Author Topic: SquareD Part 6 Bumpers, Winches, wiring, lights, assembly (Read 453784 times)

Flyin6 · « **Reply #700 on:** May 30, 2015, 08:57:18 PM »

Quote from: JR on May 30, 2015, 08:52:12 PM

Capping the mounts will look good and the gusset will help for sure.

As for the upper tube, I'm sure you will think of something.

How are you going to grind all that covered up?

Well, I don't know yet!

I have a selection of 7", 4.5", and 4" grinders, files, porting tools and a red dog

I'll use something to get in there...or I'll just leave it "Rustic" looking!

Flyin6 · « **Reply #701 on:** May 30, 2015, 08:57:49 PM »

Hey Norm, where have you been? It's almost June...!

cudakidd53 · « **Reply #702 on:** May 30, 2015, 09:32:51 PM »

Quote from: Flyin6 on May 30, 2015, 08:57:49 PM

Hey Norm, where have you been? It's almost June...!

I'll bet he's watching Mrs. Norm work really hard on that project!

Flyin6 · « **Reply #703 on:** May 31, 2015, 08:10:56 AM »

Quote from: cudakidd53 on May 30, 2015, 09:32:51 PM

Quote from: Flyin6 on May 30, 2015, 08:57:49 PM
Hey Norm, where have you been? It's almost June...!

I'll bet he's watching Mrs. Norm work really hard on that project!

Yea,

Ever notice we have never seen nor heard about Norm working on it, just Miss Kay...

So I wonder if she has gotten more done on the thing?

I'll give em grace though. It's planting season and they got hammered by spring rains...I'll bet it is/was a mess there

OldKooT · « **Reply #704 on:** June 01, 2015, 10:39:20 AM »

It's been rather unproductive project wise of late. Don was spot on, been fixing washed out culverts, and roads. The driveway at the house ended up mostly in the Corn field behind the property. The roads have been 4x4 only and then sketchy. So no UPS /usps/FedX deliveries. Good news is...... my wife broke out her summer shorts so life is good.

Nate · « **Reply #705 on:** June 01, 2015, 01:09:48 PM »

welcome back norn

Flyin6 · « **Reply #706 on:** June 01, 2015, 09:08:04 PM »

Norm and Miss Kay sighting...good, they are still alive and kickin!

So enough with the excuses...lots of people have washed away roads, no driveways, 2-3 missing children, stuff like that! Gotta work around all that and get that truck done. It's June you have 29 days!

OK, norm, turning up the heat on ya. Here's some more weight added to that way too heavy front bumper.

First, notice how the sweat from a couple days ago rusted that pretty metal up!

Flyin6 · « **Reply #707 on:** June 01, 2015, 09:10:25 PM »

So today was all about triangulating the structure and adding strength. To triangulate, I added these 1.75" Square tube uprights that go from the top of the bumper up to the upper hoop. That will add a ton of strength from a push/pull direction

Flyin6 · « **Reply #708 on:** June 01, 2015, 09:11:42 PM »

I had already started to grind down the welds, so I cleaned off the pad that I would be attaching to.

Flyin6 · « **Reply #709 on:** June 01, 2015, 09:13:13 PM »

I agree with several folks comments about the clearances being pretty tight for an off road machine, so I started trimming things up a bit

Flyin6 · « **Reply #710 on:** June 01, 2015, 09:15:07 PM »

Good, I like that better.

Same-same for the wings:

Flyin6 · « **Reply #711 on:** June 01, 2015, 09:16:12 PM »

Then those new uprights got melted into place

Flyin6 · « **Reply #712 on:** June 01, 2015, 09:18:44 PM »

Then the outboard hoop attachment points were wrapped with some 1/8" X 1/2" steel strap

ce_tx · « **Reply #713 on:** June 01, 2015, 09:19:55 PM »

I'm liking the front bumper, kinda what I have in mine for mine but less plate. How about a tube from the main top hoop to the lower one that goes around to the side fender to protect the front corner of the front fender? Does that make sense?

Flyin6 · « **Reply #714 on:** June 01, 2015, 09:20:15 PM »

Then the outboard mounts were similarly wrapped

Flyin6 · « **Reply #715 on:** June 01, 2015, 09:22:35 PM »

Quote from: ce_tx on June 01, 2015, 09:19:55 PM

I'm liking the front bumper, kinda what I have in mine for mine but less plate. How about a tube from the main top hoop to the lower one that goes around to the side fender to protect the front corner of the front fender? Does that make sense?

