flyin6:
You wanna keep it up???
I'll start checking out skyjacker leaf springs!



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 13, 2014, 09:45:24 PM
                                                                                                       (7237)
More parts

HPD60 86-99 housing
Spindles, hubs and knuckles

Rich Brandi over in PA finds and sells these housings. He supplied these parts and as you can see, took some time cleaning and painting them for me.

I plan to have then blasted again, then paint them with Dupont Centauri in Lycoming gray except for the main housing which will be done in that JD Blitz black flattened black.
(http://i.imgur.com/0GxteUC.jpg)
(http://i.imgur.com/EsV4wJn.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: ce_tx on December 14, 2014, 09:42:01 AM
I like the looks of that Yukon air locker, I've got an ARB in the rear of my crew cab project and was going to get one for my front axle but will have to look into the Yukon version now.

How do you like the GLO rear diff cover?  I'm needing one for my rear axle which is a dodge version of your chevy 11.5 AAM.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 09:48:44 AM
Posted by KensAuto:
I think I can speak for Don, and several guys on this site, that Shawn's covers are top notch.....as long as Don isn't allowed to paint over them.....he made quite the mess out of the first one he got for combat-max!!
FYI, GLO (aka Shawn) is on this site as "stlaser" if you need to pm him for something.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: ce_tx on December 14, 2014, 10:00:07 AM
Thanks for the info.

I had one of his covers years ago on a 1977 Dodge M880 truck I used to rock crawl with and it was pure beef.  Just wante to see if his stuff is still the same.  I'll get with him after the holidays for another cover.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:06:35 AM
Quote:
Originally Posted by BobbyB 
So when's H-Hour for the SAS ? I assume all the parts are gonna be cleaned up and etc.. Only wondering as I have to keep my mind occupied..

We already passed H-Hour
Catch up Sergeant!
I think when I started ordering the parts, that was H-hour
So in sequence:
Axle Parts ordered and identified: 100% complete
Parts arrive for axle build up: 60% complete
Clean, blast, and coat interior of axle: 0%
Install all internal axle parts: 0%
Assemble Axle all the way to hubs and steering: 0%
Identify and order suspension components: 50%
Remove all factory components and cut bracketry off frame
Replate frame
Install suspension arms
Hang new axle
Install Coilovers and upper mounts
Install steering
Install brakes
Final assembly

As we can see we are progressing right along on operation IFAM (Improved front axle mod)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:09:05 AM
Quote:
Originally Posted by EL TATE 
Speaking of which, i'm looking to "wife-a-fy" my Remington 870 express for when I'm gone and the Dog isn't scary enough. I'm looking for a short barrel, extended mag, side saddle, or side rail w/ light mount, drop or folding stock, composit front stock, pistol grip and some high relief optics, like ghost rings. I want to know that if they don't run when they hear it rack, that she can hit them in the dark. Anyone feel free to chime in or PM contact info. With recent local events I'm looking to hurry up on this project. Also, any better ideas and suggestions are welcomed and appreciated.

p.s. just getting all caught up here, been away for some time. This thread is a living, breathing thing that I can proudly say I'm a part of. Thank you Don, and everyone that is contributing, reading, learning, and growing from this. 

Gentlemens, this here is BT (Brother Tate) who is a guru up at Randy's Ring and Pinion. He is the guy I go to who figures out everything gear/axle/driveline related. He is personally responsible for the swap to 4.56 gears, the grizzly rear locker, and now for all the front Dana 60 magic that is happening.

Speaking of which some more of his parts showed up!

Tate, did you see the section in here somewhere where Duane built up a Remington 870 while I built a Ruger 22? He has a good stock, pump, mag extension and extra ammo holder I think. Anyway check out G&G tactical for cool shotgun parts!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:12:43 AM
Here's some of Tate's parts

The flange will go onto the pinion gear which will allow me to use a cardan joint there. The plan is to run one at either end of the front shaft. I'll defer to the experts at the driveshaft shop of course, but that is what I am wanting to completely alleviate future vibration issues.
(http://i.imgur.com/p0rI2p6.jpg)
(http://i.imgur.com/zyBr519.jpg)

Not the worlds best picture, in fact it just looks like a box! But inside that box is the new 4.56 ring and pinion gear set
(http://i.imgur.com/kj35vgx.jpg)
(http://i.imgur.com/7jCaFMZ.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:16:31 AM
Posted by KensAuto:
It's Ironic, ce_tx, that we were just talking about Shawn's covers. This post by Don, pretty much sums up his opinion on that subject!



You may have also noticed the wonderfully built tiger tank frontal armor plate.

Ah fooled you, it's not a German tank part!
Shawn has been busy again over at Great Lakes Off Road. He welded me up another axle cover to protect those gears. In fact that is why the cover is currently resting on top of the gears...so they can get to know each other since they will soon be living in close proximity.

Shawn builds these things out of .250" steel plate and this one has an additional 1/2" plate welded over top for a total thickness of 3/4"!!!!!!!!!!

He did that so that I can driven right over boulders and Kias while actually using the cover plate as a ramp of sorts!
(http://i.imgur.com/nCWICJv.jpg)
(http://i.imgur.com/JxLjKmS.jpg)
(http://i.imgur.com/OqzBwWq.jpg)
(http://i.imgur.com/Jpyg5L9.jpg)
(http://i.imgur.com/J7zLTiB.jpg)

I'm told the word "Picture" was written on the inside because this particular cover was absolutely perfect...It sure looks it! 
(http://i.imgur.com/KcuCPZl.jpg)
(http://i.imgur.com/KYQ4ueG.jpg)
(http://i.imgur.com/cBUel7q.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:19:22 AM
...KensAuto:

That's a nice cover!



Psst....Shawn, I wish you would have painted it before shipping it to big D. Did you see what he did to the last one? hahahahaaahhahahahha
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:20:11 AM
...stlaser:
Yeah we all saw that debauchery of a paint job. However, I think he felt bad & is going to make it right this go around. Thanks for the compliments.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:20:52 AM
I'll repent this time
This time it gets wire brushed, degreased, acid washed, acid primer, and DuPont acrylic enamel in Lycoming gray. I'll do the rear cover as well.

Update: Beau at WFO Concepts shipped out the shackle flip yesterday. I think it would be best to get the rear height set first, then use that as the baseline to do the front, since the front will have to be engineered.
Plus the Rear King shocks should be ready first.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:23:15 AM
Posted by Cudakidd53:
Wow Shawn! That cover should survive a direct hit form an AP round! Might not survive the paint though; might want to ship them pre-finished in John Deer Black from now on.

...stlaser:
Funny that you mention that. A guy I first sponsored from Lexington, KY. doing rock crawling events back in the day when they were the next big thing served over in Afghanistan several years back. I believe he was a reservist going to college to be an engineer of some sort. Anyhow somehow with his engineering and off road racing back ground he was selected to help diagnose and fix little issues with this new v-shaped Humvee replacement vehicle. It came with a dynatrac front axle and their cast front cover but the rear Dana 80 axle was bone stock. As such they were having problems with the rear stamped cover hanging down past the bottom of the differential and peeling off when they drove over rocks etc. Same problem off road racing guys have here in the states. So he emails me and asks if I can send a couple of our D-80 covers to him. I did and that went on for awhile and supposedly he had to get a lot of signature approvals and the idea was if he had gotten it all squared away whenever they ordered one of these this would be a stock upgrade for these vehicles. Long story short it never did pan out in the long run. I'm not even sure if the military ever put in a large order for these vehicles as I haven't read anything about them since.

And if you google "JP magazine diff cover shoot out" you can see where those magazine editors literally went out and shot at ours and roughly 15 other vendors covers. I won't let the cat out of the bag and tell you who won that silly test either.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:24:17 AM
Here's those WFO Concepts shackle flip brackets and shackles
(http://i.imgur.com/GEgKoNc.jpg)

And, look what Ash sent me!

Tried it out with hickory chips first time

Using mesquite tonight!
(http://i.imgur.com/G2xc32x.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:30:04 AM
Here's the frame plates I will be using.
After you cut all the brackets off the frame and gring the living crap out of it, it isn't always as pretty as me.
WFO makes these plates out of 3/16" which make it all pretty again and stiffen it all up as well. That portion of the frame is now going to carry the weight and could use some stiffening.

Beau (correct spelling) also makes these shock/coil-over hoops. Last ones I used, I made myself which is just a bunch of work. Easier to buy these quality units and weld them on instead
(http://i.imgur.com/ofavRGU.jpg)
(http://i.imgur.com/WAhlJMa.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:33:07 AM
We have some activity!

The axle is strapped down upside down on the pallet in case you were wondering...
That makes the casting number hard to read...Just stand on your head and it clears right up!

I'll see if I can get it pressure blasted and cleaned up some more before grass cutting sets in.
(http://i.imgur.com/eZ49s9Z.jpg)
(http://i.imgur.com/E1oldU1.jpg)
(http://i.imgur.com/89QbvqX.jpg)

I got the bearing races punched out of the housing as well as both inner axle seals.
I then soaked it with that purple grease remover that takes off your skin, then pressure washed it with hot water.
It's ready for the spark generation tomorrow!
(http://i.imgur.com/pu2Frwx.jpg)
(http://i.imgur.com/FJci1xT.jpg)
(http://i.imgur.com/N38J0p9.jpg)
(http://i.imgur.com/S9QhR5K.jpg)
(http://i.imgur.com/0zKthQ0.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:35:17 AM
Here's the knuckles, spindles and hubs

Those hubs get shipped off to WFO Concepts tomorrow to get modified
(http://i.imgur.com/z13DOxt.jpg)
(http://i.imgur.com/W2GYJc4.jpg)
(http://i.imgur.com/iSvE0nN.jpg)
(http://i.imgur.com/bBzsrak.jpg)



So, plan tomorrow is to cut those brackets off the diff, then use a new 7" grinder to smooth it all down baby butt like.
Then spray it up with simple green to get oils off and do some scrubbin'
I already have the hubs boxed up, so I'll ship them off to WFO Concepts to be machined for the tone rings so's me's anti-lock brakes still be ah werkin'

I located an axle builder the next town over who has all the cool tools. After I get that axle cleaned down to the molecular level, she's be gettin' a heavy coat of red oxide primer right after the acid bath. Then about a forth of that stack of boxes and that housing will get transported and be morphed into a single unit.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:42:00 AM
OK, did some Dana 60 stuff today, we'll look at that in a moment.
The hubs were shipped off to WFO to be modified.
Beau over there now has the order almost complete. It was complete, however we talked and decided to switch out the heims on the track bar for a Johnny joint and a bushing to soften the road bumps and quiet things out some.

