Sweet. Makes me wish I was on the West Coast so I could add to the 60 group!
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- Thread starter
- #982
weekly update
Been working on the yard, helping out family, etc. I did get some more done on the anitwrap bar.
I thought I was going to reuse the original shackle bolts (19mm) I have laying around but they ended up not being long enough due to the thick plates so I hunted for some at the local hardware store. Ended up going to 3/4" bolts, buying a 3/4" drill and clearanced the bushings to fit the bolt and drilled the plate with my neighbor's press. I made them work but suggest just buying bolts and bushing that already work together.
I bolted the axle mounts to one of the links and fit it to the axle (trimming, grinding, measuring). Once it was tacked on I put in the other link and started looking at positioning and clearance.
After I got it where I wanted it I burned in the axle mount. I also finished up the bar and got a quick shot of paint on it. I went to the steel yard and pick up some material for the crossmember but didn't get started on that yet. I think the 2" johnny joint will be the weak point in the system so it should hold up pretty well.
Been working on the yard, helping out family, etc. I did get some more done on the anitwrap bar.
I thought I was going to reuse the original shackle bolts (19mm) I have laying around but they ended up not being long enough due to the thick plates so I hunted for some at the local hardware store. Ended up going to 3/4" bolts, buying a 3/4" drill and clearanced the bushings to fit the bolt and drilled the plate with my neighbor's press. I made them work but suggest just buying bolts and bushing that already work together.
I bolted the axle mounts to one of the links and fit it to the axle (trimming, grinding, measuring). Once it was tacked on I put in the other link and started looking at positioning and clearance.
After I got it where I wanted it I burned in the axle mount. I also finished up the bar and got a quick shot of paint on it. I went to the steel yard and pick up some material for the crossmember but didn't get started on that yet. I think the 2" johnny joint will be the weak point in the system so it should hold up pretty well.
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looks good mike. I'll let cha build mine now.
- Thread starter
- #984
looks good mike. I'll let cha build mine now.
I definitely owe you some time on your rig!
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hahahaha, I should probably figure out my pinion angle for my rear axle is going to land first.
I'm hoping to get Big Blue onto all fours by Sunday night though.- Thread starter
- #986
weekly update
Got my antiwrap bar done minus paint. I went to the steel yard and grabbed a scrap piece of .250 wall 2"x2" tube to make the crossmember out of. I cut some reliefs in it where I routed it under the exhaust and over the rear driveshaft and then welded it to the frame. Mostly installed the Johnny Joint and put together a shackle that would accommodate the different widths of the JJoint and the bushing. From there I could decide where to put the crossmember bushing to get some angle on the shackle. I measured and got out the cardboard to try out some ideas.
Duplicated the shape in steel and boxed them together.
Then I welded on the bushing sleeve.
I still needed to put in the outer washer in the JJoint and I had to take off my bar to make it easier. I compressed it enough to get the snap ring in its groove.
Here you can see the crossmember and where I trimmed it. I cut pieces from that same pipe I have that I used for the corners of the rear bumper.
Attached to the crossmember. The shackle is crude but it should work. I decided on about 10 degrees of slope on the shackle and think it will clear when articulating. I'll have to watch it next wheeling trip to see if it works out.
Here it is. I'll paint the crossmember with rustbullet like the inner frame and paint the antiwrap bar black like the axle. I'll probably look into boxing some of the axle mount as well.
Impressions:
I've only driven it to work this morning and maybe I'm wanting there to be a difference but it seemed to feel a little more planted on acceleration. It also seemed like the minor clunking I got from shifting was further reduced and just feels a little more solid. I'll get some more miles on it and see what it's like when wheeling.
Got my antiwrap bar done minus paint. I went to the steel yard and grabbed a scrap piece of .250 wall 2"x2" tube to make the crossmember out of. I cut some reliefs in it where I routed it under the exhaust and over the rear driveshaft and then welded it to the frame. Mostly installed the Johnny Joint and put together a shackle that would accommodate the different widths of the JJoint and the bushing. From there I could decide where to put the crossmember bushing to get some angle on the shackle. I measured and got out the cardboard to try out some ideas.
