Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 453166 times)

Nate · « **Reply #400 on:** May 10, 2015, 07:37:16 PM »

don, who is this Darren guy?! I remember a guy named Darren from the bean state , but I thought he fell off the planet....... ;D cause nobody has heard from him in years...... ;D

I think we have an infiltrator in our midst........ :P

Nate · « **Reply #401 on:** May 10, 2015, 07:37:24 PM »

whats a krakkin Darren, long time no hear from.

how are the 3 ladies of the house doing? are you feelin out numbered yet?!

duramaxdarren · « **Reply #402 on:** May 10, 2015, 07:49:22 PM »

actually allie is just like me and HUGE daddy,s girl. abby is starting to stand up on her on and do the furniture surfing thing. Kara is good loves her fridays home from work with the girls. i have a slight problem with dogs, well busgy more or less. he is not doubt written the escape plan for alcatraz. thats a story for another day. ya the earth was flat for a while for me and i vanished but never outta reach right nate? being back in the field is great but i never sit down in front of a computer. plus we went through a few sleep months of teething and sleep regressions and i almost filed for insanity.

Nate · « **Reply #403 on:** May 10, 2015, 08:11:13 PM »

welcome back bro, just stop in ever once in a while and give some schematics on how to run electrical wire..... ;D

Flyin6 · « **Reply #404 on:** May 10, 2015, 08:38:18 PM »

Quote from: duramaxdarren on May 10, 2015, 07:10:30 PM

don. trying to catch up with everyone and everyone. been soooo busy with the girls and work. just bought our first house in a great neighborhood for the girls. safe for playin the street and our cars and whatnot. lotta projects around the house to do and makin the barbie jeep a true survival machine for allie is on my short list. just wired the house with full internet access and surviellance cameras. anyway i dont want derail the thread anymore but thought id just say hi and square d is looking macho grande!

Darren,

You've been AWOL for awhile, have to post a demerit!
But you earned a star with the build-up of Allie's Barbie Jeep 8) (Pink camo I assume!)

OK bro, you know the drill. Don't mess up my threads ;)...I just say that so I can say I did say it, although I know you nor anyone else will listen but I have to make appearances of actually being in charge!

So dive right in and get reacquainted!

Welcome back!

duramaxdarren · « **Reply #405 on:** May 10, 2015, 08:42:15 PM »

;D On it Sir!! :)

Flyin6 · « **Reply #406 on:** May 10, 2015, 08:43:32 PM »

OK everyone Darren^ is a yankee. Forgive him for that, he is not a liberal! Boston type, electrician, husband, dad and all around good guy. OK intros concluded!

It was a Sunday so the day got gobbled up and Momma's day as well so my wallet got gobbled up as well, but the food was marvelous and seeing my bride in that outfit she bought with my SquareD project money made it worth it!

But I did have time to do some bumper thinkin'

Ever hear of someone starting with a clean sheet of paper?

Well, this is what that looks like:

Flyin6 · « **Reply #407 on:** May 10, 2015, 08:45:33 PM »

I want to push the nose of the bumper out a bit more to give it a ramming, push and divide feature while giving me some room to access the winch cable should it become fouled so I'm thinking about this much, 2.5"

Flyin6 · « **Reply #408 on:** May 10, 2015, 08:46:14 PM »

Which taped together looks like this:

Flyin6 · « **Reply #409 on:** May 10, 2015, 08:49:45 PM »

Now the concept here is to make the things that need to be strong, thicker and the things that might take a pounding (Kia fenders and such) reinforced. In that vein of thinkin' I am constructing a box of sorts surrounding the winch made of .250" steel, reinforced in many places.

The bulk of the bumper will be 11 gage (3/16") which when triangulated will be mucho strong but save on weight as well

Here's that box shaping up on the bumper frame

duramaxdarren · « **Reply #410 on:** May 10, 2015, 09:01:57 PM »

i might try 3/8 plate. I've seen qauter inch plate take a good hit from a tree and bend a bit. nothing drives me more crazy then something not straight

Flyin6 · « **Reply #411 on:** May 10, 2015, 09:29:13 PM »

Quote from: duramaxdarren on May 10, 2015, 09:01:57 PM

i might try 3/8 plate. I've seen qauter inch plate take a good hit from a tree and bend a bit. nothing drives me more crazy then something not straight

There's no bumpers out there made of 3/8" bro. Most are 3/16 I think (11 gage)
I mean I could do 3/8" because the box is not that large...let me think about it

JR · « **Reply #412 on:** May 10, 2015, 09:41:59 PM »

Yep, the thicker the better IMHO. I think weight is really of little concern here. Bumpers are made for bumpin, not saving weight for the EPA.

I would go no less than 1/4 with lots of supports. Get that little bend out of there by the winch, make it straight.

My bumpers will be based on square or rectangle, not U shaped.

Flyin6 · « **Reply #413 on:** May 10, 2015, 10:19:25 PM »

Quote from: JR on May 10, 2015, 09:41:59 PM

Yep, the thicker the better IMHO. I think weight is really of little concern here. Bumpers are made for bumpin, not saving weight for the EPA.

