Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 453680 times)

Flyin6 · « **Reply #1000 on:** June 23, 2015, 09:25:02 PM »

Rasimmo:

I checked, and you were correct, somewhere in the distant past we were building a bumper. That reminded me to continue, so let's build some more!

First of all I wanted to level the vehicle since that big Cummins and that front end bumper thing are causing those front springs to retire early!

So for now I jacked the front up a bit and placed some jack stands under the front spring eyes to hold off further relaxing.

Flyin6 · « **Reply #1001 on:** June 23, 2015, 09:26:40 PM »

And Yes, the tailgate closes and opens just like normal

Flyin6 · « **Reply #1002 on:** June 23, 2015, 09:29:12 PM »

I started to wrap the bumper around all the way to the wheel well, but quickly decided that that "stretch" was all four kinds of ugly. I couldn't stand to look at it. I thought maybe I could fill it with dirt and make a planter out of it, and grow herbs for Nate, but figured, my bumper specials might not be up to his standards!

Flyin6 · « **Reply #1003 on:** June 23, 2015, 09:29:48 PM »

Soooo,

I cut it off!

Flyin6 · « **Reply #1004 on:** June 23, 2015, 09:30:59 PM »

Yep, that's about right!

So on to the fabrication of the rest of the top plate:

Flyin6 · « **Reply #1005 on:** June 23, 2015, 09:32:04 PM »

And that seemed to fit well enough

Flyin6 · « **Reply #1006 on:** June 23, 2015, 09:33:09 PM »

Next, the slanted filler plates:

Flyin6 · « **Reply #1007 on:** June 23, 2015, 09:34:40 PM »

Remember those two bolts I placed in the bed top halo?

Well, it's time to put them to work

Flyin6 · « **Reply #1008 on:** June 23, 2015, 09:38:10 PM »

That plate will serve as the top anchor for the swing part of the tailgate that will hold the spare and 3 water cans.

I decided to make this part bolt on, if I should ever want to or need to remove it. It will also make mounting the bumper much easier.

The bumper will have a square tubing receiver welded firmly to it. Another piece of slightly smaller OD square tube will through-bolt to the receiver and also to the steel halo, here it is:

Flyin6 · « **Reply #1009 on:** June 23, 2015, 09:39:56 PM »

Next, its time to box in and reinforce the right bumper wing to make it more or less immovable.

I cut a large piece of steel plate and welded it to the underside contour of the bumper wing.

Flyin6 · « **Reply #1010 on:** June 23, 2015, 09:41:37 PM »

And that was further reinforced and tied into the main structure with one of those 1" X 3" sections of tubing.

Flyin6 · « **Reply #1011 on:** June 23, 2015, 09:43:00 PM »

This protrusion along with the side plate will serve as the mount for the receiver tube of the swing away base mount

Flyin6 · « **Reply #1012 on:** June 23, 2015, 09:44:57 PM »

And here the upright is roughed in. It will get trimmed to size and straightened and finally get a tab that will attach it to the steel halo, making this one butt strong tire rack.

Flyin6 · « **Reply #1013 on:** June 23, 2015, 09:46:32 PM »

I'm going to do something cool with that up-right, just wait...I think you'll like it.

So that was what I had time to get done today. So ended build day 273 for Square D

ltldemonz · « **Reply #1014 on:** June 24, 2015, 12:11:26 AM »

Are you taking frame flex into account, I am thinking your bumpers are going to kiss the sheetmetal when flexed out like on a majorly washed out fire road.

JR · « **Reply #1015 on:** June 24, 2015, 12:59:13 AM »

I like the modular build idea but thought the same about clearance.

Will the upper mount be allowed to move with frame flex?

Does SD still have rear blocks??

cudakidd53 · « **Reply #1016 on:** June 24, 2015, 09:47:18 AM »

I'm liking that rear bumper as well! Glad the clearance is GTG though like JR wonder of flex and roll might turn into buckle and bulge? Regardless, the build thread will continue to evolve at that point!

Spark on Don! ;)

Flyin6 · « **Reply #1017 on:** June 24, 2015, 09:49:36 AM »

Quote from: ltldemonz on June 24, 2015, 12:11:26 AM

Are you taking frame flex into account, I am thinking your bumpers are going to kiss the sheetmetal when flexed out like on a majorly washed out fire road.

