Builds Fly By Night (3 Viewers)

[NikP]

That bumper design is close to what thinking. Is there a buy one get one free option?

 

[tucker74]

That’s so much stouter than the stock design of the rear, I couldn’t believe how rinky-dink that area was until I had to fix mine. I had the same issue with the receiver hitting the 55gal tank that others mentioned, ended up bolting a 4plus to the bumper but never liked how low it hung.

Tucker

 

[RUSH55]

Awesome of you to chime in Tucker! Thanks!

 

[RUSH55]

Almost 10 hrs of work in on this thing today and it feels like more should have gotten done. Even made a specific 20 item list to keep me focused, and got 7 things done. Guess it’ll keep me busy throughout the week.

Finished up on the crossmember. The crappy welds are the only welds that will be actually visible, and would like to grind them out and re-weld them, but you know how that goes, so I just left them for now.

Did some final prep work on the front hangers. Decided to do away with the wing on the tail. The idea was to tie it in to the front crossmember, but after doing some mock-up, that looked to be more of a PITA than what it would be worth. I’ll go a different route.

After that, pretty much spent the entire afternoon shaping out fishplates and the outer shackle hanger pieces. Used the oxy-acetylene to blow them out, but spent a ton of time grinding them into shape, so.... whatever.
Had to go get more acetylene at ACE. Could barely find a parking spot.

 

[RUSH55]

...

 

[scrapdaddy]

Whole lota grinding going on!

 

[Ol Yeller]

Yeah looks like that wing would’ve needed a lot to blend in, welds may not be purdy but functional for sure.

I was looking at my 4” material today trying to decide if it was worth plating the frame at each hanger even if it doesn’t reach the top...I have no experience on this frame & leaf springs stuff so tough to know the right path forward.

 

[RUSH55]

It’s not 100% necessary, it’s just my preference. 3/16” lines the center of the front hangers. It actually doesn’t do that in the rear. If 3/16” fishplate is used on each side, and you outboard the same distance as you do in the front, the spring perches still need to be inboarded 11/16”. Without the fishplate, you’d inboard the perches 7/8”. IIRC, you say you’re just inboarding the perches to match the 55 suspension, so even less work. I kinda wanted a matching “custom built” setup, thus my gluttony for punishment.

 

[mmcinnis]

That's an HD frame now. Looking great.
Mike

 

[xtiaan2000]

Something Pighead suggested to me was to put a 45 in the front drivers corner to support the frame from the steering box’s forces. I guess with all that plating you really won’t need it.
Killer work!

 

[RUSH55]

Thanks for that reminder @xtiaan2000 . I keep forgetting to put it on my list. Want to do it, if for nothing else, so I can be a part of that club.

 

[RUSH55]

That's an HD frame now. Looking great.
Mike

Thanks Mike! More to come...

 

[61twpw]

Looking really good. Like your progress, wish I could keep up!

 

[RUSH55]

Thanks Bill. It feels like a snails pace, but at the same time really enjoying this part of the build.

For instance, making this shackle hanger. Number one of two for the front. Lower profile than the rears will be.
Here’s a side-by-side with an OEM piece.

 

[RUSH55]

With a shackle mocked up.

Will probably remove a bit more material from the inner piece to allow some more swing in the shackle’s arc of rotation (). Other than that, can’t wait to finish the other one and get them tacked onto the frame!

 

[bobm]

BEEF!!!!

 

[Ol Yeller]

With a shackle mocked up.

Will probably remove a bit more material from the inner piece to allow some more swing in the shackle’s arc of rotation (). Other than that, can’t wait to finish the other one and get them tacked onto the frame!

View attachment 2254922

View attachment 2254924

I have a length of DOM tube for making the shackle hangers, just match the spring pack for width I assume?

I’ll have to get at a lathe to true it up after the bandsaw...

 

[RUSH55]

So great point - after all this, my hindsight is that a length of DOM with an ID close to the bushings OD and of a decent wall thickness would suffice to make the bushing sleeves for the shackle hangers. Great decision J

Kurt’s bushings showed up today. They’re marginally larger than the bushings Ruff Stuff provided in their sleeves. One could turn the bushings down a hair to fit the sleeve, or have the sleeves turned to fit the bushings, probably .030 - .050 or thereabouts. The bushings are also longer by at least 1/4”, so the ends will need to be trimmed.

Found a machinist nearby to turn the sleeves and hopefully be able to chuck up the hanger I built. Or maybe say eff it and not worry about it?

 

[Ol Yeller]

I don’t think the bushing length is too critical, probably the biggest deal here is getting everything square to the frame honestly

Someone who has actually done this will chime in, my dad gave me some good advice tonight...don’t over think it, get on with it.

 

[RUSH55]

As square to the frame as possible. Yep, have to agree with that 100%. Lots of double and triple measuring. This method with the plates is probably more of a PITA to get correct than other methods of welding a hanger to a plate, but have to say I’m more enthused over the end result.
I jigged the hanger off a piece of 2”x4” rectangle tubing, measuring and eyeballing everything over and over until satisfied it was as close as it was gonna get before tacking. Checked everything again after tacking and then just went for it.