So as promised, I cut off the brackets and ground everything flat on both sides.
I then spent about an hour with a 1HP wire cup grinder thing and de-rusted the axle housing. After that it got a coat of primer. This is just a temporary coat of rust inhibitor paint that will be removed before the real painting takes place. That will be after the brackets and tabs get all welded on.

Here's the plasma-Arc festivities:
(http://i.imgur.com/T0AHk8P.jpg)
(http://i.imgur.com/IBeXYKa.jpg)
(http://i.imgur.com/EBJvVFN.jpg)
(http://i.imgur.com/RWugR8G.jpg)

And the spring mount
(http://i.imgur.com/xSftU0s.jpg)
(http://i.imgur.com/GrfM5Uo.jpg)

The drivers side was a bit more difficult due to the confined space to maneuver in
(http://i.imgur.com/PZt6AiR.jpg)
(http://i.imgur.com/r6k3sKZ.jpg)
(http://i.imgur.com/YjiQky2.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:44:35 AM
Next the heavy artillery was called in to grind off the rest of the weld and slag
(http://i.imgur.com/dLKR24J.jpg)
(http://i.imgur.com/E94zNXO.jpg)
(http://i.imgur.com/DZfsGdZ.jpg)

Then the cup wire brush went to work destroying rust buildup and the cartilage in my lower back between L5/S1
(http://i.imgur.com/U3WEB3W.jpg)
(http://i.imgur.com/XENIFYP.jpg)
(http://i.imgur.com/Qsjdaou.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:46:36 AM
Then I sprayed everything with a medium coat of automotive black primer. This coating, again, is just temporary, as I expect it to bet banged all to heck and back installing gears, welding, pulling out the king pin stuff and so forth.

But for now it's good to go

That's it, had to go cut grass, then cook the boyz some tacos!
(http://i.imgur.com/SBbKM3m.jpg)
(http://i.imgur.com/dvObNWF.jpg)
(http://i.imgur.com/vPamtmN.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 10:54:43 AM
All right
Today I think I'll try to get that axle painted up inside and down to the gear install guy and get that part started.
I also have to get the Fox Shocks actually ordered. We have been chitty-chatting about this and that, but it's time to actually get something done!

The topper is not here yet. I make it the last of this week or sometime next week. That's easy. It gets here, they install it...Done!
Well done enough to get it home where I can drill, paint, weld, add to and so forth, typical Don fashion...

Parts to show up? Lots and lots. Beau from WFO sent me a list yesterday two pages long of all the nit-noid pieces parts to make the suspension sing like a homesick angel! We talked about substituting this for that and I gave him the card # which set all that on auto pilot. It may be bagged and shipped, but my money sez he went after the bestest of the best I wanted and will wait those parts out to ship. But after that I will need nothing for the suspension except for those Fox coil-overs.
I was looking over tires and wheels last night. I will need more offset to make the track a little wider, especially in the front. I am really focusing on the right parts and a plain simple steel wheel keeps coming up to the top of the list. It bends and doesn't crack and leak air. It's cheaper. I can modify them into bead locks. I can paint any color I want.
They do, however limit me to 17" tires. If I go that route I'm looking at a new set of shoes...Now there is an area of coming controversy. I may not go full aggressive mud tire. How's about a BFG AT??? I ran them on my H2 and by-golly, they work pretty well in all but pasty stuff. They hook up well on the cheapo chrome strips they put all over those horrid kolean and jap kars, and they wear like steel!
The rear suspension is going to get a shackle flip so that the shackle hangs down like it is supposed to! Ever see anything hanging up? I rest my case!
By playing with the shackle angle, I can achieve more droop out for sure. Those air bags telescoping lower mount might need scruitinizin' but only time will tell. I think I need to get the shackles on and do some measuring. Then I can decide about the mounts, and the length of the shocks. I will be holding onto the Fox shocks until I get that puzzle solved.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:01:20 AM
Easy day today of parts ordering and purchasing.
I picked up a quart of Nasan urethane with hardener in Lycoming gray. I like that color as it's understated and was chosen by Lycoming aircraft engines because it will show cracks and oil leaks more readily than other colors. By using the hardener, should a knuckle or something develop crackitis, then I'll be ah' knowin' prudy quick!

I did get the axle housing prepped for the gears install. I cleaned the case inside a bunch finishing with lacquer thinner. I couldn't even get a rag to discolor, so I know I got it all. Then I sprayed the interior with a good quality UPOL acid etching primer.
Here's some shots
(http://i.imgur.com/uGhrFZP.jpg)
(http://i.imgur.com/fofRTY4.jpg)
(http://i.imgur.com/6DMBrB4.jpg)
(http://i.imgur.com/xqiR5GZ.jpg)
(http://i.imgur.com/zWUvFL9.jpg)

I waited until the stuff was setting up, then wiped the machined surfaces free of the paint with some lacquer thinner.
I ended up applying 3 wet coats
 (http://i.imgur.com/W1iRJnz.jpg)
(http://i.imgur.com/48jNddJ.jpg)
(http://i.imgur.com/DdwUqUu.jpg)

Then the finish...
Tomorrow this housing is off to the gear installer
No I won't be installing these gears this time. The Dana 60 requires a case stretcher tool to expand the case to be able to drop in the carrier with shims.
(http://i.imgur.com/iJ1glgV.jpg)
(http://i.imgur.com/7vfQD9B.jpg)
(http://i.imgur.com/P4f1Ghw.jpg)
(http://i.imgur.com/i7sZzPx.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:06:08 AM
Picked up these King pin Bronze bushings.
They will replace the nylon cone bushings that are normally used and make things even mo-better.
Thanks to Dr. DOT, Shawn for pointing me to them
(http://i.imgur.com/RP77hy1.jpg)


....KensAuto:
If those bushings need honed, make sure to find an oldtimer that has some experience with knuckle honing and has some good hones. I actually had to start using plastic ones because of the 'talent' that my local machinists' have.( I would end up with as much play or oblong as the old ones had sometimes)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:08:06 AM
Quote:
Originally Posted by a****
Hey don I may have missed it somewhere trough this jungle we call a build thread.. but are updating the steering box at all? Or is the newer factory unit stout enough for a hpd60.



The factory box is a heavy duty unit and will serve proudly. WFO is sending me a HD sized dropped pitman arm in hopes that it will slide over the largish splines of that box. That is the only change which I am doing to that sucker.

I was just over at Performance Off Road, a local 4X4 shop which has been around about as long as I have. They were snooping over the truck and were really excited about the SAS treatment.
They thought that truck was the perfect candidate.
I dropped my axle housing diff and gears for them to install for me.
I had them look over the King Pin cones...We are all agreeing they are in great shape, so it's starting to be a toss up as to whether I change those out or not

Special K: I had no idea I had to hone anything with those bushings...better not need to! I don't want to create work, but make it mo-simpler.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:10:23 AM
So Kiddies, big update tonight so pay attention. There will be a short quiz in the near future. People with more than 3 incorrect answers will be permanently expelled from this thread!

OK, first here is a couple of pics of the shipment coming out of WFO which includes most of the suspension parts:
(http://i.imgur.com/VvzIXZq.jpg)
(http://i.imgur.com/w030Olz.jpg)

You can see the frame plates, 3/16" steel which will weld over the frame rails.
There are shock hoops and struts, crossover steering (a change) Track bar, bushings, heims, johnny joints, steering bar, tie rods, weld in sleeves, tabs, brackets, bolts, steering arms, a dropped pitman arm and who knows what else.
As extensive as all this is, it is not nearly all of it.
In addition to that will be 12" stroke 2.5" King coil-over shocks with remote reservoirs and dual rate springs, a pair of 2" X 2" stroke air bump stops, Limit straps, a front custom designed 1.25" hollow spring steel sway bar made by Speedway for circle track cars with steel bent ends and heim joints. We just decided to make the front and rear sway bars permanent with a heavy bias toward hitting the rough stuff at speed. There will be a rear sway bar as well, same basic setup of around 1" in diameter.
This truck will not only flex 6 times more than factory at a minimum, but should handle well going around corners as well.
Here's some of the joints we are looking at:
(http://i.imgur.com/ttiWSzv.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:11:14 AM
We also made some big decisions as well
The design was changed to leaf springs instead of radius arms!
OK, just did that to mess with Shawn
I did change from High steer setup to crossover steering.
The reason for that was that since I do not plan to put this truck up in the sky, and have it sit about where it does now, at full compression, the high steer may not clear. So what we decided to do was to mount the crossover steering to the Factory arms with a twist, literally. Instead of having the tie rods mount in from the bottom, I will drill out the hole to 7/8" and insert a tapered sleeve allowing me to drop the tie rod in from above. That moves the crossover steering bar which will be 1.5" heavy wall DOM up a full 3" out of harms way of pesky Hyundai hood ornaments!

Additionally, since the track bar has been bent to provide more clearance around the diff section of the axle, we decided to fish-mouth it and weld a sleeve and use a fixed bushing at that end. I wanted to use a threaded joint, but Beau pointed out that without the bar hard welded to the bushing, it might rotate and get in the way of something. There will be considerable forces at play when this truck is moving.
I already mentioned the decision to go to air bumps instead of poly or rubber bushings. Even though I don't plan to go around jumping this truck, I am building that contingency into the suspension since this is a bonafide survival vehicle.