I don't think so
Frame flex occurs along the longitudinal axis of the vehicle (Front to back)
The bumper attachment points are arranged in a vertical fashion so they act more like a slice of a long bar. The whole "Slice" will react the same. If the frame moved independently of the bed, then body mounts would be torn and see cracks, but that never happens.
If the bed twisted it would do something called "Oil-Canning" which I am all to familiar with having flown the chinook. Take a soda can (Oil can of earlier times) and twist either end in opposite directions. The force manifests in slanted lines of "Twist" in the skin. The skin actually ripples up. Depending on how resilient the metal is it either recovers or eventually cracks (Chinooks)
Truck beds don't do that. The most they do is try to fold in on themselves at the tailgate which is their weakest point. This upright of mine will serve to reinforce that area, and the steel top halo likely really stiffened up how the bed might twist anyway.

No, I don't think twisting will be a real problem. Also keep in mind, my frame has several more cross members that the truck never had. It has the rear electrical compartment box. It has that thick wall rear water/alcohol tank boxing up the entire rear of the frame. It has a new transfer case cross member, it has the structure for the rear anti-torque bar bolted in. The weak area of the frame in the hump has a steel plate bolted over it, the front of the frame is boxed in and on and on.

Flyin6 · « **Reply #1018 on:** June 24, 2015, 09:52:50 AM »

Quote from: JR on June 24, 2015, 12:59:13 AM

I like the modular build idea but thought the same about clearance.

Will the upper mount be allowed to move with frame flex?

Does SD still have rear blocks??

No movement allowed, it will be rigid

SD does have blocks for the moment, but they will soon go away.
With the shackle flip, and longer Silverado springs, I will likely not need a block. I have a 4" block in there now. The shackle flip adds 5" of lift. So right there I will be about the same, but we won't know until I bolt in those new springs.

JR · « **Reply #1019 on:** June 24, 2015, 02:22:35 PM »

I knew you were anti block, just wondered.

Will you add a flap to back of the bumper? Heck with the mud on the farm and kia parts you could be hauling a couple hundred lbs in that cavity!

Flyin6 · « **Reply #1020 on:** June 24, 2015, 08:13:00 PM »

Quote from: JR on June 24, 2015, 02:22:35 PM

I knew you were anti block, just wondered.

Will you add a flap to back of the bumper? Heck with the mud on the farm and kia parts you could be hauling a couple hundred lbs in that cavity!

JR, I think I'm going to punch some 2" holes in it in places to allow stuff to pass through and me access to hose out the inside cavities

Flyin6 · « **Reply #1021 on:** June 24, 2015, 08:14:46 PM »

The first thing I attacked today was the upright swing-arm base. Here it is now bolted to the bed halo support and is very rigid and strong. No give or play what so ever.

Flyin6 · « **Reply #1022 on:** June 24, 2015, 08:16:57 PM »

I had to slice apart that side panel to get the vertical bar to level. No big deal, I planned on plating over that panel with a couple plies of 10 gage to get it very strong while fighting cracking by using independent plies in lieu of one thick piece of steel

Flyin6 · « **Reply #1023 on:** June 24, 2015, 08:17:51 PM »

I have it standing vertical in all axes

Flyin6 · « **Reply #1024 on:** June 24, 2015, 08:20:06 PM »

And here is the little extra you are either going to like or dislike depending on your perspective. This is a 48" hi-Lift jack. I use these things and they are a must for recovery and some maintenance. I was wondering where I might attach it when that vertical bar showed up...problem solved!

Flyin6 · « **Reply #1025 on:** June 24, 2015, 08:21:14 PM »

I'll create a foot to hold it, then an upper arm to clamp it in place.

Here is a piece of 1/4" plate that is about to become that foot

Flyin6 · « **Reply #1026 on:** June 24, 2015, 08:23:20 PM »

By setting 4-7/16" bolts into the foot, which align with holes already present in the jack foot, the jack will slide down onto these studs to keep it located. If I want to add security, a simple nylon lock nut is all that is needed to foil a would be less than really-determined thief.

