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Offline Flyin6

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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #400 on: October 06, 2014, 04:17:42 PM »
I ran out of time to start fabbing, but me thinks it will be going in here:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #401 on: October 06, 2014, 04:18:15 PM »
KC (Kool Cat) was watching over things
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #402 on: October 06, 2014, 04:18:54 PM »
And here is the SOB at the conclusion of BD 68
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #403 on: October 06, 2014, 04:21:05 PM »
That's the general concept, but these styles, are more solidly mounted, proven in thousands of aircraft, FAA approved (which is a total nightmare,) and unique enough to discourage theft.

Anyway, it's not a big issue, only a consideration as I move forward and build some utility into the bumper design.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #404 on: October 06, 2014, 04:21:45 PM »
OK, time to post up today's progress.
The weather is messing with me, so there was not as much progress as I'd like.
Having completed the Air Springs, the rear mounted second battery is next in queue.
It gets mounted here:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #405 on: October 06, 2014, 04:22:41 PM »
The original spare tire mount was removed in favor of something much stronger
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #406 on: October 06, 2014, 04:24:06 PM »
The plan is to anchor the new frame into each side frame rail. It will actually be constructed in two halves, bolting together in the center. This will facilitate installation since it will actually be larger than the opening due to the shape of the frame.

So first up was to construct the side pieces. I cut them to fit in there snugly and again utilize some of the many holes preexisting in the frame. Once punching the holes, I welded sleeves into the box sections to prevent crushing when the bolts were tightened.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #408 on: October 06, 2014, 04:27:16 PM »
The idea is to bolt this new inner frame to the existing frame and cross members wherever the opportunity presents itself. Looking at it, there will be no need to drill additional holes
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #409 on: October 06, 2014, 04:28:28 PM »
The other leg and the center piece were then tacked into place. The forward bar is tilted to give it more clearance from the 4" exhaust pipe
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #410 on: October 06, 2014, 04:29:13 PM »
This "L" ties the two cross members together much the same as in the original design
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #411 on: October 06, 2014, 04:30:17 PM »
I envision the battery tray sitting about here:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #412 on: October 06, 2014, 04:31:29 PM »
I picked up some 3/16" plate to armor up that area some once the frame is completed
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #413 on: October 06, 2014, 04:32:23 PM »
And the S.O.B. at the end of Build Day 69
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #414 on: October 06, 2014, 04:33:39 PM »
OK not to dwell on a step backwards
The battery box mount is about done. I might fit something else in there yet, so it hasn't been removed for painting yet, but that's coming right up!

Here's the start point for today's labor
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #415 on: October 06, 2014, 04:34:42 PM »
The battery box support frame needed to be tied into the cross member. Using existing holes, I cut some spacers and drilled the holes into the box tubing
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #416 on: October 06, 2014, 04:35:39 PM »
The large piece of angle will serve as a stiffener and will join the two halves of the interior frame together. Here it is drilled for 4- 7/16" bolts
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #417 on: October 06, 2014, 04:36:59 PM »
Yep, that's .250" thick steel. so nothing is going to be moving in that area!

Next the two legs were cut and tacked in to complete the box
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #418 on: October 06, 2014, 04:37:48 PM »
Then spacers and bolts were added to that section as well
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #419 on: October 06, 2014, 04:38:47 PM »
Then two more tie-ins were added between the front of the box and the shock mount cross member. This is probably the strongest that cross member has or will ever be!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #420 on: October 06, 2014, 04:39:38 PM »
Then the battery box mount itself was drilled into place. Note that the bolt also captures the left half of the two piece frame uniting the two pieces in two separate axis
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #421 on: October 06, 2014, 04:40:23 PM »
A quick check for fit shows everything is fitting together like peas and carrots!

The box is shown in the lowered and the raised/stored position
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #422 on: October 06, 2014, 04:41:28 PM »
Then two "Down" legs were added to further anchor the soon to be filled battery box
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #423 on: October 06, 2014, 04:42:02 PM »
You can see that there is no significant loss in ground clearance with the addition of this box
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #424 on: October 06, 2014, 04:42:52 PM »
This was going on outside:

I open the garage doors maybe twice an hour to evacuate the stale dusty air, get all cold, then light the heater and repeat.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #425 on: October 06, 2014, 04:43:32 PM »
Shawn and Duane will appreciate this.
I was looking at that proportioning valve and it suddenly occurred to me I could mount it differently and get the protection everyone thinks I need.

Here is the start:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #427 on: October 06, 2014, 04:44:59 PM »
The nylon tube got melted to death...hot metal does that to nylon, cardboard welding tables, stools and other flammable things, so no worries, it will get "Newed"

It was time for chicken and dumplings, so here is the S.O.B. at the end of build day 70
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #428 on: October 06, 2014, 04:45:53 PM »
Speaking of adding weight, I added some more useful weight this afternoon. let's take a look.
This is the area I will be adding some plating and a pump
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #429 on: October 06, 2014, 04:46:38 PM »
The truck will need an onboard air supply. The rear bumper will be the air tank, and this ARB unit will be the air pump
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #430 on: October 06, 2014, 04:47:26 PM »
It's a respectable, albeit noisy little unit.