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:12:45 AM
Quote:
Originally Posted by Cudakidd53 
Quality stuff and well planned as always- more technical than my level, but sounds like Monster Truck stuff in a daily survival driver!

More like desert pre-runner stuff, especially with the air bumps and way long travel.
There is a reason for the air bumps
and that is finished height.
You see on a 12" stroke shock you could set it up anyway you want...typically people gloss over it and make it for 6" compression (Stuff) and 6" of extension.
However if you were prerunning you might want more compression length and with rock crawling you'd want more droop.
For a survival truck you need good handling and a suspension that can handle whatever you come across, but probably nothing extreme.
Most off road obstacles are mot that big...a hole, a rock and so forth. The off roading crowd choose to go into the hole and over the biggest rock. A survivalist will simply drive through the nearby debris strewn field bypassing the difficult stuff. It's not about cool when your hide is on the line.
So we need a suspension for dirt roads, muddy areas, running over stuff like trees, and wreckage like you would see after a tornado.
Like I said about 500 pages ago, I might be in a situation where I'm being pursued and have to leave the road at a high rate of speed, smash through a fence and then out across a bumpy field to lose my pursuers.
Part of driving at speed is a low center of gravity. Putting a truck in the air is definitely counterproductive but it looks cool. Most people don't think so they raise or lift to, well, look cool.
I need to keep the truck handling well which it seems to do at 6" above factory height with the aid of a widened track, but no higher.
So I know I am using a 12" shock. I will set that up for 4" to 5" of stuff which will establish a shock maybe 26" long. So I have to physically place a 26" long piece on top of the axle and still keep it in the wheel well. So there you go...That and that alone will establish the ride height.
Now I have a shock that will only stuff 4.5" lets say because I don't want to get an ATC clearance to go driving. So what happens when I slam into that ditch doing 55 leaving the highway.
Well, the suspension will only have 4.5" of travel to accommodate those considerable forces...not much you're thinking.
You're right, but you only have maybe 3" tops and likely closer to 2" so I'm already 100% better than stock. A 2.5" shock will double the dampening over the factory sized skinny girl shocks so that is working for me. With the addition of air bumps I can really soften up that last 2" of travel, possibly allowing my suspension and truck to survive leaving the road, where the stock truck would have been totaled.
Now with all that droop out when I come up to a ditch while crawling along the suspension can fall well away from the truck (Unlike stock) and keep the tire which has traction through a locker (Again not possible with the stock stuff) which will keep you going.
That's a readers digest of why all this happened the way it did...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:16:02 AM
So, today I went down to Performance Off Road again to talk about the Zip Locker install. Roy, the owner there has done several in the past and knew exactly what to do. They will get on it first of the week so I should have the basic axle done pretty soon.

While that is going on, I will be cuttin' drillin' sawin' and prayin' out loud over stuck bolts and such as I get into this shackle flip project.
When I got home there was a box sitting next to the orange cat with WFO written on it.

Inside was this:
(http://i.imgur.com/CsIVGzX.jpg)

Speaking of left coast crap, this would definitely not qualify in any way shape of form. These are quality parts, the first of this expansive order I made with Beau over at WFO Concepts.
Look at the robustness of this shackle flip bracket:
(http://i.imgur.com/NzGUF4i.jpg)
(http://i.imgur.com/LnvaBqg.jpg)
(http://i.imgur.com/o5sm4Fn.jpg)
(http://i.imgur.com/j6HZOhg.jpg)
(http://i.imgur.com/FRdxkpO.jpg)

The shackles are 6" long bolt center to center and will provide for 5.5" of lift by themselves. That, of course will permit me to remove that horrid lift block and get that rear axle safely bolted in place.
(http://i.imgur.com/Z05Pemc.jpg)
(http://i.imgur.com/qh0jEHw.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:18:09 AM
Rotating the spring downward will kick up the pinion angle about 6 degrees. I like the current pinion angle so I purchased these 6 degree shims to make all that just like it is now. Hard to see but those two thin slices of pie right there will correct the improper angle.
(http://i.imgur.com/Busitbn.jpg)
(http://i.imgur.com/uplRrO8.jpg)

3" wide bushing for our wide spring
(http://i.imgur.com/W4MDoRc.jpg)

You got to love the quality of those welds! Stacked dimes going on there big time!
(http://i.imgur.com/po8vU6X.jpg)

Soon to be used paint supplies:
(http://i.imgur.com/GSl6DEg.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:19:06 AM
Here's the SOB (Stack of Boxes)
What were you thinking? Eh?
This thing got smaller with the stuff hauled off to Performance Off Road. Randy's Ring and Pinion had thoroughly populated that area with enough stuff to block the view of the bottom 2 branches of that jap maple. Then before the WFO addition, I could see it pretty well...But, alas, it's getting covered up again...
(http://i.imgur.com/hEfaFd9.jpg)
(http://i.imgur.com/0tX85C5.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:24:27 AM
Quote:
Originally Posted by flyin6 
Rotating the spring downward will kick up the pinion angle about 6 degrees. I like the current pinion angle so I purchased these 6 degree shims to make all that just like it is now. Hard to see but those two thin slices of pie right there will correct the improper angle.


Posted by El Tate:
I know you have front custom driveline plans in the works, but what are your plans if any for the rear driveshaft? with that back axle dropping down, you have the pinion correction taken care of but that also pulls the driveshaft further out of its slip yoke. I would hate to see you on other threads in this forum chasing vibration in your old age.


...by stlaser:
El Tate, what's your recommendation on proper spline engagement? At what point does vibration become a factor? I have my own opinions but thought I would hear your professional opinion or what is recommended by your techs.


...El Tate:
I really don't like to see more than an inch of exposed spline in a fully unloaded suspension. Once you start to get beyond that, the bearing/bushing inside of the slip yoke no longer supports the end of the driveshaft and you get that really fun vibration gremlin everyone can't seem to figure out.

Push it too far, and you wind up slamming on your brakes when a honda stops short, sucking the rear axle back far enough to drop the driveshaft on the street, and slam your slip yoke into your gas tank and making a mess in front of your dad's place. Oh wait, that was MY learning experience.





Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:31:03 AM
Quote:
Originally Posted by c*************
how much does this SAS cost? id like to get the straight axle at some point but seems like it will cost just under an arm and possibly a few toes


It's expensive
HPD60 housing knuckles/spindles $800
Brakes, adapter, milling $400
Axles $1200
Locker $1200
Set up gears $350
Gears and set up kit $500-$600
Yoke $200
Free/lock hubs $300
Diff cover $150
Sway Bar $800
Air bumps $400
Limit straps $50
Drop pitman arm $100
Fab new cross member $150
Front Driveshaft $400
Tabs, arms, brackets, plates, steering stuff $1700
Two 2.5" Coil overs $1300
Rear 2.5" shocks $1100
Welding (Free for me)
Set up (Free for me, but maybe 50 hours @ $80 an hour)
Wheels $350
Tires if necessary, $700

All said and done 12K-13K
That would be for total premium parts like this project here.
You could save thousands by going with a stick 4.10 axle you purchased for a grand.
I still don't think you could easily get it under 7K even with a friend in the business, and then you'd have a marginal setup...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:41:42 AM
All right popcorn man and all your funny buddies!
Ready for some topper pics???

I don't know what you all think, but this thing looks just "right" sitting on that truck.

So with a slow drum roll and a warm up, here's the pics of it sitting in the delivery rack:
(http://i.imgur.com/cKtwmbY.jpg)
(http://i.imgur.com/aLNvqIH.jpg)
(http://i.imgur.com/Cb5DJBy.jpg)
(http://i.imgur.com/EHo1s2D.jpg)
(http://i.imgur.com/fCa4B4t.jpg)
(http://i.imgur.com/Hvde6mb.jpg)
(http://i.imgur.com/huFrx93.jpg)
(http://i.imgur.com/rl9gusj.jpg)
(http://i.imgur.com/Z5ur6S2.jpg)

Some detailed shots:
(http://i.imgur.com/TpuT1As.jpg)
(http://i.imgur.com/uhhMd99.jpg)
(http://i.imgur.com/NWQuHpf.jpg)
(http://i.imgur.com/ug5xG6q.jpg)
(http://i.imgur.com/IaErbwp.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:45:43 AM
Little reflection going on in that last photo...hmmm...

Here's a moment before pulling the truck in, the last time it would be outside without the new addition
(http://i.imgur.com/WhU95IU.jpg)

Next the tailgate was removed along with all the hardware in there.
Then they cleaned the bedrails and put down a couple layers of foam sealer strip.
(http://i.imgur.com/TunYm8i.jpg)
(http://i.imgur.com/we14PXC.jpg)
(http://i.imgur.com/aq13zyt.jpg)
(http://i.imgur.com/U7RKNcW.jpg)

And here it comes:
(http://i.imgur.com/bIEi6Wr.jpg)

Shipping weight was a paltry 175 pounds. When it was on, one guy lifted the whole thing with his back!
(http://i.imgur.com/aZ2WABP.jpg)
(http://i.imgur.com/TbJjj3l.jpg)
(http://i.imgur.com/CxcKgrp.jpg)
(http://i.imgur.com/usVX23B.jpg)
(http://i.imgur.com/dqMB9uL.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:46:48 AM
Finishing up at the shop
(http://i.imgur.com/lkKqUZX.jpg)
(http://i.imgur.com/WcDofpy.jpg)
(http://i.imgur.com/7yX8Rl6.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:48:19 AM
Anyway, I drove it home for some "hero" shots. Actually it looks better with the casa in the background.
(http://i.imgur.com/Hpe1Vqd.jpg)
(http://i.imgur.com/z2oFcul.jpg)
(http://i.imgur.com/BTfSFIr.jpg)
(http://i.imgur.com/WCmSoe8.jpg)
(http://i.imgur.com/5CX9u31.jpg)

I'm liking the square boxy look!
Now the top of the cab is screaming for a basket! Guess I'll see what I can do up there.
(http://i.imgur.com/OdnXoCF.jpg)
(http://i.imgur.com/j5Kfzog.jpg)
(http://i.imgur.com/fsXiBRh.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:49:15 AM
As you can see, the side doors open way too far. I think one of the first things I do will be to add in a limit strap to hold them open and level.
(http://i.imgur.com/tLQgQTj.jpg)
(http://i.imgur.com/6XhziB7.jpg)
(http://i.imgur.com/TFpiv9z.jpg)
(http://i.imgur.com/NsrmlBK.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:50:11 AM
So, we all know the Scout thing fell out because of some funny business with the VIN
I really wanted to build that thing...