Flyin6 · « **Reply #1027 on:** June 24, 2015, 08:24:49 PM »

That business got welded to the base receiver tube which made it quite solid. You may have noticed, I welded in a section of angle first to give more welding surface for the attachment

Flyin6 · « **Reply #1028 on:** June 24, 2015, 08:26:05 PM »

To is angled up a tad to allow the jack to stand up with an aft tilt which just might help that tangle foot shed some vines and branches

Flyin6 · « **Reply #1029 on:** June 24, 2015, 08:27:03 PM »

I just kissed the base plate with a 5/8" drill to clean up the holes and make for an easy install/removal of the jack

Flyin6 · « **Reply #1030 on:** June 24, 2015, 08:28:17 PM »

Then the top arm was fabbed up from some 10 gage plate and a couple 1/2" coarse thread bolts

Flyin6 · « **Reply #1031 on:** June 24, 2015, 08:30:16 PM »

Those studs align with the holes in the center of the jack I-Beam. The jack is captured with a "C" clamp and a simple wing nut, stainless, of course

Flyin6 · « **Reply #1032 on:** June 24, 2015, 08:33:16 PM »

That thing doesn't move at all. It's completely solid and rattle free mounted like this and I'd say easy to get to when needed (Unless the truck just rolled on it's right side) :o

Next up, time to close off the open spots in the bumper. But first I welded in the second plate, an angle doubler, and a third plate to bring it all home

Flyin6 · « **Reply #1033 on:** June 24, 2015, 08:35:31 PM »

The squiggly area in plate #2 was just to get me some more weld area to get that bond as strong as it could be.

I just started on the other side when I got the call. "Get a shower and bring the kids to bible study tonight." Of course I wasn't ready so wrenches went flying and just like that, I was done!

JR · « **Reply #1034 on:** June 24, 2015, 08:46:49 PM »

That is a great counterbalance for sure! That jack is just the thing for catching kia's as you pass by. Drill a hole in the bolt above the wing nut for a small lock.

Vertical is good, but does that mean it is perpendicular to the bumper or not an issue for swing?

Is that the "pup" looking at your work??

Flyin6 · « **Reply #1035 on:** June 24, 2015, 09:19:17 PM »

Quote from: JR on June 24, 2015, 08:46:49 PM

That is a great counterbalance for sure! That jack is just the thing for catching kia's as you pass by. Drill a hole in the bolt above the wing nut for a small lock.

Vertical is good, but does that mean it is perpendicular to the bumper or not an issue for swing?

Is that the "pup" looking at your work??

I'm so tired, I'm not sure what you just asked! ;-)

Yup the growing puppy. Fearless mutt. Nothing startles or bothers him. Welding sparks, other dogs, loud noises. Well, spraying water gets his attention, but he comes at it and bites at it instead of running away. But when I take him into the shower, he's crying like a democrat after Regan got reelected!

duramaxdarren · « **Reply #1036 on:** June 24, 2015, 09:53:47 PM »

i'm not sure i'm in love with the jack on the side....perhaps when its painted OD or blitz black. still my thoughts are onpossibly now creating a hang up hazard and a blind spot. not to mention forgetting its on there as you squeeze the nose through and gets snagged causing untold damage or just stopping the SD dead and testing your seat belt

cudakidd53 · « **Reply #1037 on:** June 24, 2015, 10:33:55 PM »

At that point Darren, Frankensnorkle will have ripped off already so not to worry!

duramaxdarren · « **Reply #1038 on:** June 25, 2015, 08:40:11 PM »

hahaha lol very true ;D

Dustoff35 · « **Reply #1039 on:** June 26, 2015, 05:45:40 AM »

Neither Franken-Snorkle nor the Rear-Bumper-Pintle-Mounted-Hi-Lift-Jack have seen the trail yet, so Darren may have a valid point.

For that matter, none of us (Don included) know if that motor is even going to start…

There is an internet rumor circulating (started right here) that the engine in Square D is actually one of those Payr.com hard-foam engine mock-ups that hot-rod builders use when fabricating chassis'…

...so, all of that parasitic-drag inducing hardware hanging out in the slipstream won't make any difference!

SQUARE D IS A HANGAR QUEEN!!! START IT UP AND PROVE ME WRONG!!!

Consider the gauntlet thrown! Stop farting around with bumpers and such! Start it up!