Yea, we've been discussing a tube that wraps around high and angles down to the outboard mount, or a gusset plate

There is more coming in tonight's post which sets the stage, so hang on to your horses for just a bit and I'll show what direction I'm heading. ;-)

Flyin6 · « **Reply #716 on:** June 01, 2015, 09:24:30 PM »

Next up, I attached the new upright to the stubs on the main upright to tie all that business together

Flyin6 · « **Reply #717 on:** June 01, 2015, 09:26:58 PM »

Then I tied the top of the bumper below that new upright into the base .250" plate

Flyin6 · « **Reply #718 on:** June 01, 2015, 09:28:58 PM »

Then I closed off the tubing ends to keep moisture out

Flyin6 · « **Reply #719 on:** June 01, 2015, 09:33:02 PM »

Now, we get to the outboard reinforcement for the upright. Still undecided abut which direction I want to go, I built in a base plate, lightened, of course to hold what I have, or prep for the upright reinforcement.

Currently this bumper is getting pretty strong. I think it is easily capable of pushing cars out of the way of piercing and dividing a standard stick build house wall, so I might just stop here.

I am likely going with a light case of exoskeleton, so there in more tubaliarity over that next hill

Flyin6 · « **Reply #720 on:** June 01, 2015, 09:35:21 PM »

The plates required a good deal of custom fitting as each side is slightly different, but I got them to fit in

Flyin6 · « **Reply #721 on:** June 01, 2015, 09:38:22 PM »

Then after application of smoke producing sparks, I had this:

Flyin6 · « **Reply #722 on:** June 01, 2015, 09:40:29 PM »

And that was a spark filled day, numba 261 in the Square D exaggerated oil change

Nate · « **Reply #723 on:** June 01, 2015, 09:44:36 PM »

my mark 1 may be off calibration don, but the square upright you put on the driver side looks crooked....................?

Flyin6 · « **Reply #724 on:** June 01, 2015, 09:50:41 PM »

It's square Nate, did it with a piece of square...but...the outside tube on the drivers side is inclined slightly inward. I noticed it right away. I am nearly 2cm different left to right

DA#(!@&!!!! it!

OK, spilt milk, it's done, I'm moving on...

TexasRedNeck · « **Reply #725 on:** June 01, 2015, 09:55:33 PM »

Looks good Don. I like the horizontal you added. It looks better than what I drew, for sure. Any idea of the total weight so far?

Nate · « **Reply #726 on:** June 01, 2015, 10:06:36 PM »

brother, I just wanted to make sure that your mark 1 has not been compromised.

JR · « **Reply #727 on:** June 02, 2015, 01:01:59 AM »

The square tube support with it tying into the push tube looks great.

Just don't stop fast, I think you may roll onto the front axle!

Flyin6 · « **Reply #728 on:** June 02, 2015, 02:14:09 PM »

Quote from: TexasRedNeck on June 01, 2015, 09:55:33 PM

Looks good Don. I like the horizontal you added. It looks better than what I drew, for sure. Any idea of the total weight so far?

Haven't weighed it, but it's heavy. A couple hundred pounds without the winch, for sure!

Flyin6 · « **Reply #729 on:** June 02, 2015, 02:16:03 PM »

Quote from: JR on June 02, 2015, 01:01:59 AM

The square tube support with it tying into the push tube looks great.

Just don't stop fast, I think you may roll onto the front axle!

Counterweight my friend

The thing I'm building on the back end will make this look like an erector set!

It'll balance. But when I come to a stop in hot asphalt, the truck might just sink!

cudakidd53 · « **Reply #730 on:** June 02, 2015, 05:21:39 PM »

Quote from: Flyin6 on June 02, 2015, 02:16:03 PM

Quote from: JR on June 02, 2015, 01:01:59 AM
The square tube support with it tying into the push tube looks great.

Just don't stop fast, I think you may roll onto the front axle!
Counterweight my friend

The thing I'm building on the back end will make this look like an erector set!

It'll balance. But when I come to a stop in hot asphalt, the truck might just sink!

You might have to up the load rating on those tires! Bumper looks great Don-

Flyin6 · « **Reply #731 on:** June 02, 2015, 08:34:30 PM »

Thanks Mike

Well tonight I got it close to being ready to finish

Let's start with a view of these welds that are smoothed.