But anytime something is taken away, something comes along that is generally better
Ya know, you hated losing that girl friend, but then in waltz's your future wife...like that.

Well, I offered a gentleman 4K for a 1991 intercooled Dodge 2500 Cummins 4X4.
He just said OK.
So
I'll be doing the paperwork check on that one to see if it works out, so don't get all excited just yet!
But I am!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:52:25 AM
Well to update, things are moving right along
The axle is becoming an assembly. Sort of feels weird not doing it myself, but no case stretcher says it's out of the realm of possibility for the kid from Kentucky.
The WFO parts shipment required FedEx to add another truck to it's vehicle fleet just to get all that stuff going. Sort of reminds me of the way our Bell 214ST (sort of a fat looking Huey thing) looked all filled up with mail. And I mean filled. I saw that bird take off completely cubed out with boxes and oned I chuckled when I saw it hovering beside me prior to takeoff with a couple of boxes sitting on the instrument panel glare shield. I'll bet the pilots also had letters stuffed in their flight suit pockets!
Anyway I diverge, which is totally unlike me!
The topper seems to have made just a tad difference in fuel economy. I had been running 18.3 prior to it's addition, and now I run 18.0-18.1. That may just be the temp change as it went from 80's and dry to 90's and humid.

Anyway, I'll find something to do to it tomorrow. Seems ashamed to have owned it a day now and not to have drilled a hole in it...

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:52:39 AM
Went over to Performance Off Road in Alexandria, KY to check on the diff progress.
I was surprised to find it was done! Yep all bolted together sitting there pretty as a pin!
I was in my buddies jeep which would be totaled if you placed a HPD60 housing in the back, so it's still sitting there, pretty as a pin!
Roy and his mechanics evaluated the king pin cones and we are all in agreement that they are fine to reuse...There is barely any discoloration in them, let alone wear.
So that will make the job of rebuilding the king pins about 500% easier!

Hopefully, I can buzz over there in the morrow and get that sucker policed up and packed back to my shop where I can begin reassembly of all these pretty
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:57:29 AM
Well, something else happened today
(http://i.imgur.com/5DSnO44.jpg)

Remember the Scout purchase that fell through, well, way back then the square fender Chevy V3500 as well, but this one worked!
It's a 1991 Intercooled 12 Valve Cummins W250 Dodge. 171K really ugly automatic and needs some serious stuff right away, but other than that it's a sweetheart!

I'm going to start a build thread down in non-duramax, other diesels on this truck as I take it from its current questionable condition to restored and an EMP proof additional survivor truck
I'll post up the link after I get that thread started.

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:04:33 PM
The HPD60 axle is finished
Here's a couple pics of it at Roy's shop:
(http://i.imgur.com/TR3Ygv6.jpg)
(http://i.imgur.com/aCPOie5.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:09:16 PM
The problem with the way ARE set up doors, both side and rear, they open too far.
At one point I thought about adding a limit strap onto the doors, but that might get in the way and hang outside when closing.

So, after some study, I noticed that all I had to do was to relocate the gas strut mounts and they would be self limiting.

So that's what I did.

Here's the doors open before the mod:
(http://i.imgur.com/oY2x8R8.jpg)
(http://i.imgur.com/AIIR3yS.jpg)

The rear doors pushed hard against the bumper and the side doors went up almost out of reach.

By repositioning it all got much better.

Here's the brackets
(http://i.imgur.com/A2oW5dt.jpg)
(http://i.imgur.com/WvMOMwE.jpg)
(http://i.imgur.com/p2txkPz.jpg)
(http://i.imgur.com/TT5glbB.jpg)
(http://i.imgur.com/Cs9gosC.jpg)

The side window/doors get a lot flatter. I believe if I place a good rubber gasket at the hinge they would shed water well enough to leave open in the rain
(http://i.imgur.com/81PSefD.jpg)
(http://i.imgur.com/4a9K2Xm.jpg)
(http://i.imgur.com/ZxXKkqJ.jpg)
(http://i.imgur.com/kEf5IRu.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:09:58 PM
The rear doors now, no longer rest on anything, yet swing open far enough to be out of the way.
(http://i.imgur.com/NXqINbx.jpg)
(http://i.imgur.com/rIwc4qd.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:14:26 PM
Look what just showed up:
(http://i.imgur.com/4xrJpHz.jpg)
(http://i.imgur.com/7orzQPT.jpg)

Tracey of WFO Concepts just sent me these photos. Beau laid everything out that was going into this SAS radius arm suspension he sent me to showcase it all.
It won't look like this for long!
(http://i.imgur.com/QZpwjPO.jpg)

Well, there's always something...
That WFO Shipment was 3 boxes, not two
They shipped three boxes, and UPS delivered 2!
I'm not that smart but I can get that much.
By my estimates I should have blocked off yet another set of branches on the Jap maple, but I can clearly see them still, all purple and lacy lookin'...
That means something that should have restricted my vision is missing...
The bad part in all of that is that UPS says they delivered the shipment!

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:16:54 PM
                                                                                                        (7690)
Box #3 is now sitting at the house!
Yippee

This was posted 9-5-13....just sayin' Don.
vvvvvvvvvvvvvvvvvvv
Now it's on to the Dodge
Get that thing partially civilized so I can drive it and whamo, the sparks will be flyin'
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:18:52 PM
Firstestest, is the fixin' of Square D

eyes B needin' basic transportation, and that truck is just a couple rungs of the ladder above peddlin'

So that's the next big adventure. I figure a solid week of well, cutting, grindin' replacin' kleenin' and discoverin' and that old bird will be ready to carry my happy butt around while I accumulate wounds and scar tissue cutting apart the Chebby!

But, yes, I'm gigglin' just a tad bit!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:22:15 PM
Got the axle home finally along with the assembled axle shafts
(http://i.imgur.com/ScXtggQ.jpg)
(http://i.imgur.com/EYoVykT.jpg)
(http://i.imgur.com/BjoLIf2.jpg)

I am actually ordering and stacking in all the parts for the SAS
It's a perfect time to build Square D while I get everything for the big project.

It is going to be my best build yet. some smart people (I would not be one!) are really looking into this build and throwing their two cents into the mix. I am arguing with them and explaining how little they know, while secretly adopting their ideas!
It's going to be a good one, and understated as well
Less is more!

....Not much to report except Square D, the support/back up truck is coming right along. Not much longer before I am ready to tear into Combat Max

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:24:03 PM
 painted up that cool diff cover with acid etching primer today, thought I'd show that pretty part
(http://i.imgur.com/T2lWOG6.jpg)
(http://i.imgur.com/x4M60kY.jpg)

The axles are finished with the exception of painting.
Yes, I am going to paint them...Just one more area which will not form rust down the road.

These things are beefy!

Compare these to those spindly looking stock axles and tell me which ones you'd rather trust your life with?
(http://i.imgur.com/a02Tv3N.jpg)
(http://i.imgur.com/AGzfNBf.jpg)
(http://i.imgur.com/34tRNYk.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:25:19 PM
I can't remember what I posted here, with so much going on with Square D right now, and writing all of that on it's build thread.

But, Beau at WFO Concepts has the shocks. We had some 2.5" king 12" stroke coil overs built for the front, and 2.5" smooth body King shocks with remote reservoirs made up for the rear.
He additionally added in a pair of 2" Air bumps along with the weld on brackets for those.
When the suspension pieces were specked out, consideration was given to a mission gross weight of 10,000 lbs. and a daily running weight of 8700 lbs. The scenario where I have to leave the pavement at high speed into the rough was a driving consideration.
We felt the shocks, given the unsprung weight of the Dana 60 and the front vehicle weight of around 5,000 pounds would likely overcome even those really big 2.5" pistons. So we added the air bumps to soften up what would have been a sudden stoppage (Read: break something) event.

So all of that will soon be on it's way.

I sold the lift kit and the steering stuff to a gentleman, Patrick, yesterday. He's local so we'll work together taking everything off which will arm him with the knowledge of how to reassemble. Scrutinizing the lift kit yesterday, I have to say, it is still in excellent condition. It should last for years to come.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 12:34:32 PM
Most of you on here are also on the 12 valve survival truck build as well, so these pics will be from the department of redundancy department.

I painted the GLO cover Shawn sent me with some Nason Acrylic enamel, a Dupont product
(http://i.imgur.com/PHgHS6M.jpg)
(http://i.imgur.com/z3vqvLm.jpg)

That color is "Lycoming Gray" the color that company paints all of it's aircraft engines with. Over the years and thousands of prefight's, I have found that color is good for showing leaks, chaffing areas and cracks...Yes aircraft engines crack!

Here it is on that beefy cover Shawn makes over at Great Lakes Off Road.
The others in the pic are the front and rear covers for the 12 valve project I also have going on (For those of you who remain D-Max pure)
(http://i.imgur.com/1eevic1.jpg)
(http://i.imgur.com/MD3EtiL.jpg)
(http://i.imgur.com/gGQXcbU.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:18:31 PM
I was keeping the WFO parts box, one of three closed up until project Square D was out of the way and serviceable, but I couldn't wait any longer.