Now, where is that poll function...

cudakidd53 · « **Reply #1040 on:** June 26, 2015, 06:33:52 AM »

Duane- you know that means YOU'LL actually have to report for "hand over turbo" duty; pre-rangers hands are too small and Don hasn't worked with Red Dog enough to get her to sleep next to the turbo and sacrifice herself for the sake of the Build!

Nate · « **Reply #1041 on:** June 26, 2015, 11:57:49 AM »

Quote from: Dustoff35 on June 26, 2015, 05:45:40 AM

Neither Franken-Snorkle nor the Rear-Bumper-Pintle-Mounted-Hi-Lift-Jack have seen the trail yet, so Darren may have a valid point.

For that matter, none of us (Don included) know if that motor is even going to start

There is an internet rumor circulating (started right here) that the engine in Square D is actually one of those Payr.com hard-foam engine mock-ups that hot-rod builders use when fabricating chassis'

...so, all of that parasitic-drag inducing hardware hanging out in the slipstream won't make any difference!

SQUARE D IS A HANGAR QUEEN!!! START IT UP AND PROVE ME WRONG!!!

Consider the gauntlet thrown! Stop farting around with bumpers and such! Start it up!

Now, where is that poll function...

and this is coming from the guy that just disappeared for 2-? months to oversee a pool being built and has left us all hangin in regards to his build..............;D

KensAuto · « **Reply #1042 on:** June 26, 2015, 02:55:18 PM »

Yeah, good point Nate....2 peas in a pod !!

JR · « **Reply #1043 on:** June 26, 2015, 03:23:53 PM »

Well, a garage queen at least, for now,,,,,,,,,,,,,,,,,,,,,,

What I meant on the upright, is it going to be the mount for the swingout carrier? That is why I said square to bumper, vs vertical to the ground.

Now, lets give BD a little break here, he has done more work in the last couple years on Dmax and SD than most of us combined. Dmax does run and pay its way, now SD has to prove itself,,,,,,,,,,,

KensAuto · « **Reply #1044 on:** June 26, 2015, 03:42:23 PM »

JR, you're goin soft on us....remember, you're the one that gave the most grief!!

JR · « **Reply #1045 on:** June 26, 2015, 03:56:23 PM »

Quote from: KensAuto on June 26, 2015, 03:42:23 PM

JR, you're goin soft on us....remember, you're the one that gave the most grief!!

Yes, I started it and will stand by it. You guys are jumping on and now I am just watching the show!!

Carry on!!!!!!

START IT UP!!!

Flyin6 · « **Reply #1046 on:** June 26, 2015, 05:01:46 PM »

Quote from: JR on June 26, 2015, 03:23:53 PM

Well, a garage queen at least, for now,,,,,,,,,,,,,,,,,,,,,,

What I meant on the upright, is it going to be the mount for the swingout carrier? That is why I said square to bumper, vs vertical to the ground.

Now, lets give BD a little break here, he has done more work in the last couple years on Dmax and SD than most of us combined. Dmax does run and pay its way, now SD has to prove itself,,,,,,,,,,,

Yes, the vertical piece is the swing away mount. I couldn't build it because I ran out of tabs, but I have them now so on to swing away things.

Tell ya what. As soon as I get the rear bumper thing done, I'll start the engine before going on to the front and rear springs...OK?

TexasRedNeck · « **Reply #1047 on:** June 26, 2015, 10:50:13 PM »

Quote from: Flyin6 on June 26, 2015, 05:01:46 PM

Tell ya what. As soon as I get the rear bumper thing done, I'll start the engine before going on to the front and rear springs...OK?

I'll believe it when I see it, brother....jus sayin

JR · « **Reply #1048 on:** June 27, 2015, 02:00:49 AM »

Don, I am just on the band wagon now. I'm sure it will run, but with all you have done, we are all anxious is all!!

I understand why you want to have a pro around when you fire it up. Just don't have a run away so wood is handy. The old V12's we did had a mech flap for just such a reason!

Dustoff35 · « **Reply #1049 on:** June 27, 2015, 07:10:46 AM »

Quote from: nmeyer414 on June 26, 2015, 11:57:49 AM

and this is coming from the guy that just disappeared for 2-? months to oversee a pool being built and has left us all hangin in regards to his build..............;D

Fair enough. I see your point. Duly noted.

But its way more than just a pool…

(ready for some DOT action?)