Builds 86 Xtra Cab Build (4Wheelunderground 3 link front, 4 link rear and 3.4 swap) (7 Viewers)

[aztoyman]

There's no tubular part inside that stamped section on the driver side. (If I properly understood your suggestion) Pretty sure anyway because these parts are bare steel from the factory and I saw inside it when I sprayed it down with phosphoric acid to get rid of the rust. I'll take another look at it though in case I'm wrong. I think the one from my spare cab is in my shed. I hope it is, if not it's about an hour away at my buddies place.

But either way, It needs to be stronger and I think you have a good idea about running the tube through it or somehow merging/blending/welding the stamped part to the new dash bar to keep the attachment point for everything in place. The passenger side would be just the new dash bar tube continuing across. Eliminate the thin original section. I think I would still tack the small attachment points for dash structure back in place. Including the tie plates bolted to the cab. THANKS!

 

[aztoyman]

I got a chance to look at the dash bar situation today and decided to just pull the factory sheet metal one out. The one I need to weld in needs to be in the same space. I'll just add brackets for the steering column and all the other mounting points for pedal return springs and A/C ducts.

@littlevulture The factory dash bar is pretty much sheet metal halves spot welded together on the drive side and the passenger tube is spot welded on the end of the driver side section. Doesn't go across. Cutting it up to merge the two isn't something I want to try. I may steel the column bracket off it though.

 

[aztoyman]

Right about the time I was cutting my piece of DOM for the dash bar, a sudden and pretty nasty monsoon storm hit. I was determined to at least get it fit up but I didn't get to clean it up yet. I was ready to spray it down with phosphoric acid when the rain hit.

Looks like I have some serious dash mods to do. I have no idea how all that will work out.........yet.

 

[littlevulture]

View attachment 3974821

View attachment 3978430

Looks like I have some serious dash mods to do. I have no idea how all that will work out.........yet.

What am I missing here...comparing your pictures it looks like it slots in exactly where you need it to be so not much dash mods needed?

 

[aztoyman]

I'm still thinking about how I'll be welding this sucker in. Pretty sure I'll either have to cut off the roof (Oh PLEASE no!) Or cut the cage and sleeve it.

I originally thought this spot marked in red would be best as far as having good welding access to weld it back together. But now that I have the dash bar, I'll need to get to those joints too. I think the area marked in yellow is my best option if I end up having to cut it.

I really won't know for sure until I get all pieces cut and fit up, including gussets.

 

[aztoyman]

@littlevulture , it fits pretty close but the tube is larger diameter so kind of interfering with A/C ducts mainly. I'll be trying to get all the plastic in place after cutting it for the A-pillar tubes and modifying the dash top to move the two outer vents inboard of the tubes.

I think I'll either be making a new dash top or using foam and fiberglass to modify it like a bunch of YouTuber's have done to fix the cracks.