I fashioned up this plate to mount it high up in the frame. the base plate is 3/16" steel
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #431 on: October 06, 2014, 04:48:04 PM »
This is about where I think it should be mounted. That will leave room in there for something else which is always coming
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #432 on: October 06, 2014, 04:48:38 PM »
Actually, let me correct myself. It will be mounted aft. in the previous pic it was sitting forward
The holes indicate where it will sit.

I tacked the plate in and checked the fit again
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #433 on: October 06, 2014, 04:49:15 PM »
The fit looks good. Plate beneath, frame to the outside and soon to be battery to the left
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #435 on: October 06, 2014, 04:51:30 PM »
With everything added that I plan for the moment, I pulled the frame halves out and finished welding them together
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #436 on: October 06, 2014, 04:52:28 PM »
As per normal, I used the rotary wire brush on everything, then cleaned everything with brake cleaner in prep for the paint
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #437 on: October 06, 2014, 04:53:23 PM »
Then the primer was sprayed on
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #438 on: October 06, 2014, 04:54:02 PM »
And then the Lycoming gray
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #439 on: October 06, 2014, 04:54:39 PM »
And that wraps up the building of the rear battery frame. I'll install it and run some cables next and wire the air pump in.

Here's the truck at the end of Build Day 71
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #440 on: October 06, 2014, 04:56:02 PM »
No church today...roads are horrible and it's still snowing...

So yestertag I am happily burning metal and bending stuff when I discover just how powerful a plasma cutter really is.

Hypertherm has a great feature. It has a starter arc. It's actually a ray gun. It blows out a lower amperage plasma stream...that is an electrical arc (220VAC) in a focused jet of 90 psi air. So yea, it's a ray gun.
Remember the scene in Ailens three or two where you are inside the survival capsul and all of a sudden some jet thing cuts a fast straight hole right through the door? Well that is a plasma cutter doing it's thing.

So I'm happily cutting this and occasionally pointing it at the cat and pulling the trigger (Because they jump like 6 feet into the air!) and I hit the trigger when my hands were in all the wrong position. I am wearing gloves...That fact is important or I would not be typing my "T's", "G's", or "F's" Without relearning rudimentary skills.

Well you know how fast you can move your hand when you grab a hot manifold or something stupid like that. There is timing involved there. You sense it with the nerves getting vaporized, then the pain signal has to travel to your brain which is, what...about some 3 feet of wire's length away. THat electric signal travels at the speed of light. So we're talking a couple nano seconds here. Then the "OH CRAP, I'M ON FIRE" signal has to spread all over your face then travel back to your arm actuators to pull back away from danger...A few more Nano seconds.
So all of that takes a billionth of a second, give or take... Well in less than that amount of time my glove turned into hot searing gas! The type of gas that things like the surface of the sun is made up of mostly. Then in the next couple fractions of those micro-Nano seconds (If there is such a measurement) the raw plasma reacted with my dermis. My skin did not do so so well against that raw steel melting power, but much to my surprise, instead of seeing a charred stubble of a finger on the floor, it was still attached to my hand!
I had to pull out my best 2" masking tape to repair that one. Of course the pain caused a failure on some recent (And obviously inferior) dental work, but, hey, I'll get that fixed. For me, I learned something! And for you the typing speed is only mildly impacted.
Mission continues!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #441 on: October 06, 2014, 04:58:17 PM »
OK dog or no dog, the build goes on! And I am going to return her as soon as I can figure out who that is.
Back to bees wax as my daddy used to say. I think that means back to business, not completely sure.

SO today it was time to reinstall that "Sub frame" assembly

Here it is going in
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #442 on: October 06, 2014, 04:58:50 PM »
With the left section at the ready
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #443 on: October 06, 2014, 04:59:41 PM »
Those two halves were such a tight fit it took a rubber mallet to smack it in all in there and get it to fit
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #444 on: October 06, 2014, 10:48:35 PM »
Then the back of the battery tray, which I secured with 6 ea 5/16" bolts with nylon locking nuts
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #445 on: October 06, 2014, 10:49:17 PM »
Speaking of batteries, here it is:

An interstate deep cycle group 24 battery
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #446 on: October 06, 2014, 10:49:56 PM »
To get it to fit the battery box, I actually had to saw off the handle extensions molded into the battery sides
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #447 on: October 06, 2014, 10:50:40 PM »
With that sawed off, the battery dropped right in place into the box which is now locked into the vehicle sub frame
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #448 on: October 06, 2014, 10:51:36 PM »
Then it was time to permanently mount the ARB air pump. I decided to install it with rubber biscuits on either side of the base to try to isolate some of the noise it makes...Those things are noisy!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #449 on: October 06, 2014, 10:52:45 PM »
It fit like a glove and was tightened down
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