Here is a handful (Literally) of pics of the components soon to become a permanent part of Combat Max

Look at the 1.25" rod end and mount that will anchor the radius arm to the frame:
(http://i.imgur.com/pOPeTJ5.jpg)
(http://i.imgur.com/uIxn010.jpg)

Even if I was a small guy that would be a huge part, but I'm not a small guy...

Here's the steering arms that will attach to the D60 knuckles:
(http://i.imgur.com/Kuygpp6.jpg)
(http://i.imgur.com/JobbTe6.jpg)
(http://i.imgur.com/fAmJdyK.jpg)

These brackets weld to the axle. This sort of stuff took me days on my earlier SAS build. I will be saving that much time on this one
 (http://i.imgur.com/BitCG6F.jpg)
(http://i.imgur.com/XLQITZ3.jpg)

These will attach the upper and lower control arms
(http://i.imgur.com/fNFmzS5.jpg)
(http://i.imgur.com/FOb5LCv.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:21:28 PM
This is one of the track bar or panhard bar end links
(http://i.imgur.com/OWhOXqT.jpg)

The cross over steering link tie rod links and weldable fittings
(http://i.imgur.com/kXnzB3B.jpg)

I will be using some poly bushings here and there to reduce harshness and road noise
(http://i.imgur.com/T4JMJ6c.jpg)
(http://i.imgur.com/9rv6PLy.jpg)

Another well constructed weld in mount
This one will attach to the drivers side frame and be the mount point for the track bar
(http://i.imgur.com/nePBC7h.jpg)
(http://i.imgur.com/FYZc4w6.jpg)
(http://i.imgur.com/6T2cdUw.jpg)
(http://i.imgur.com/GOi9ykN.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:24:05 PM
                                                                                                          (7775)
Here is one of the axle mounts that will serve to connect the radius arm links
(http://i.imgur.com/cFHMZJ8.jpg)
(http://i.imgur.com/EYazqBm.jpg)
(http://i.imgur.com/qxs8WaA.jpg)

To help with steering angles, we think this dropped pitman arm will fit and alleviate some of the angle
(http://i.imgur.com/EUMsJmS.jpg)
(http://i.imgur.com/e3mC5IH.jpg)

The quality of this stuff speaks for itself
(http://i.imgur.com/fInQVF3.jpg)
(http://i.imgur.com/w5M2hoR.jpg)
(http://i.imgur.com/JbUybZn.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:27:38 PM
Update:

Not much actual work going on with this project, but there is quite a bit happening behind the scenes.
Beau over at WFO Concepts has machined and pressed on the tone ring onto the Ford HPD60 hub.
He has ordered a 2011 LML tone ring sensor to make sure the bracket works, or to make up a proper one.
We have been talking about brakes and bolt circles. I will need to convert to the 8 on 6.5" for sure, since there is not enough material in the hub to machine holes for the 180mm bolt circle. That's all well and good, but we are unsure as to whether we can use the 2011 rotor which is a massive 14" and not have to convert back to the 2010 rotor which is around 13". He has obtained a LMM and a LML rotor and is awaiting a LML caliper to mock all of this up. There is an even chance that I will be able to simply swap on the factory brakes which will make this SAS one of the best and most innovative anywhere.
The rear is still a question, and I will soon be digging into all of that, when I get Square D up and running, and that's coming right up. I am somewhat hopeful that I will just be able to bolt on a 2010 LMM hub and be done with it. I am a bit concerned, however since the AAM 11.5 axle in the LML actually has larger differential carrier bearings than the LMM has...EEK! Yea, I don't want to be buying another axle, and I definitely don't want to be swapping all those pretty locker and gears into some other housing in which it just may not fit.
Well, that's the thing about leading...someone has to go first!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:32:11 PM
Quote:
Originally Posted by t****
I love your build, but I'm sorry man for what you're spending I'd have them figure out the front axle to keep 8x180mm and the LML brakes front and rear. It can be done, it's that simple.

-TJ

Actually, it can't be done and that is the problem.
Look at the D60 hub
It's cast steel
The 6.5" bolt circle it has would have to be welded up then redrilled for the 180mm pattern. The problem there is the circumference of the hub is not large enough to accommodate the bigger bolt circle.
So I suggested we mill a steel ring and press it onto the hub, then weld it. Then drill the thing for the studs. Well, there is a problem with welding to cast steel and getting good penetration. Now keep in mind that you'd have to drill through a questionable area to anchor a stud that ultimately holds your front tire/wheel on. Sound like something you'd feel comfortable with?
Me neither!
So the fact is that you can't just install the 180mm lug pattern. But we may be able to use the stock brakes, the jury is still out on that one.

Posted by t****:
I suppose you're just making my case... it sounds like you (and anybody else that ever plans to SAS a '11+ truck) needs a custom hub made. Like I said, it can be done...
...
there is no reason that can't be made with a bigger flange and whatever bolt pattern you want on it. I had Porsche 996 TT front brakes on my '99 Camaro Z/28 because they were far cheaper/better than aftermarket options back then (nearly 10 years ago). It took some custom made brackets for the calipers and we were lucky that the factory rotors had plenty of meat to drill in a new bolt pattern. Trust me, it CAN be done.

If I was you I'd rather spend the $ to get the front axle to take your brakes, wheels etc. and then not have to touch the rear axle vs. downgrading everything to work with the old bolt pattern.

I know I said this before, but at this point you are changing the entire truck... you might as well have started with a Dodge if you wanted compromises. If you want to make this truck perfect for you don't accept defeat...







Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:33:09 PM
Quote:
Originally Posted by flyin6
Good attitude
Thought the dodges had an ugly front end
Chevy gave me 0% financing
(Which is laughable since I paid the truck off in 5 months!)

OK there Airborne, I'll take a look at those hubs.

But I think Beau Huskins at WFO already checked them out


...t****:
Those are just a random picture of D60 hubs I found. My point was just that any good machinist can build those hubs with any flange and bolt pattern you want. Sure, they'll cost you... but probably less than buying all new wheels, maybe new brakes, a new rear axle or hub swap on yours etc. And besides being more cost effective in the end you keep all the big, beefy '11+ parts.

-TJ
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:34:45 PM
Now having said that

There was a reason I wanted to "Go back" to the 6.5" lug pattern.

The 180mm pattern is really only for the 2011 forward GM HD's...whereas there are millions of trucks with the 6.5" pattern.
Now consider my theme
Survival
I get a set of tires shot out or worn out or just out
I find the nearest Ford or Dodge and I'm back in bees-wax (I guess that meant back in business)as my momma used to say!
So I didn't look at it as a defeat, but a step toward the ultimate survival truck.

...t****:
.......The point wasn't that those hubs are your answer, just that they are big hunk of metal carved out for a specific duty. Anything can be made... it's just a matter of cost. I still think a custom set of hubs (maybe 3 total, to have a spare) would be less total cost than changing everything else. Then there all the advantages of keeping your big brakes etc.

-TJ

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:42:00 PM
Quote:
Originally Posted by t****
Thank you sir! I just try to think beyond what is available or easy and pick what is actually best. If you can keep your LML brakes, swap rear hubs to keep the bigger rear axle bearings (and LML brakes) out back, and run a super-common lug pattern that does fit your requirement better.

-TJ

Ah, young sky-walker, that is exactly what we are trying to do at the moment.
Beau is fitting up the factory caliper and both rotors, 10 and 11 along with his modified bracket to see if we can get all that to work.
The one piece that seemed insurmountable was the 180mm lug pattern.
Given that I'd rather have a more common size, I'm not arguing with that issue, it's a work around
The good news is that very soon indeed, we will have figured out haw to SAS a LML truck the right way and have parts to duplicate...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:42:26 PM
Well, I continue to press forward on the Square D project, which will back up this truck when it get's plasma'ed.
That is turning into more of a project than changing out some fluids and a couple parts.
Check out that build thread to see how it that Dodge Cummins build, in a Duramax forum, may now have a Ford Sterling rear axle...
Yea...
No I don't understand me either...

Edit: But it's Sunday. I'm going to the Lord's house, I need to get recharged
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:43:26 PM
save
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:44:14 PM
Quote:
Originally Posted by BobbyB
Any new parts show up / any more word?

The tone ring is pressed onto the newly milled hubs

Awaiting the shocks

I came up with a possible total redesign for the rear suspension

1. Weld on WFO's 2010 shackle flip kit, 1" higher to maintain current ride height

2. Eliminate the block, keeping the factory spring

3. Fab up an axle and a frame bracket for a level resting panhard to aid in cornering and sway control with the springs mounted in the extended position

4. Fab up a single arm traction bar with a shackle style front mount that allows for full flex, but no axle wind-up.

All that during this morning's 4 miler!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:45:26 PM
                                                                                                  (7867)
Quote:
Originally Posted by Armalite 
Why swap out the axle flip kit? You already have one installed, so I'm assuming that the new one will add height, by 1", is that correct?


The single arm traction bar will work. Seen that setup used on a friends monster truck down here. Running 2.5 ton rocks, with 6' tractor tires. Used a single traction on front, and a single on the rear. Kept them from winding up, but he was able to keep all the flex when tackling those bad holes that he needed the flexing in...

I flipped the U-bolts
Shackle is still factory configuration, which is a pretty good design.
But to keep it, I would have to eventually get new springs in order to eliminate the block(s), instead of just reusing the excellent factory spring.

I built a single sided traction bar for the Tundra...I might have posted it a thousand or two pages ago, can't remember...
But I know how to do the design, Bar mounts to top and bottom of axle with a simple bushing. Then triangulates to single front point which has a Johnny style joint. That connects to a shackle which connects to the frame (cross member) with another bushing.
As the axle moves up and down the shackle simply moves fore and aft. But the moment the axle tries to rotate due to engine torque, it is prevented, and actually lifts the rear of the vehicle instead. This momentary lifting force applies a force downward (Newton's third law of physics, for every action, there is an opposite and equal reaction). The downward force acts to plant the tires harder into the pavement (Mulch beds) providing more traction (Just in case you get into some of the slippery cypress mulch!)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:46:25 PM
Quote:
Originally Posted by nmeyer414 
So its been a while since we have heard anything about big red. Whats her story as of late?