Duplicated the shape in steel and boxed them together.
Then I welded on the bushing sleeve.
I still needed to put in the outer washer in the JJoint and I had to take off my bar to make it easier. I compressed it enough to get the snap ring in its groove.
Here you can see the crossmember and where I trimmed it. I cut pieces from that same pipe I have that I used for the corners of the rear bumper.
Attached to the crossmember. The shackle is crude but it should work. I decided on about 10 degrees of slope on the shackle and think it will clear when articulating. I'll have to watch it next wheeling trip to see if it works out.
Here it is. I'll paint the crossmember with rustbullet like the inner frame and paint the antiwrap bar black like the axle. I'll probably look into boxing some of the axle mount as well.
Impressions:
I've only driven it to work this morning and maybe I'm wanting there to be a difference but it seemed to feel a little more planted on acceleration. It also seemed like the minor clunking I got from shifting was further reduced and just feels a little more solid. I'll get some more miles on it and see what it's like when wheeling.
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Tapage
Club 4X4 Panamá
I need to work in a crossmember like yours .. tought it will be in the middle of my straight exhaust ..
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nice work Mike... I'll pencil you in for the trac-bar and the Hydroboost brakes now.
- Thread starter
- #989
nice work Mike... I'll pencil you in for the trac-bar and the Hydroboost brakes now.
Sounds good to me. Did you get big blue on the ground?
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not quite... angle grinder died, plasma died, wife left later than expected tabo the beach. I did get all the scab plates and frame side brackets welded up though.
sounds like I'm going to have to have the hydroboost unit sent out to vanco to have it re-worked for "high flow" due the full hydro and 1405psc pump...
I'm done hi-jacking your thread now.
sounds like I'm going to have to have the hydroboost unit sent out to vanco to have it re-worked for "high flow" due the full hydro and 1405psc pump...
I'm done hi-jacking your thread now.
awesome truck and awesome rubicon report!! Is that front bumper the 4 plus from man a fre or custom?
- Thread starter
- #992
Thanks
I've returned your PM and included brokenparts on it to answer your questions. Hope it works out.
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It's a 4plus bumper. I'll PM ya.
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ummm... bumper sold. I promise I'll stop hi-jacking your thread now Mike.
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hahaaha, thanks for doing the modeling. I should have some time during the next few weekends or week nights if you want to come over and bend up some more tube. Plasma is up and running again too.
Trac bar is coming up really fast on my list. I was dreaming up something on the drive home today and it pretty much looked like what you've got there.
Did you start with the ruffstuff kit and widen up the bracket on one side to slide up on the housing like that? Think it will provide any protection for your d-shaft out on the trail?
Did you start with the ruffstuff kit and widen up the bracket on one side to slide up on the housing like that? Think it will provide any protection for your d-shaft out on the trail?
- Thread starter
- #998
Yes I copied the axle mounts from Brokenparts or Dirtgypsy (they both had the same plates from Ruffstuff and I grabbed one of them to trace). Then I bolted them to one of my links to keep them straight/aligned, positioned them on the axle and clearanced the plate closest to the 3rd member. I wanted to position the bar on the middle of the axle and that's pretty close. I moved it just a hair driverside to eliminate interferance with the 3rd. Again I'd suggest bushings/bolts that go together (there are several places offering DIY kits). I'm pretty sure the JJoint is my weakest link in the system so you might consider a 2.5 instead of the 2.0 I'm using but it's probably strong enough and I won't have any problems. I just won't know for certain until I get some wheeling time on it.
The driveshaft hangs lower so mine probably won't offer any rock bashing protection.
Yes it does, I should use my eyes when looking at pictures.