I would go no less than 1/4 with lots of supports. Get that little bend out of there by the winch, make it straight.

My bumpers will be based on square or rectangle, not U shaped.

A clevis is going in that little Bend (flat area), that's why it's there
3/8" eeh...

OldKooT · « **Reply #414 on:** May 10, 2015, 10:36:24 PM »

My two cents worth, build the bumper to bend. Dodges frame wasn't deigned to be a battering ram. The trick is strong enough to not cave in and allow damage to the grill/body...week enough to not bend the frame.

Sammconn · « **Reply #415 on:** May 10, 2015, 10:49:20 PM »

Yeah, I'm with Norm on this. We want the frame to stay the strong point and the bumper or parts of anyway the 'weak link'. I am of the feeling that the 1/4 - 3/16 plan you are speaking of is the way to go.
That is my plan as well if winter ever lets off its fury on me. Got another 5-6" of snow, ice pellets, rain and freezing rain last week. So I'm waiting it out to get on my front build. I'm liking the paper it out plan, let's you see it first.
Looking good chief.

JR · « **Reply #416 on:** May 10, 2015, 11:50:02 PM »

I will agree with that to a point. build the center solid as a rock as it is square to the frame and will add rigidity. Build the sides to give some, but not to the point where you can't push things out of the way first. Don't need to hit them at 50mph to do the job

JR · « **Reply #417 on:** May 10, 2015, 11:51:39 PM »

"CAD" cardboard aided design

(I can't take credit for this but like it)

OldKooT · « **Reply #418 on:** May 11, 2015, 08:06:06 AM »

This is an example of the fame flex Don will be dealing with to a degree. If you notice that's not a stock bumper. Not my truck BTW

I feel a bumper of similar material thickness as the frame is a good idea. As the picture shows it will then allow the needed movement and still properly anchor the winch. If one ties the "wings" of the bumper to the frame to strengthen the bumper, it will redirect that energy into the frame horns every time the frame flexes. That will in my experience cause the frame to move at the engine cradle and likely eventually crack. Just food for thought....

In simple terms, my experience with 1st gen Dodges has always been "embrace the noodle" it will groan flex/pop and return to normal...

Flyin6 · « **Reply #419 on:** May 11, 2015, 08:22:22 AM »

Good write-up on the frame flex phenomena of the early Dodges.

Remember, I have a heavily reinforced front frame on my truck, an extra cross-member, a reinforced and doubled cross member, a big 1/4" alcohol tank tying the aft couple feet of frame, the super duper front spring hangar cross member that is actually yet another cross member, and upcoming rock rails which almost double the frame's strength.

So this is not the same animal at all my friend.

But, I know a little bit about ramming road blocks (That was taught to a small slice of militarie guyz, and I had made that cut) Plus in the Baghdad and in the Kabul, ramming cars, trash, cinder block walls, and the occasional slow to move haji was all the norm...I have learned from all that.

The bumper has to house a winch, allow it to work to it's full capacity of 24,000 lbs in my case (12K with a pulley at the other end) and push through cars and open and separate a 2 X 4 wall in extremis. The extreme things are (will) likely leave a damaged bumper but allow the truck to drive off the "X".

So 1/4" box with reinforcement actually means 1/2" thick material in places and a dead strong box from which to winch, carried between the frame rails and low, whilst having "wings" plenty strong enough (Through triangulation and reinforcing) to push cars out of the way.

So sez me without quoffee!

JR · « **Reply #420 on:** May 11, 2015, 10:22:19 AM »

Well, Don added what I was thinking, plus you have a single cab.

OldKooT · « **Reply #421 on:** May 11, 2015, 11:38:42 AM »

I won't clutter Don's most excellent build thread with Dodge truck frame ideaers, experiences and simple math... Ima go do that on my build thread, and you can read it there if interested.

Now back to building......

Flyin6 · « **Reply #422 on:** May 11, 2015, 12:13:01 PM »

Quote from: OldKooT on May 11, 2015, 11:38:42 AM

I won't clutter Don's most excellent build thread with Dodge truck frame ideaers, experiences and simple math... Ima go do that on my build thread, and you can read it there if interested.

Now back to building......

Norm,

Feel free to clutter up any thread you desire

Good info is good info. Just be sure to copy it back to your thread for reference.

I already nominated this numbskull for Old Dodge SME, anyone second the motion?

Sammconn · « **Reply #423 on:** May 11, 2015, 01:21:29 PM »

Heck, I'll second it. Seems he may be the ultimate SME, been around and seen a lot of 'em.

OldKooT · « **Reply #424 on:** May 11, 2015, 06:15:23 PM »

SME? SMF would be better...Stupid Middle aged farmer... That fits LoL

Now I have to get back to work staring at a frame, my wife has another pair of shorts and everything....

KensAuto · « **Reply #425 on:** May 11, 2015, 06:59:47 PM »

Norm, you forget one thing, Don's truck may have to "Ram" a parking curb at the mall....at the most!!