Big red sits there with the trans partially torn apart. It's $3200 for the parts and another 3K-4K for labor...Figure $800 a day to install it.
The problem I'm having is that only fixes the transmission with used parts. The final drives would remain untouched and could fail. For now on every time something breaks, figure 10K.
So I have 20K invested in it at this point. It's a cool piece, and I need a track unit. But there are just no guarantees it wouldn't fail right away like it did this last time.
My wife actually wants me to but a new Caterpillar!
I started way back when looking for a compact track loader, sort of like a bobcat, but with tracks, and that eventually led to the purchase of big red.
I need a permanent piece of earth moving equipment to develop the farm into a training and "camping" area, but I can't just throw away $$$.
I did find another 1150B Case but this one is a rebuilt and painted Dozer, not a loader. It's only 5K so a great buy...Am considering it and parting out Big Red or keeping it on the farm hoping I can fix it cheaply...Dammed shame!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 14, 2014, 11:47:56 PM
                                                                                                    (7893)
Here's an update:

I am continuing to acquire parts for the SAS

Beau is still messing around with the caliper adapter to use the factory LML brakes on this early HPD60

I am really hoping he will be able to figure that out.

Other than that, I am spending every day building out the Square Dodge which has turned into more of a restoration than a simple repair.

I just can't stand to do anything half way. I want it looking new and running that way as well. Square DI is coming along nicely though and will be a great truck to use part time and depend on whenever I need it.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:04:11 PM
Update:
Talking with Beau over at WFO Concepts today. He has the front caliper brackets prototyped and is having them laser cut in a day or so. These will mount the slightly longer LML wheel anti-lock sensor, but, sadly, will use the 2010 calipers and rotors.

That's not all bad, I mean I will lose some braking with the LMM stuff being smaller, but at least I retain the anti-lock feature and keep the calipers fairly modern. The hubs are finished and ready to ship.
Of course even though I will have all the parts, I will still not begin the tear down of Combat Max until Square D is up and ready to assume transportation duties
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:08:07 PM
Project update:
The truck got washed!
That's big news around here! I'm not sure I ever washed it before!

Anyway with the beehive of activity going on with Square D, the poor old Chevy is just living a normal truck life for now!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:10:03 PM
Anyone see those HMMV wheels/tires I have over on my 12 valve survival truck build thread?
Well, looking at the worst tire on the D-Max, the left rear, now below 50%, and with snow approaching...I am thinking
Thing is, that to run HMMV wheels, I'd have to change up the bolt pattern to the 180mm size.
But to build in the SAS, for now anyway, I need to stick with the 8 on 6.5" pattern used on LMM and earlier.
Possibly me or Beau can figure out a way to build the 180mm pattern into some custom hub later on, but for now...
Looking at Stazworks centers, the ones pictured below. It sure would be cool to add a set of double bead locks onto the LML about now, instead of waiting.

After messing with those Armee tires/wheels, I'm thinking I will be stepping up to the 37" tire with the SAS conversion... That truck could really use larger rubber to cut down that 4.56 ratio somewhat. I think there is easily another 1+ MPG in that motor by reducing the rpm and using the torque more...
(http://i.imgur.com/kF6RDg7.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:10:47 PM
Quote:
Originally Posted by streetrodchev 
I don't know if it will work, can you just swap the hubs and rotors from the older trucks to get the 8 on 6 1/2 bolt patern on the rear? Or will you have a spare for each bolt patern?

Actually you hit the nail on the head. I am planning to try exactly that, swap out the rear hubs for the 2010 units and see how that pans out.
It may be possible, but the 11.5 AAM actually got upgraded in 2011! Tate check me on this, but the carrier bearings are bigger on the LML over the LMM. We (Me and Beau of WFO Concepts) do not know about the outer hub bearing yet. Or the axle. I think the axle is the same which helps considerably, but just not sure.
The problem with the front is that you can't drill a Dana hub to fit a stud at 180mm. It gets into the very edge. We have some hope in looking at custom hubs. Beau is looking into that to see if they can tool up to make one to accept the wider bolt pattern.
We have solved the rotor problem for the 6.5" bolt circle, though by using a Dodge 14" front rotor and Beau's custom bracket and our stock front caliper. I really want to keep all that as stock as possible. As of right now he has the Chevy reluctor ring pressed onto the Ford hub, so the brake computer will not know there is a HPD60 sitting under there.
Like I said some time ago, I need to mature this technology a bit more before pulling the Plasma out and committing me.
I am installing most of the link suspension setup into my square Dodge as an enhancement to it, and as a dry run for the eventual Chevy build.
We're just getting smarter all the time!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:12:34 PM
Posted by El Tate:
The carrier bearings remained the same, (3920 races and 3994) but the inner pinion bearing did graduate to a much larger O.D. 4.375 and is now a New Process timken factory. like most GM projects, the ring an pinion stayed the same, but the housing changed around it giving it a higher load capacity. I happen to know a few people that deal with bearing hubs...(yukon spin free kit for dodge) if i knew the dimensions you were looking for in particular i could at least check stock on blanks. PM me details if you like and i'll see if it's even a possibility.


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:13:06 PM
Quote:
Originally Posted by Armalite 
Was hoping to get back and read about some cutting going on in the front end of this black truck... 


Sorry buddy...
Tate is sitting on the edge of his chair as well...
I seem to have gone whole hog on the Square D project. It is turning into a complete restoration/build in my typical style...I still haven't sourced the 105mm cannon, but I'm looking!
That build is consuming all my time and will for some time to come. When it is done enough to drive and be proud of what I have, that is when Mr. Plasma meets Mr. Chebby for a major weight loss program!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:16:16 PM
Some unrelated photos, considered DOT posting:
(http://i.imgur.com/UzY7cSd.jpg)
(http://i.imgur.com/UXTWIhZ.jpg)
(http://i.imgur.com/o9cmJiu.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:18:28 PM
Quote:
Originally Posted by Cudakidd53 
Thanks for the cool photos- answered my question on how the rotors turned in relationship to each other, -in opposition to each other "like" a blender. I wondered if the were both going same- guess that'd cause the craft to corkscrew everything you goosed the throttle?

Yes, they turn opposite and mesh in the center. They are separated by a combining transmission which both engines feed into at the front of the aft pylon. It's one of the secrets to the success of the Chinook. There is no torque effect as each rotor cancels out the torque effect of the other rotor.

Tail rotor helicopters like the Black Hawk have the tail rotor to keep them from spinning. Those tail rotors use a lot of available power. So essentially the tail rotor sucks up power just to keep the pilots from getting dizzy!

Most tail rotor helicopters use 60-80% of their available power just to hover! A Chinook with no load uses 40% !!
It has so much extra power, it can actually hook up and carry, Earth!

The Blackhawk sometimes has a problem with lifting its paint!

No throttle goosing when two 4,500 horsepower engines are trying to rip themselves off your aircraft! You set them at 100% Rotor RPM, and governors keep them there. Goosing the throttle is done with the thrust (Up-down) lever

The Blackhawk has no such power problems, because, well, it has no power!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:24:14 PM
Posted by Cudakidd53:
Poor neglected BattleMax.......gone the way of Big Red, Tac Topper and Gator Build.....we still think fondly of you all and eagerly await your returns to the lime light. Some day, SquareD will be coved in salt and dust, and you all will be wrenched upon again soon. WELLLLLL maybe not Tac Topper.


...Don:
Naw the tac topper is gone, gone, gone

You will see Combat-Max wrenched on again...as sure as I own it, I will not be able to properly leave it alone!

To update the progress on this build,

I will be using the same coil spring setup as I eventually arrive with for Square D. The more I thought about it, the more that a single unit, coil-over shock setup was literally gambling on the success of just that one unit. A simple coil spring would be much more durable alongside a replaceable shock absorber would be more along the lines of a survival truck requirement for simplicity and stuff that works.
Hopefully this suspension on the Dodge 12 valve swap will be fertile proving grounds for what is to come.



Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:25:31 PM
Quote:
Originally Posted by Armalite 
Ohh boy... 24 valve p pump... We may get to that in 3-5 years from now... 

We may indeed!

Here's the way this is rolling out:

The chebby is a great truck. I have made it extremely capable for the nightmare scenario I am preparing for.
The Dodge which I am crafting up already has all of that and is of a more simplistic (Maintainable) design. And it will survive EMP and run on chicken grease. The Duramax will do neither. It will be a huge planter should the north Koreans or Chinese or Russians or Iranians pop a nuke in the upper atmosphere over these united states.

If I went backward in time with the Chevy, removing that wonderful Duramax engine and ally transmission, the sale of all that stuff would almost pay for the 6BT acquisition and installation. Then I would have a truck fully capable of handling anything.
Plus the 6BT's can easily (As in more easily) be turned up to make as much power as the duramax engine, and there are no tunes! Nada on the electronics! No messing with cruise or tire size to get some da$$@!ed sensor to think it is doing the right thing. In fact, there are no sensors!

Just good old Chevy truck with a reliable, tunable, dependable, post society meltdown truck!

So, yea, a 6bt in the Chevy is a definite possibility, and I do not believe that would be "Going full retard!"
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:29:05 PM
Quote:
Originally Posted by FBJR 
Don, know the max is on hold but came across this and thought of your issues.

08 Duramax TT GT4718r/HTT66 build - Norcal1320.com

I don't think I am going to mess with that engine any more.

After messing with that old 12 valve mechanical injection Cummins motor. I am not going to put another dime in this incredibly complicated Duramax engine.

I think what I'll do is finish the Dodge build, then do the SAS on this truck, then yank out that Duramax and about a cubic yard or wires and replace it with a built P-pumped Cummins mechanical injection Cummins engine.

