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Author Topic: SquareD Part 2 Here's where we depart the rebuild and start the big change  (Read 117118 times)

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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 #350 on: October 06, 2014, 03:30:09 PM »
And here is the SOB at the end of build day 65:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #351 on: October 06, 2014, 03:32:03 PM »
OK, build time again.
First up today was the removal of the smooth and shiny new lift blocks from the hanging jungle.
They are replacing the old ones which you may remember I reconditioned and repainted
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #352 on: October 06, 2014, 03:33:09 PM »
The old block was 3" tall, this one is 4", obviously providing another inch of lift. I am building a bit of insurance into the suspension with consideration to the larger diameter military tires.
The blocks were physically much larger and dwarfed the wedge sky jacker attaches to the bottom of the hi arch spring. I'm not 100% comfortable with the fact that the block is larger than the wedge/contact area, but sometimes, you just have to take what you get
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #353 on: October 06, 2014, 03:33:54 PM »
With the suspension at the corrected height. it was time to bolt in the traction bar. First I assembled it on a bench
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #354 on: October 06, 2014, 03:34:25 PM »
The welded in mount area turned out OK with the fresh(er) paint
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #355 on: October 06, 2014, 03:35:28 PM »
 ran a tap through the holes in the nose mount, then slid that into place and started bolting it up
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #356 on: October 06, 2014, 03:36:01 PM »
It bolted up just fine
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #357 on: October 06, 2014, 03:36:48 PM »
That mount is not only uber strong, but also triangulated and anchored that side of the cross member, which is the largest in the aft of the frame.

I did some trimming to the muffler front mount by first shortening the studs, then tapp9ing them. Then as I was finishing tapping the thing, I twisted it all to heck and back. I guess all that weight lifting I do works...!
So I built another one with the bolts aligned, shorter and tucked up some more. It's a better fit
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #358 on: October 06, 2014, 03:40:18 PM »
Then it was time to lube the bushings and hardware.
I used a special "Poly" lube which is sticky and stringy, but lasts like a bad cousin staying over too late.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #359 on: October 06, 2014, 03:41:26 PM »
That made sliding it all together much easier than when I was fabbing the thing
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #360 on: October 06, 2014, 03:42:22 PM »
Then the new muffler mount was reinstalled
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #361 on: October 06, 2014, 03:43:29 PM »
OK, we can call the traction bar project in the bag...time to move on

Next up I'll be mounting the air bags.

Now, you might have noticed that this suspension is going to pretty flexy, that is if I detach a sway bar link, and if I just bolt the air bag into place, I believe the suspension will flex enough to tear the bag apart.

Therefore, just like I did in the Chevy, this one will be constructed to extend full, then the mount itself will expand several more inches to allow full travel of that spring.

With that in mind, here is how the lower mount will be constructed
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #362 on: October 06, 2014, 03:44:25 PM »
The inner cylinder will be welded to the U-Bolt plate, and the larger sleeve will be welded to a disk which is bolted to the bottom of the air spring.

The spring will end up sitting about here:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #363 on: October 06, 2014, 03:45:05 PM »
Remember I said I was going to do something about that?

The upper mount will use those holes and be built from a plate that covers all that mess and bolts through some of those holes.

So, that was it for build day 66

Here's the S.O.B. at the end of the day
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #364 on: October 06, 2014, 03:46:31 PM »
Quote:
Originally Posted by Cudakidd53 View Post
Don, did you watch any Extreme RV this weekend? I caught it and immediately thought of you! Military International "like" All Wheel drive with center pivot mounted, telescoping camper box using beadlocks on military wheels and tires. Made in Missouri, four letter town name starts with an "E"..... No, it's not a joke.


We need to open up the discussion on this tactical camper thing
We'll call it:
TacCam
If you're a military pilot it sounds like TACAN
Anyway, what we have going on here is the grand experiment.
Starting off with an EMP proof dirt floor, as reliable as a sunrise, vehicle. Just about any part fits, and frankly there are far fewer of them than with the chevy. None of them are subject to anything that will kill them and most things on this truck that stop working can be corrected with a hammer!

That's survival DNA right there.

So what started as a backup and spare to the D-Max is finding it's way as an equal or more.

I had a big rush on this truck so I could dive into the SAS on the Chevy. Then a combination of immature technology for the chevy stuff and a growing interest in this gem of a truck has spawned what is at the very least a restoration plus.

Had I thought I would be going this far, I would be assembling fresh fenders onto a freshly dipped frame but I did not plan on going this far initially.

The same force is still at work, still very much in play here.

I built tac topper one resulting in an overweight fail. Then came a lighter and better designed topper 2 which busted the weight budget late in the build and it too failed. I settled on a commercial aluminum topper and just gave up on the idea of being able to live out of it in extremis.

But considering this truck, the Dodge, why couldn't I build a unimog looking full on militarized expedition vehicle out of the truck right now. I mean, possibly flat bedding it and purchasing aluminum welding equipment and starting with the aluminum structure of a built on living quarters right on the truck and completely integrated into the truck design?

Well, simply, I could, and I want to. But there would go the utility of a truck right out the garage door! But I would have a true full on survival vehicle. The Chev easily tows the 36 foot RV, so that thing carries a nice house anywhere I want. The Dodge could climb into a holler or mountain pass if needed and sit it out there if properly built.

So while I weld, and sand, and bolt, I am seeing dead space where a 2K generator could be fitted, a 20 gal water tank, a slide out stove and the like.