EL TATE · « **Reply #426 on:** May 11, 2015, 07:02:13 PM »

Quote from: duramaxdarren on May 10, 2015, 07:49:22 PM

actually allie is just like me and HUGE daddy,s girl. abby is starting to stand up on her on and do the furniture surfing thing. Kara is good loves her fridays home from work with the girls. i have a slight problem with dogs, well busgy more or less. he is not doubt written the escape plan for alcatraz. thats a story for another day. ya the earth was flat for a while for me and i vanished but never outta reach right nate? being back in the field is great but i never sit down in front of a computer. plus we went through a few sleep months of teething and sleep regressions and i almost filed for insanity.

Nice to have you floating about again!

Flyin6 · « **Reply #427 on:** May 11, 2015, 07:04:16 PM »

Quote from: KensAuto on May 11, 2015, 06:59:47 PM

Norm, you forget one thing, Don's truck may have to "Ram" a parking curb at the mall....at the most!!

I've spoken on the dangers of mall travel

When you sink in a mulch bed and have to get one of those cube lookin kars to pull you out, just remember I warned you!

Flyin6 · « **Reply #428 on:** May 11, 2015, 07:07:18 PM »

Speaking of danger, allow me to start tonight's post with a safety tip

Do Not Set Yourself On Fire!

Should you be welding, or grinding, or cutting with a plasma torch and you smell something burning, something that smells like, you, then stop what you are doing and extinguish yourself. Do not use flammable lacquer filled rags to do so with.

Nuff said

Flyin6 · « **Reply #429 on:** May 11, 2015, 07:09:01 PM »

OK, so before I discovered myself on fire, I restored this fender badge and gave it a prominent new home:

Flyin6 · « **Reply #430 on:** May 11, 2015, 07:10:06 PM »

And I installed the transfer case (new) leather boot

Flyin6 · « **Reply #431 on:** May 11, 2015, 07:11:23 PM »

Keeping in the spirit of getting stuff off the floor or out of boxes, I stuck on the decals as well:

Flyin6 · « **Reply #432 on:** May 11, 2015, 07:12:11 PM »

Then for no apparent reason, I stuck one on the alchy tank as well

Flyin6 · « **Reply #433 on:** May 11, 2015, 07:13:44 PM »

You may recall, I had just mocked up the winch enclosure with cardboard. I transferred those onto some 1/4" steel

Flyin6 · « **Reply #434 on:** May 11, 2015, 07:14:25 PM »

All that business got cleaned up

Flyin6 · « **Reply #435 on:** May 11, 2015, 07:15:23 PM »

Then with the assistance of some leveling stock, I tacked up the lower plate

Flyin6 · « **Reply #436 on:** May 11, 2015, 07:16:43 PM »

Then the winch fairhead mount plate got created

Flyin6 · « **Reply #437 on:** May 11, 2015, 07:17:55 PM »

I welded in some 3/4" NFT bolts to make removal of that dude an easy proposition

Flyin6 · « **Reply #438 on:** May 11, 2015, 07:19:23 PM »

They while using a section of rectangle tubing to square it up, that plate was glued and fused into permanence!

Flyin6 · « **Reply #439 on:** May 11, 2015, 07:20:32 PM »

Then on went the subsequent plates

Flyin6 · « **Reply #440 on:** May 11, 2015, 07:22:50 PM »

Then the next panel was ciphered out

Flyin6 · « **Reply #441 on:** May 11, 2015, 07:25:06 PM »

The red dog has not carried off anything to chew up. Seems she has something else to chew on, that chews right back. The sled dog is ignoring me as she lies in comfortable disgust at the loss of all her hair

Flyin6 · « **Reply #442 on:** May 11, 2015, 07:27:07 PM »

Those collection of polygons found fitment on the sides of the fairhead assembly

Flyin6 · « **Reply #443 on:** May 11, 2015, 07:32:22 PM »

Next up comes the "wings" which are spreading out more

Flyin6 · « **Reply #444 on:** May 11, 2015, 07:33:55 PM »

Next up came the inside top riser that takes things up to the grill level

Flyin6 · « **Reply #445 on:** May 11, 2015, 07:35:25 PM »

And the top plate mocked up

cudakidd53 · « **Reply #446 on:** May 11, 2015, 07:36:06 PM »

The sled dog "willed" your shirt on fire for that awful hair cut.....reminds me of that first paint job on the GLO diff. cover! : :(

Flyin6 · « **Reply #447 on:** May 11, 2015, 07:38:35 PM »

Quote from: cudakidd53 on May 11, 2015, 07:36:06 PM

The sled dog "willed" your shirt on fire for that awful hair cut.....reminds me of that first paint job on the GLO diff. cover! : :(

Malamute hair cut: Everything down to the epidermis or nothing at all. Just ask any groomer
Sled dog likes the coolness

Flyin6 · « **Reply #448 on:** May 11, 2015, 07:39:58 PM »

And that right there concluded a pretty good build day IMHO

TexasRedNeck · « **Reply #449 on:** May 11, 2015, 08:28:36 PM »

Arent there a few other stickers/badges/decals you have not installed?? Maybe a Powered by Perkins or IHOP , Snickers, Good Sam Club, Kentucky Fried Chicken?? OK now that I've gotten that off my chest....I'm just anti social and anti emblem