- Thread starter
- #1,000
weekly update
I've been putting off the front bumper because I needed to cut out some mounts from that 3/4" plate that I got for free. I didn't try very hard to find a local shop to cut it out so I got on a mask, put on my glasses, and started up the angle grinder. It only took me about 3 hrs to cut them out and I only used up 3 cutting disks. I went over to brokenparts place to return his bumper and once we got that one out I found my measurements were off and the plates were too tall
. With some plasma and a little more grinder action I took off 1/4" more and they slid in the frame. Then my crossbrace ended up being 1/2" too short. Zach swapped out a longer piece with me and I ended up heading home. So I pretty much only got the plates cut and drilled. I decided to step up to 1/2" bolts so I drilled the holes in the plate and enlarged the holes in the frame. Zack's drillpress and sharp drill bits made cutting holes in 3/4" steel easy! I'll have to add one of those to the growing tool wanting list. I started on it the next day. Here is the mounting plates and crossbrace. I wanted a sturdy crossbrace for possible winch support in the future.
I used my engine hoist to play with positioning the bumper. My pregnant
can't lift much anymore (yes for those following along that will be #3 due in Nov). I also added in a tube crossbrace.
I measured the height and angle when the bumper was where I wanted it and cut and notched some tube supports. Did some test fits and welded them on.
Tube supply is getting minimal and I'll probably have to buy some more to complete the fender protection. To save on uncut length I took some scrap pieces and rejointed them.
I cut and shaped those pieces to fit as more supports for the lower main tube. Did a little filling and took it off the truck to weld it all up.
Here is a couple of shots with it attached to Dora.
I'll eventually add the fender protection and tie it into the sliders. It will be bolted so the whole thing can be removed. I did want to put holes for shackles in the mounting plates but forgot so I'll try and add those later. I will also add something to the lower part on the front. Zack's got some dimple dies I might try out and I've also got some expanded metal from a sliding door that was in the stepvan that I'm thinking about too. It will be a solid piece in front and whenever the right winch comes along I'll open it up to fit. So what do you guys think will look better: Dimple died plate or expanded metal on the lower section?
I've been putting off the front bumper because I needed to cut out some mounts from that 3/4" plate that I got for free. I didn't try very hard to find a local shop to cut it out so I got on a mask, put on my glasses, and started up the angle grinder. It only took me about 3 hrs to cut them out and I only used up 3 cutting disks. I went over to brokenparts place to return his bumper and once we got that one out I found my measurements were off and the plates were too tall
. With some plasma and a little more grinder action I took off 1/4" more and they slid in the frame. Then my crossbrace ended up being 1/2" too short. Zach swapped out a longer piece with me and I ended up heading home. So I pretty much only got the plates cut and drilled. I decided to step up to 1/2" bolts so I drilled the holes in the plate and enlarged the holes in the frame. Zack's drillpress and sharp drill bits made cutting holes in 3/4" steel easy! I'll have to add one of those to the growing tool wanting list. I started on it the next day. Here is the mounting plates and crossbrace. I wanted a sturdy crossbrace for possible winch support in the future. 
I used my engine hoist to play with positioning the bumper. My pregnant
can't lift much anymore (yes for those following along that will be #3 due in Nov). I also added in a tube crossbrace. 
I measured the height and angle when the bumper was where I wanted it and cut and notched some tube supports. Did some test fits and welded them on.
Tube supply is getting minimal and I'll probably have to buy some more to complete the fender protection. To save on uncut length I took some scrap pieces and rejointed them.
I cut and shaped those pieces to fit as more supports for the lower main tube. Did a little filling and took it off the truck to weld it all up.
Here is a couple of shots with it attached to Dora.
I'll eventually add the fender protection and tie it into the sliders. It will be bolted so the whole thing can be removed. I did want to put holes for shackles in the mounting plates but forgot so I'll try and add those later. I will also add something to the lower part on the front. Zack's got some dimple dies I might try out and I've also got some expanded metal from a sliding door that was in the stepvan that I'm thinking about too. It will be a solid piece in front and whenever the right winch comes along I'll open it up to fit. So what do you guys think will look better: Dimple died plate or expanded metal on the lower section?
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