The technique is to hit the weld with the big 7" grinder with an aggressive disc, then finish it with a 4.5" #40 then 80 grit flap wheel for a polished appearance that will vastly reduce finishing with the body filler

Flyin6 · « **Reply #732 on:** June 02, 2015, 08:36:08 PM »

There's a lot of work at this point, several hours in fact. Enough to have you spitting out grit.

But it's starting to smooth up

Flyin6 · « **Reply #733 on:** June 02, 2015, 08:37:44 PM »

There are a lot of big heavy welds. There is around 15 or so pounds of .030 welding wire and an entire tank of gas spent on this piece of steel to this point

Flyin6 · « **Reply #734 on:** June 02, 2015, 08:39:34 PM »

Most exterior welds were smoothed and the panels blended, however some were left untouched such as in the inside, and a few on the outside, and some got a minimum cleanup because they will be covered by things like the fairhead

Flyin6 · « **Reply #735 on:** June 02, 2015, 08:41:34 PM »

I'll need to sandblast the corners to clean all that junk out of there prior to coating with the acid etch primer.

Here it is about half way through

Flyin6 · « **Reply #736 on:** June 02, 2015, 08:46:07 PM »

And getting done

I still have to cut the holes to mount the parking lights. They will be going directly into the bash plate and have a rib of steel formed around them to keep them intact when punching through cheap foreign cars.

I am also considering adding a lower "Skirt" to the thing. Right now it just ends with an edge. I think I might add another piece, perhaps a 3-4" section extending aft at a steeply swept back angle so that when a Civic passes under I won't spill a drop of my micky-D's quoffee.

Flyin6 · « **Reply #737 on:** June 02, 2015, 08:48:14 PM »

So there it is, and I just crunched on a piece of grit with my teeth! YEOWWWLL

That's it for Build Day 262

Sammconn · « **Reply #738 on:** June 02, 2015, 11:18:41 PM »

Ahrgh! I do not so fondly remember the grinding and polishing.
It is a metric ton of work. And somewhere half way or so I realized why the cost so much to just buy.

Looking good tho chief!

OldKooT · « **Reply #739 on:** June 03, 2015, 07:32:33 AM »

Looking good Don, and just wow at the welding/grinding on that thing. Where will you mount the license plate?

Atkinsmatt · « **Reply #740 on:** June 03, 2015, 08:23:01 AM »

Looking good.

Flyin6 · « **Reply #741 on:** June 03, 2015, 08:23:11 AM »

Quote from: OldKooT on June 03, 2015, 07:32:33 AM

Looking good Don, and just wow at the welding/grinding on that thing. Where will you mount the license plate?

Don't need no stinkin front license plate in the Tucky!

Flyin6 · « **Reply #742 on:** June 03, 2015, 08:24:13 AM »

Quote from: Atkinsmatt on June 03, 2015, 08:23:01 AM

Looking good.

Not that good...Adequate though, I'll give it that much

Should knock a deer into the next county without losing step

Flyin6 · « **Reply #743 on:** June 03, 2015, 06:58:19 PM »

Let's get that skirt sewn on the bumper.

I flipped the bumper over to gain access. I was noticing the weld penetration. All the way through that base .250" plate!

Flyin6 · « **Reply #744 on:** June 03, 2015, 07:00:16 PM »

So starting at the "Nose" and using some 3/16" X 4" plate I tacked in the first two pieces. Like I mentioned earlier, the lower skirt is laid back at a pretty good angle to help slide over stuff and to reinforce the front plates

Flyin6 · « **Reply #745 on:** June 03, 2015, 07:01:32 PM »

Then the two center pieces.

I was able to cut these on that carbide chop saw so the work went faster and the cuts were square

Flyin6 · « **Reply #746 on:** June 03, 2015, 07:03:29 PM »

This time I was grinding and smoothing as I went to keep from having a spark fest that lasted all night!

Sort of upside down/right-side up but I'm showing the center wedge that will help divide things I wish to "lift and separate"

Flyin6 · « **Reply #747 on:** June 03, 2015, 07:04:32 PM »

Then onto the wings, piece by piece

Flyin6 · « **Reply #748 on:** June 03, 2015, 07:06:02 PM »

And here are the parts crudely welded into place before I cut them in

Flyin6 · « **Reply #749 on:** June 03, 2015, 07:07:06 PM »

I cut out the corner with the plasma and blended it all in with the grinders