Builds 2018 Premium 460 build

[Washingtontaco]

Last oil change I noticed my front differential weeping on the right side where the CV shaft goes into the axle housing. This should have been replaced when Nitro Gears installed the gears and locker but I have my doubts. Not a difficult job but takes a bit of time. $25.00 part 2-3 hours to replace.

 

[Washingtontaco]

My rear stabilizer bar clamps at my KDSS actuator and fixed link started to deteriorate and migrate. My front ones failed fairly quick after installing my suspension system. I replaced those with DR KDSS ones.

This time around on the rear I installed the Overland Custom Design clamps. These are a prototype and will be available in the spring of 2024 ish. Pretty simple replacement. Place a bottle jack under the stabilizer, remove the caps from the fixed link and KDSS actuator, displace them out of the way, use a wire brush to remove any bonded rubber on the stabilizer, locate the new clamp, drill the set screw hole, reverse the disassembly, install the new clamps with red Loctite and you are done.

 

[Washingtontaco]

Residual rubber, wire brush in your drill or wire wheel in a grinder is your friend. The OCD are a much wider clamp than DR KDSS ones and have the set screw.

Overland Custom Design

Overland Custom Design

overlandcustomdesign.com

Maybe @Mstudt can chime in here for more detail on the clamps!

 

[Washingtontaco]

Been a while! New truck parts arrived today, Perry Parts bump stops. Time will tell if these are a updated part compared to Timbren? The design and engineering thought looks promising!

 

[r2m]

That cross section of the bumper looks like what my 3D printer pattern filler does.
Wonder how long they would last if I printed them in TPU filament?

 

[Washingtontaco]

Easy swap of the front bumps but the rear was a PITA due to the aftermarket Daystar bumps I installed when I installed my suspension system.

 

[Washingtontaco]

Finally getting some company window graphics!

 

[r2m]

Finally getting some company window graphics!

View attachment 3568209

Awesome! Hope this generates a lot more work.
Okay, some questions:

1. Is this your day job? I was thinking it was just a weekend gig.
2. Did you do the artwork yourself?
3. Is the $120 for printed art for both left and right?

 

[Washingtontaco]

Awesome! Hope this generates a lot more work.
Okay, some questions:

1. Is this your day job? I was thinking it was just a weekend gig.
2. Did you do the artwork yourself?
3. Is the $120 for printed art for both left and right?

1) Its mostly a weekend business with commercial clients occasionally during the week.
2) Artwork/logo is collaborative project between my business partners son and my daughter.
3) I believe its a side. $120 x 2 installed.

We are attending a bunch of Rallies and Expo events this year, never hurts to be noticed.

 

[GrizzlyClint]

Finally getting some company window graphics!

View attachment 3568209

Looks good!

 

[GrizzlyClint]

I did notch the tail light housing for better clearance. From the housing the wires rout down and under the vehicle to the sPOD box under the hood. View attachment 2489462View attachment 2489463View attachment 2489464

View attachment 2489462View attachment 2489463View attachment 2489464

Hey man, got a link on what silicone you used for holding the wires put?

 

[r2m]

Hey man, got a link on what silicone you used for holding the wires put?

I know the question is for Builds - 2018 Premium 460 build - https://forum.ih8mud.com/goto/post?id=13475900, but you should be able to use any RTV (room temperature vulcanizing) silicone.
Just clean the surface really well with IPA (isopropyl alcohol).

 

[GrizzlyClint]

I know the question is for Builds - 2018 Premium 460 build - https://forum.ih8mud.com/goto/post?id=13475900, but you should be able to use any RTV (room temperature vulcanizing) silicone.
Just clean the surface really well with IPA (isopropyl alcohol).

How well will that hold up to low temps? Like the -20 or -30 temps we can experience in north Idaho?

 

[r2m]

How well will that hold up to low temps? Like the -20 or -30 temps we can experience in north Idaho?

https://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U/ref=sr_1_4?crid=2Y2RBL8KMX2Y2&dib=eyJ2IjoiMSJ9.hBh_zGCuLAe7nZbhjI6lpNBlZzhsGacTnZdIziRGWiH4qvfeN8LB7M1dSMz463WCYxUYNlXk5HDwrz08tSXHLe2j5bUvYF7EsQBgbA97uluyVuqyJCS_lDwAVO0em5xxqbYC4gg7dPwsgJXtzct5qT5hyKgaDpxJECur1LodmUyZPtzxST5ljj3GtLi_lT7sXkEr29f-jzrvWL8HVgdUnYXTDlcSuIyeaJ6eoQqvNXyQE96_EuwYZyHlSDfONU6ABFjWx5wNFp_KznPErLwCciiQa2EBMyiO0j6ncx6u9qc.U5YWzey_qRBVPzWGCfJmvSNhYeZKxFC0xqpDrObJ6Kw&dib_tag=se&keywords=Permatex%2B81160%2BHigh-Temp%2Bblack%2BRTV%2BSilicone&qid=1709487871&s=automotive&sprefix=permatex%2B81160%2Bhigh-temp%2Bblack%2Brtv%2Bsilicone%2Cautomotive%2C140&sr=1-4&th=1

When you read the description it's good down to -65° F up to 500° F. Don't think you get colder than that...