I'm thinking about it, just not solid in moving in that direction yet.

Think about it, you would be able to turn to this silly thread for years to come and see another ten thousand pics and posts on the never ending build!
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #365 on: October 06, 2014, 03:47:24 PM »
Well, lets get started on the air spring mounts.
We will build some brackets and show everyone how to turn plate steel into the parts one needs. Pricing spring buckets from Ballistic, I saw prices from $40 to $50.
I spent $12 on this sheet of 3/16" plate steel
Granted it took me all day, but this piece was not stamped on a die, it was home cooked
Here is the area of interest:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #366 on: October 06, 2014, 03:48:19 PM »
Once I decided where it was going to fit, the next step was to create a template and fit that to the frame and bag
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #367 on: October 06, 2014, 03:49:00 PM »
That covered all those unsightly holes and fit nicely.

I then made a template out of 1/4" plywood to use to create the steel parts
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #368 on: October 06, 2014, 03:50:01 PM »
That was clamped to the plate steel and a quick drag with the plasma torch produced the blanks
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #369 on: October 06, 2014, 03:50:36 PM »
Next, the corner gussets
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #370 on: October 06, 2014, 03:51:31 PM »
The plate will have to be bent into a 90 degree "L" so I used an old trick of cutting the bend line leaving some small bridges of parent steel:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #371 on: October 06, 2014, 03:52:33 PM »
Then some grinding with the 60 grit flap wheel and we're on the way
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #372 on: October 06, 2014, 03:53:19 PM »
Then, with the brackets clamped in place over the holes, I dusted some black paint over the holes to mark the drill points for the frame mount.

Having made a template for the top of the air spring mounting bolts and air connection, I made those holes as well
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #373 on: October 06, 2014, 03:53:50 PM »
Then over to the brake to bend the 90
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #374 on: October 06, 2014, 03:55:00 PM »
After some adjustments I had a true 90 so I tacked then welded in the side gussets
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #375 on: October 06, 2014, 03:55:41 PM »
Then I made a second
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #376 on: October 06, 2014, 03:56:29 PM »
While those were heating the atmosphere, I cut out the bottom spring mount from the same plate
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #377 on: October 06, 2014, 03:57:36 PM »
Then I made another paper bolt hole template and located the spots for the mount screws
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #378 on: October 06, 2014, 03:58:41 PM »
Then those were welded to the bottom slider
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #381 on: October 06, 2014, 04:00:52 PM »
Then a coat of copper rich U-Pol primer meant for corrosive environments
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #382 on: October 06, 2014, 04:01:38 PM »
After drying, three coats of Nason Acrylic enamel with hardner
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #383 on: October 06, 2014, 04:02:19 PM »
I really don't care if I get a run or two, it's more important to get this nearly unseen part completely covered so it can live down there in the water, mud, exhaust fumes, salt and jap kar parts.

Anyway, I'm tired so here's the S.O.B for build day 67:
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #384 on: October 06, 2014, 04:03:22 PM »
All righty, lets get the air spring mod finished up
The paint dried so after searching out some brass fittings, it was assembly time.

First up, I welded the stationary cylinder to the spring plates
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #385 on: October 06, 2014, 04:04:24 PM »
Then the air spring was mated to the cylinder base
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #386 on: October 06, 2014, 04:05:28 PM »
Next, the brass fittings were screwed in with plenty of Teflon tape
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #387 on: October 06, 2014, 04:06:13 PM »
Then the spring assembly was mated to the top bracket
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #388 on: October 06, 2014, 04:06:48 PM »
I used plenty of grease to hold off the effects of corrosion and moisture.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #389 on: October 06, 2014, 04:07:45 PM »
All of that was slid over the lower cylinder, then bolted permanently to the frame.
All those bolts are total overkill. But since I drilled all those holes, what the heck, I felt I might as well use them (All)!
That's 16 3/8" frame bolts holding those air springs in place. It really only needs 4 per side.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #390 on: October 06, 2014, 04:08:22 PM »
The air lines simply slide in and lock into the fitting completing the installation, well as far as I can presently go with it
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #391 on: October 06, 2014, 04:09:14 PM »
Here's some views of the now completed rear suspension
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #392 on: October 06, 2014, 04:09:59 PM »
OK, that project is in the bag, time to move on again.

Next up is a second aft mounted battery

Here are some of the parts we will be using
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #393 on: October 06, 2014, 04:11:57 PM »
Of particular interest is this cool battery box

It has a back plate which bolts to the frame. That threads into the battery box and is held together by a large stainless spring clip/catch. The cool thing about this box is that it allows you to tuck a battery way up high but if you ever need to service the battery, you simply lower the box or remove it all together with one hand.
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #394 on: October 06, 2014, 04:12:57 PM »
Here is the box hanging in the lower or maintenance position
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #395 on: October 06, 2014, 04:13:28 PM »
And here it is tucked up in the "carry" position
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #396 on: October 06, 2014, 04:14:01 PM »
I'll be using 2 gage PVC coated copper cable
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #397 on: October 06, 2014, 04:14:32 PM »
These nifty mounting lugs will allow me to remote mount a set of jumper cables, or ???
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #398 on: October 06, 2014, 04:16:05 PM »
And these will cover the terminals
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Re: SquareD Part 4 Here's where we depart the rebuild and start the big change
« Reply #399 on: October 06, 2014, 04:16:41 PM »
Here's the supplied lug mount, but I think I'll do something different in the bumper I will soon construct
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