DIY - Rock Slider Build

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Gavin Dennis said:
I will definitely add gussets to the legs once it is all where i want it. I will use 1/4" for the gussets because that is all my welder will do. I am also planning to add mounts for some rock lights to replace the lights that were in the running boards. Does anyone know where to get the factory plug so i can wire it like the factory?
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i have the white knuckle offroad slider pix installed onto a GX sport in my album...
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Very slight angle from the main slider tube... Can't go much more, when compared to 4R and other versions, b/c of the plastic body cladding... but without that you could and a generally smaller rocker panel in the GX..
these are 3 leg passenger 2 leg driver (b/c KDSS)
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Looking forward to your progress!! 🤘🤘
 
I made some good progress today.
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I had to lobster tail the rear 90* because my bender was starting to disfigure the tube at 45* so I decided on 35* front and then sectioned the back for the 90*. I plan to use 3 or 4 legs for the outer bar, placed inline with the main legs.
 
With all the legs and the main tube, I made sure that the welded seam is up. For the legs I placed the seam on the rearward up side so it wouldn't take a direct hit from rocks.
 
What kinda bender are you using? It wasn't able to do another 35* or 45* bend?
 
ElliottB said:
What kinda bender are you using? It wasn't able to do another 35* or 45* bend?
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Is it the HF tubing crusher? ;)
A buddy had one, it crushed more than bent. . . .
 
It is the HF crusher! I used some aluminum in the die to reduce the crushing. I stopped at 35* because that is the point where the tube started to visually deform. I placed a leg directly behind that bend to add support. Ultimately, I elected to use 5 1x0.120 legs for the secondary tube. My thinking is that if for some reason a high lift jack had to be used, I want to distribute the load into as many spots as possible. Additionally, if I am to slide into a rock or tree, I want as many points as possible to reduce the likelihood of bending the 1-1/4" tube.
 
If it's below freezing outside you could try to freeze water inside the pipe and then bend it. The ice would act like a mandrel inside the pipe. It works on exhaust pipe. Might not work on thick tubing.
 
Jstawgn said:
If it's below freezing outside you could try to freeze water inside the pipe and then bend it. The ice would act like a mandrel inside the pipe. It works on exhaust pipe. Might not work on thick tubing.
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pack the tube with sand works too. Tack caps on the ends to keep it inside.
 
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This is the passenger side. It is mostly welded but I still need to add gussets and a U-bolt bracket. I ordered a dimple die tool today to make the tread plate.
 
Truth be told, I haven't been working this week. Monday was my first day off since October! I want to get these done and my Super 7 through scrutineering for an SC VIN.
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I made a little more progress today. I added 3 gussets using 3/16" plate. I only had enough scrap to create 6 gussets (3 per side). I added gussets to the front 2 legs and then the one in the middle of the other 3 legs because the rear leg has a bolt right above it so I can't add one there.
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Looking good, the top tread plate will look really good on top.

Not to derail, but that Super7 looks ridiculously fun!
 
Gavin Dennis said:
I made a little more progress today. I added 3 gussets using 3/16" plate. I only had enough scrap to create 6 gussets (3 per side). I added gussets to the front 2 legs and then the one in the middle of the other 3 legs because the rear leg has a bolt right above it so I can't add one there.
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I'd suggest scouring for moar scrap. The last gusset looks like a lot of leverage from the end off the slider to that gusset.. I know you'd like more gussets, and should probably get one on the last leg before your really go out and want to trust it...
just a thought.



Have you sourced a local shop where you can secure scraps or drops? That's basically how I source material for 90% of my projects...
 
Dranged: we must be on the same wave length. After posting I thought about it and didn't like not having it. So I dug through more scrap and found what I needed. All gusseted with 3/16"!
 
ElliottB: The Super 7 should be fun once it is street legal. 150bhp/1300lbs = similar power to weight of a current Porsche 911 and only cost 5% as much :)
 
The treads are taking longer than I expected. But, I think they are coming out okay.
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