Seriously, why are we messing with this lunacy anyway? It's so restrictive, so complicated and we spend thousands eliminating stuff and playing with tunes that mechanical injection diesels don't even have!

I mean, how can this be a survival truck when a decent sunspot will kill the electronics.

Yea, I know I said all this before, but the more I work on that ancient Dodge the more I am wondering why I sew 60K into this truck when half of what it offers and has I don't even need.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:30:23 PM
Quote:
Originally Posted by duramaxdarren 
What are the exact results of an EMP. Not what the movies show us. As far as vehicles go? If the diesel is running will it just die? Do we need all that would be effected to keep running? Would my Chevelle run? Got me thinking about having a back up plan




It depends on what size nuke and at which altitude it detonates.
If it's low altitude or in the atmosphere, the effect is only slight. Well other than you just got exposed to the surface of the sun and the explosive force of every round fired from the WW1 and back through the beginning of time, EMP is probably only local and in the (I'm guessing) thousand or so watt range.

But a funny thing happens when the weapon detonates a couple hundred miles up. Is it called the Watson effect?? Can't remember, but the effect of the earth's magnosphere multiplies the pulse of electrons hundreds to thousands of times. So assuming someone wants to hurt us, I'm guessing they loft a pretty weapon from ships off our left and right coast to say 100 miles in altitude and pop them.

The pulse would likely be in the hundreds of thousands of watts range. So picture a wall of something like static electricity where everything it touches now passes it on. Big wires just pass it along, but when you try to squeeze all that wattage into a fine wire, say like a circuit board, then the wires all just pop, melt, or get fused together. Electronics which control everything are noting but micro fibers. To EMP these circuit boards are akin to kindling!

If your chevelle has a carburetor and a distributor with points and a condenser, then it will start just like it doesn't know the end of civilization just occurred.
Your Duramax will never run again. All computers, sensors, switches, processors and a lot of wiring would have to be replaced. The factories that make that stuff would also have been destroyed...forever.

You see the scale of the destruction is so immense that we don't recover, at least not to anything we would envision. The modeling I have seen suggests one in six survive the first year, and maybe a forth of them go away during year two. Starting with 350,000,000 people in 1 Jan, the following year the US population would be less than 60 million, the following year we would start to stabilize around 45,000,000. A city of 3 million would be sitting around 480,000 and in trouble then settle around 360,000.

That's not the whole truth though. Because of the effects of the loss of civil control and civil obedience, the cities would suffer much worse numbers and those still there would likely live a hellish existence. All the 99% ers would be gone or turned to anarchy and the smart ones who protected and fed and managed would have long since departed. Country people, however, would now form the bulk of the survivors.

That's why I am not so worried about "it" if it happens. The loony left would be left to suffer that which they fostered and created, while we "Normal" Americans would inherit a ruined country to rebuild, but that's what we do anyway!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:34:35 PM
Yesterday my D-max let me down for the first time

I started it and after maybe warming for 5 minutes it shutoff all by itself.

Hmmm. so I started it again and it ran for maybe 2 minutes, then died

It did that several times so I abandoned further attempts.

It was around -9F outside so I suspected gelling fuel

I grabbed my trusty spare Quoffee pot and drained the water separator part of the filter into it.

Just look at what came out:
(http://i.imgur.com/17klVC8.jpg)

That was Kroger stuff that I am paying less than $3.00 a gallon for with my discount, so I run a lot of it.

I tried an little experiment

I brought it into the house which was 71F and set it on the counter
(http://i.imgur.com/LfqyCTt.jpg)
(http://i.imgur.com/UBt7w81.jpg)

Then 30 minutes later:
(http://i.imgur.com/Twanz8G.jpg)

Quite a difference between the stuff below zero and near room temp
(http://i.imgur.com/uu2wkbs.jpg)
(http://i.imgur.com/A5xfRWg.jpg)
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:54:02 PM
Quote:
Originally Posted by tcr0148 View Post
4.56 and 38's are what I'm running and i have no complaints!

Hmmm...
Everyone has me thinkin'

Here's the truck as it sits today
(http://i.imgur.com/fCipzQ6.jpg)
(http://i.imgur.com/nCnZn5M.jpg)

And a close-up of the front and rear tires.
That locker is chewing up the rear tires a bit, which I'll gladly accept given the excellent drivability I have gotten with it over the G80 Eaton break-ah-locker
(http://i.imgur.com/bYKdOIQ.jpg)
(http://i.imgur.com/uH7DpD1.jpg)


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:54:45 PM
Quote:
Originally Posted by nmeyer414
If rust is on combat max, I would ahte to see what has happened to tac gator.

so since big red has not been talked about in a while, whats the status of her? (Sold or?)

Big Red might be coming back

Duane introduced me to Dan, to be known here with, as "Dan the Man"

He and another gentleman can actually machine the shaft that broke that Case no longer supports!
Yea...

And the problem with the fuel in the oil.

Leaking injection pump???

Dan the Man's brother is a diesel mechanic

I'm smellin a rebuilt refurbished Big red, which will become Big Green when I OD it out...I can almost smell the diesel smoke from here!

And

Last night

I had a dream of me cruising the farm in the bottom of a big hole sittin on big Red...
Like
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 09:59:05 PM
Quote:
Originally Posted by BobbyB
Any word on the brake situation you and the guy were trying to figure out? Anything new?

No, Beau seems to have gone dark...

Maybe the commies or hippies (Same thing) got him!

I think I'm gonna have to cipher that out all by my lonesome
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:03:44 PM
Quote:
Originally Posted by stlaser 
Maybe I can help with custom brackets etc, I have a little experience there in that dept.....


You sure do!

To recap, I was looking at several directions. One using all the stock stuff, bolt pattern and so forth with factory 2011+ large calipers.
Next we were looking at using the big Late Dodge rotor which has the 6.5" bolt circle and the Chevy rotor just so the master cylinder still works OK.

Next up was downsizing to the 2010 and earlier Chevy HD setup, caliper and all, and swapping out stuff in the rear to fit the new bolt circle.

Beau was in the middle of trying out a bunch of parts when his company got a huge order from that electric car company. He was distracted from my project to say the very least.

Right now, it isn't a factor because of Square D, but as that project matures and is finished, then the attention will once more shift back onto the SAS D-Max .


Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:04:00 PM
Folks, the more I play with this truck, the more I think it is one huge mistake and problem dealing with all this unnecessary garbage.

I am so fed up with all this wiring and electronic do-dads, that I may very well be the first to convert a late model 2500 to 12 valve Cummins power.

No electronic programs to write. No overpriced fuel pumps. Room enough to actually see something, and the ability to work on it without it taking a week and requiring post graduate engineering PHD's.

I am sick with this electronic stuff...Did I mention that already???
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:08:57 PM
Let's talk about the future of this truck

To say the very least, the building of Square D, the 12 valve Dodge 1991 truck has been an eye opener.

I can say unequivocally, that building this LML truck as a survival vehicle is a flawed concept from it's inception.

You see, it's just too complicated to last in a survival setting where there is no access to a parts store and troubleshooting, and tons of support.

It is just too complicated. It is too expensive, and it will not survive an EMP event intact. It would be useless.

Used in the modern world where one doesn't mind waiting for someone's permission to tune or until someone writes a "Tune" or provides extra fuel or figures out how to fit some brakes to make some practical wheels to fit.

Bottom line: Not another cent is flowing into this truck until I decide whether I install a 12 valve Cummins into it, which is choice #1 or just sell it.

The latter would provide a vacancy which I would fill with a much older non computer controlled square fender Cummins powered Chevy or a Crew Cab Dodge circa 1991-1997 that has no rust.

I'm just going to be happy without some widget calculating how fast I am travelling. Nope, I think I prefer a worm gear and a steel cable noisly spinning a set of nylon gears that attach to a orange needle which points to 70mph.

I don't want some complex software computer logarithm determining how much fuel to dump in the cylinder at this exact millisecond. Nossir, I think I'll be happy with a purely mechanical Bosh pump and a mechanical injector which knows not whether it is pumping or spraying diesel #2 or chicken grease into my marine grade engine. I don't want some pressure switch failing and putting me into a limp mode...Fact is I don't ever want to know about no stinkin' limp mode. If it fails, well, wait a moment, it won't be there anymore so how could it possibly fail????
Exactly...
And when I look for a turbo, by golly I want to see it. I don't want to have someone point and say "I believe it's down in there somewhere." When that turbo fails, I want to trip in the dark and fall on it. I want to be able to pull it off in three hours, not three days. I don't ever want to have to delete anything, because, lookey there, it isn't anywhere to be found!
No catylitic converters converting anything. No pre heaters for an EGR that really doesn't do anything purposeful. No strange caustic cancer causing fluid being injected on or in anything, just dump oil dino inspired fuel finding it's way down some equally dump steel line into something with a couple of moving parts and spraying into a horribly inefficient combustion chamber, that, oh, by the way, is producing about 22 MPG and causing a fire that only ends when it runs out of the wet stuff.

How in the name of anything that makes any sense at all have we been duped into thinking tunes or star mags and 20" tires mean anything except that we are all really, really stupid? We gave up $20K vehicles that ran on anything so that we could purchase 60K cadilliacs that can scratch your butt, but go into some failure mode half way across a stream on your first outdoor trek! Why did we give up 20+ MPG for computer controlled engines that don't pollute anything and through the magic of their wizardry produce tons of power and 15MPG. So I pay 3 times more than I need to so that I can get 25%-30% less mileage just so that some geek driving a prius that likes other boys can feel he is helping save the planet?

Well, forgive me Mr. brain dead, self induced comma, I'm getting off this bus...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:10:27 PM
As I became more and more serious (Focused) on what this build was going to be about, the EMP think became the white elephant in the room. Not so small either was the problem with all this electronic overlay. HEck if any of a hundred different and unknown parts failed, I'd have stacked all my eggs in the single basket and proven only to have been a very busy fool.