 

[GrizzlyClint]

https://www.amazon.com/Permatex-82180-Maximum-Resistance-Silicone/dp/B0002UEN1U/ref=sr_1_4?crid=2Y2RBL8KMX2Y2&dib=eyJ2IjoiMSJ9.hBh_zGCuLAe7nZbhjI6lpNBlZzhsGacTnZdIziRGWiH4qvfeN8LB7M1dSMz463WCYxUYNlXk5HDwrz08tSXHLe2j5bUvYF7EsQBgbA97uluyVuqyJCS_lDwAVO0em5xxqbYC4gg7dPwsgJXtzct5qT5hyKgaDpxJECur1LodmUyZPtzxST5ljj3GtLi_lT7sXkEr29f-jzrvWL8HVgdUnYXTDlcSuIyeaJ6eoQqvNXyQE96_EuwYZyHlSDfONU6ABFjWx5wNFp_KznPErLwCciiQa2EBMyiO0j6ncx6u9qc.U5YWzey_qRBVPzWGCfJmvSNhYeZKxFC0xqpDrObJ6Kw&dib_tag=se&keywords=Permatex%2B81160%2BHigh-Temp%2Bblack%2BRTV%2BSilicone&qid=1709487871&s=automotive&sprefix=permatex%2B81160%2Bhigh-temp%2Bblack%2Brtv%2Bsilicone%2Cautomotive%2C140&sr=1-4&th=1

When you read the description it's good down to -65° F up to 500° F. Don't think you get colder than that...

Perfect.

 

[Washingtontaco]

Perfect.

What r2m said. Its held up well. I don't recall PN. Its basic RTV from the hardware store.

 

[GrizzlyClint]

What r2m said. Its held up well. I don't recall PN. Its basic RTV from the hardware store.

10-4!

 

[PerryParts]

That cross section of the bumper looks like what my 3D printer pattern filler does.
Wonder how long they would last if I printed them in TPU filament?

Depending on the filament, they'll work. But you'll be susceptible to batch to batch material variation, so you might see fatigue failures. I moved away from filament in October of '23 because filament manufacturers could not reliably control their material.

We now print with screw style extruders to print directly from injection molding granules. Made a BIG difference in product durability and longevity. Gen 2 ran for over 100k cycles on our suspension dyno.

All my gen 1 customers got a free upgrade offer to move to the latest product.

 

[r2m]

Depending on the filament, they'll work. But you'll be susceptible to batch to batch material variation, so you might see fatigue failures. I moved away from filament in October of '23 because filament manufacturers could not reliably control their material.

We now print with screw style extruders to print directly from injection molding granules. Made a BIG difference in product durability and longevity. Gen 2 ran for over 100k cycles on our suspension dyno.

All my gen 1 customers got a free upgrade offer to move to the latest product.

Thanks for sharing that video! VERY interesting! Being an R&D engineer (med devices) I too have had to do a ton of testing, one of which was an accelerated 30 year product life test. I had to design and build a test fixture to cycle a device for the stomach compression over 3 million cycles in about 9 days. Side note, it passed!
One thing I noticed is that you had a hard stop of the compression cycle. Is that how it would be on a vehicle? Is it possible to make sure the suspension will not over compress? I'm assuming if the bump stop cycles too many times in over compressing, it'll start to get too hot and break apart.
I know TPU is an amazingly strong and durable material, in almost any durometer, but truly impressed with what you and your team has been able to do!

What FDM printers are you using? Did you have to design and build your own hoppers and feed system for the printers or was it an off the shelf system? I have not heard of any off the shelf pellet/hopper FDM printers, but then I'm only using the hobbyist grade, sub-$1,000 printers. I think the next big evolution in FDM printing will be going to pellet/hopper setups for many reasons:

1. Material is cheaper (but the manufacturers will have to start selling in 1 or 2 pound bags instead of 50 lbs at a time)
2. Ability to mix and match materials together, maybe a little PETG with PLA, or TPU with PETG or ABS? or...?
3. Mix your own colors.
4. No more clogged extruders with filament getting into the gears.
5. Not having to deal with where to place filament rolls to feed into the bowden tubes.
6. Not having to feed filament through long bowden tubes.

 

[Washingtontaco]

Depending on the filament, they'll work. But you'll be susceptible to batch to batch material variation, so you might see fatigue failures. I moved away from filament in October of '23 because filament manufacturers could not reliably control their material.

We now print with screw style extruders to print directly from injection molding granules. Made a BIG difference in product durability and longevity. Gen 2 ran for over 100k cycles on our suspension dyno.

All my gen 1 customers got a free upgrade offer to move to the latest product.

Going to put the Perry Parts bumps through a two and half week test starting mid June. A couple Overland Shows and travel in between mapping a guided trip in Oregon etc! Lots of rough miles coming up!