Now that I think I have encapsulated what a pseudo combat vehicle needs to be, these newer trucks are not useable. Well, not with the existing powertrain. Now, install an early mechanical fuel injection diesel with a non electronic transmission, either a manual or an old school automatic, and then this truck is in there. Just needs some additional hardening...

So I have to look at the cost of converting it vs selling it to recoup the $$$ and simply hunt down the right early truck to convert.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:13:07 PM
Quote:
Originally Posted by duramaxdarren 
Ok ok ok. Now before you go a sellin combat max or doing something crazy like . Let me ask you something. Can we shield against an EMP? What would it take to shield against it? Can you feasibly install it?



A thing called a faraday cage routes electrical current around things. EMP is essentially just a big wave of electricity that crashes through things and overloads circuits, destroying them physically.

Military wiring harnesses reside inside a sheath of braided wire which all runs to a ground. It works to a point. But if hit by a big enough pulse, that won't work either.

Something like an old school galvanized steel trash can is a faraday cage. put your radio in there and it would survive intact following an EMP event. I have seen one guy with a length of chain welded to his axle tube, and allowed to drag on the ground. He felt this effectively grounded him and would allow the voltage to flow through the vehicle onto the ground. Thing is when a sewer pipe full of hot rushing liquid meets a fine filter like the electrons of EMP finding a micro circuit, chances are the blockage will get blown out.

No real way of absolutely insuring fine electronics will survive an event, so to absolutely guarantee you have stuff that works, don't use electronics that are essential to it's operation.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:24:39 PM
BTW, I test drove a 2012 Ram 3500 dually this weekend.

It has a solid front axle so I got a taste of what that would ride like.

I have to say the Chevy has it all over the Dodge. I do like the Cummins engine better, but the ride is all Chevy.

Plus after a few hours of highway, country, and city driving, the mileage on the truck's computer only said 13.4

That's terrible!

Cuddos to the Chevy Duramax guys for getting that engine sorted out

Granted I'm deleted and tuned, but the mileage on my computer said 17.3 when I pulled into the dealership!

That makes the Chevy's mileage 23% better!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:26:30 PM
Upgrading to second gen Rare Parts Tie rods today

The first set of 1st generation ones are all worn out!

I believe it is a lubrication issue. I pressure washed the truck a lot during the salty winter and that pressure washing blew away the grease me thinks...The sockets were dust filled!!!!!!!

New ones are here, headed over to the shop...

Look at the difference between the stockers, 1st gen and base ball bats about to be installed:
(http://i.imgur.com/gQZFZOi.jpg)

Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:33:45 PM
Quote:
Originally Posted by OVERWATCH_09
I know we're way too far into this for you to care, but just for future threads, make sure you reference the POST #, not the page #.

I've got my posts per page maxed out, which only yields a total of 211 pages and renders your index totally useless. Post # never changes though, which would be much more helpful.

Well before the great candy bar fire of 2014 cast its ugly spell upon me, I was hard at work on coming out with my own site. I/we are going to pull these threads/posts and feature them on a pay part of that site. I'd update periodically here, but host over there

there you will have more of these build threads including Duane's transformation from a Blackhawk pilot into a respectful man
oops, started day dreamin' there! But his build of that 76 power wagon into the best in the world will show up there.

I will be building other vehicles as well, and even get some of you knuckleheads to stop by and pull weeds all weekend in exchange for a rooe rack or something.

So the growth will not be happening here, although I will share here as well as at expo forums and perhaps some other places as well.

CM...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:41:31 PM
A bit of DOT activity before I hand the reins back over to Don:

Quote:
Originally Posted by Cudakidd53 
ALRIGHT! That's more like Don! Bobby, I'm thinking if we showed up on his doorstep right now, we could prop him up in a Lazy-boy with a custom built workbench (old door over saw horses with a protective cardboard top) and serve as his human "grabber" (thing used to pick stuff up without bending) and if we could get Duane there as technical overseer, make some progress!

Keep healing Don- in all seriousness, glad to see more cognizant verbiage flowing from the keyboard 

If Duane came over all work would stop. Atmospheric conditions would not favor the particular molecular makeup of my sockets or something insignificant like that.
Duane is so particular and has standards so high that work is seldom or ever produced. The forethought that went into the project, however would have maxed out the Pentagon's Cray computers.
One day he was checking his own work, I heard it said...
He was checking to ensure the break away torque of the bolts he had just torqued was perfect. He allows the lockdown torque plus or minus seven millionths of an ounce.
As the story goes, one offending bolt in a hyper-critically stressed part did not break within the gracious .000000000007 of an ounce. That part, the vinyl steering shaft cover if memory serves me correctly, was improperly secured!
Blasphemy!
Out came the holy oil, incense, and much gnashing of teeth!
Afterwards he took the appropriate corrective action which started, of course with discarding of the bolt, the vinyl trim, the steering column, and indeed the entire vehicle! Next I believe he set fire to the garage, spread the ashes, salted the ground, and sold the property!
I stopped him on the way to the church where he was going to enter the priesthood and run out his days in silent meditation of his immense failure.
We barely saved him from that one, and I can only hope we never see anything like that happen again!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:43:13 PM
                                                                                   (8462)
Got some new projects in queue for Combat max.

I want to add on a roof rack now, then really beef up the front end so the truck can punch through heavy stuff unscathed.
I'm thinking it needs two 3/8" thick steel uprights and then some tubular cross bracing that wraps back around the headlights.
Then add in some steel cables from the corners near the headlights up to the roof rack and those should direct debris and branches away from damaging the windshield.

I thought about integrating a hi-lift jack, shovel and axe into the front structure, as in bury it in the steel so that it is protected if the truck punches through a wall, but also provides secondary protection from branches, boards and debris from getting to the radiator, intercooler, and other coolers.

Right now, I am no longer settled with adding the Dana 60 to the front. The existing front suspension is robust and frankly, working well. No decision here, but when Square D gets up on it's feet and I can evaluate a Dana 60 front on longer springs, I'll have a good comparison.

I still definitely see a mechanical fuel injection 12 valve Cummins under the hood somewhere down track...without that swap, the truck will not be useable following an EMP event. So until I figure out how to harden all these delicate electronics, I'll inevitably go down that road.

The truck does not have many miles still, only mid 40's (K), but is running very well. The only problem it has had is blowing the hot end IC pipe off the turbo outlet many times now, at pressures above mid 20's. Admittedly, that is a problem and the only remedy I ever came up with that works has been to liberally clean both boot and pipe and turbo with brake cleaner, then spray adhesive into the silicone coupling, then clamp it all back in place.

So far, that has been good, but I have definitely kept my foot out of it, even when towing.

All this new stuff will show up in detail on the new web site and appear here in a one or two pic readers digest version.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 10:46:33 PM
Posted by Cudakidd53:
subject: R.I.P. DOT legacy

--------------------------------------------------------------------------------

Quote:
Originally Posted by flyin6 
You're welcome, glad I could help

I'll be leaving this build thread here, but I condensed it over on my web site...well its actually still in progress, but we took out most of the non related stuff.

REAL MAN TRUCKWORKS & SURVIVAL - Index

Ouch.....all that whitty banter left on the editing room floor!

....by Ken:
.....A whole bunch was left on the floor....like....most of it!!!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: KensAuto on December 15, 2014, 11:02:27 PM
Posted by KensAuto:
My work here is done for now. From this point forward, whoever's avatar is next to a post, that post belongs to that person. I will no longer be the voice of fellow DOTs, nor our Elderly....errr....I mean knowledgeable leader, BIG D.


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I understand and agree that these materials will become the property of the Department of Labor
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Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: Flyin6 on December 16, 2014, 07:55:40 AM
Wow!

Great job Ken!

Ladies and gents, Ken has finally and successfully transferred thousands of posts from the web site where they were first penned to their final resting place, here at Real Man. He is finished the historical phase of C-Max, or Combat-Max the present name for the big Chevy. From now on it's up to me to push that truck in the direction I want it to go. The emphasis is obviously on Square D as we endeavor to get the axle back under the front end and get that power plant reinstalled.
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: Sammconn on December 16, 2014, 12:46:49 PM
Posted by Cudakidd53:
subject: R.I.P. DOT legacy

--------------------------------------------------------------------------------

Quote:
Originally Posted by flyin6 
You're welcome, glad I could help

I'll be leaving this build thread here, but I condensed it over on my web site...well its actually still in progress, but we took out most of the non related stuff.

REAL MAN TRUCKWORKS & SURVIVAL - Index

Ouch.....all that whitty banter left on the editing room floor!

....by Ken:
.....A whole bunch was left on the floor....like....most of it!!!

Well, now that Ken has tirelessly moved it all over here, I believe the DOT legacy can resume...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: Flyin6 on December 16, 2014, 02:56:57 PM
Posted by Cudakidd53:
subject: R.I.P. DOT legacy

--------------------------------------------------------------------------------

Quote:
Originally Posted by flyin6 
You're welcome, glad I could help

I'll be leaving this build thread here, but I condensed it over on my web site...well its actually still in progress, but we took out most of the non related stuff.

REAL MAN TRUCKWORKS & SURVIVAL - Index

Ouch.....all that whitty banter left on the editing room floor!

....by Ken:
.....A whole bunch was left on the floor....like....most of it!!!

Well, now that Ken has tirelessly moved it all over here, I believe the DOT legacy can resume...
You joining that crowd?
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: cudakidd53 on December 16, 2014, 06:03:20 PM
Sammcon.....ssssh.......stay dark on this, we must reserve the element of surprise!
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: Sammconn on December 17, 2014, 02:36:09 PM
 8)
Mike sees my roll...
Title: Re: LML Duramax Silverado Build Thread....C-MAX [Part 3-Titan Fuel Tank & SAS]
Post by: Flyin6 on December 17, 2014, 06:50:54 PM
OK, so at this point, the historical part of this build is complete with part 3

The continued build/life of the C-Max project will be continued in part 3. So with the addition of a couple DOT comments, I'll sticky this Part 3 and in the near future open up Part 4.