Frame repair and repower

[73fj]

Ha! Ya, I like to go as hot as I can, lots of penetration.

So today I was able to miter the small pieces I made to box the top cut on the rail. I know that it kicked up 20 deg behind the cab so I needed a 20 deg miter. I used a simple trick I learned years ago in trade school. To figure out 20 deg I simply drew a right angle triangle, then divided it into nine equal parts, thus each division is 10 deg, then cut out my template using 2 divisions and laid it over where I wanted the cut. I poked a hole in it so I could see my center line, then using a cut off wheel I cut INSIDE the line, bent it by hand in my vise, and gently using a BFH, I placed it in. I will wait to weld it until the springs are installed and the frame is square. Should be roller next week, pretty happy so far with how it's going, can't wait to drive it again!

 

[73fj]

and one more of the box

 

[cult45]

Nice work man!

 

[73fj]

Nice work man!

Thanks!

Picked up my steel today, had to see how well it fit, so I measured twice and went for it, fits like a glove guys, perfect. Also my Ruff Stuff hangers showed up....very pleased with their product, super beefy.

 

[73fj]

And I thought I would share this, on Friday night my wife surprised me with a new bike, a 2012 Honda ST 1300, she caught me completely by surprise.....I have wanted one of these since Honda introduced them in the early 90's. What a ride, even with her on the back I have to keep checking if she fell off, not that she's a big girl, just so balanced.

 

[PG45er]

Awesome work!! The body on yours looks pretty good considering the condition the frame was in. Good info and keep the pics coming.
Don't be suprised though, if you wake up one morning and half the 45's in the country are lined up on your street for a frame job!! I have a couple here and there was another in Quesnel that just sold, that need the same treatment.

 

[73fj]

Thanks brother! The body is in what I would say normal condition for a 39 year old Cruiser, front fenders are rusty in the usual spot, the floor has large holes on the drivers side ( some wannabe hacked the s*** out of that too ) I don't know why the 45 frames are all so bad, there is/was another one here with the same issues as mine, and it seems to be a regular issue. Poor steel? no idea, my 1973 40 has a bit of rust on the frame, but is still in very good condition.....

If I could make a living fixing Cruisers, I would be a happy man.

 

[73fj]

I was able to get a temporary cross member in place so I could get a measurement for a real cross member, laid it out in CAD, test fit it and will build it tomorrow, too late tonight for cutting steel.

 

[73fj]

More progress, got the cross member fabbed and temporarily in place, and the axle is clamped into place very close to its final home. looking like a truck again! New frame just needs some tweaking, right now is 1/2" out of square, should be a simple task to square it.

 

[73fj]

Any body want my old frame? It's rare because it's a 45, I know because the internet told me. Still has some of the factory duck ivory inlays, and since they were sealed in with the dust of a ground up Unicorn horn, you can still see where it was signed at the factory by Elvis. Some assembly required, batteries not included.

 

[73fj]

Could I trouble one of you guys to take a measurement from the back of the cab to the center line of the axle? It's the only measurement I forgot and I need it to confirm axle placement.

 

[Pauciflora]

G'day 73Fj, That looks absolutely superb. Keep it up.
Cheers,

Ben

 

[Pauciflora]

G'day I'm not sure if this helps you. The distance from the centre of the front axel to the centre of the rear axel is 2960mm. This is from a post '81 model sales brochure. I know brackets on the chassis changed through the years, but I don't know if overall length did. Cheers Ben

 

[73fj]

G'day to you sir, that is a very helpful diagram, thank you!

 

[whitey45]

Wheelbase on all lwb fj45's is 116". I think your 45 frame rust is a northern climate, salted roads issue. I just presure washed a california native 67 fj45 frame, and it still has its original black paint! It was sitting in the weeds for 20 years too. Frame repair looks great btw.

 

[73fj]

Yes, northern life has it's drawbacks, especially on vehicles, I would kill for a rust free original frame. Thank's for the wheelbase info, good stuff.

 

[73fj]

Big move forward in progress today, the axle is in it's forever home and the frame is square within 1/16". Also took a couple leaves out of the 200 lb pack so maybe I can have some suspension movement and mocked up the crossmember/shock hanger................and then my welder ran out of gas..........on friday night. Hopefully someone is open tomorrow, fingers crossed. Something I have noticed when you are rebuilding a Cruiser, lots of people stop to chat and see what I'm doing, even a local Cruiserhead who just lives around the corner. Going to try and get it off the jack stands and get some weight on the springs before I weld anything in place..........thats if I can get a new bottle tomorrow.

 

[73fj]

Well I couldn't get a bottle of Mig Mix today so I spent some time fabricating. I got the frame cut to length and perfectly square and some box sections cut and in place, as soon as I can weld again she's coming off the jack stand's, then a few hours coating the inside of the frame and final welding with weight on the suspension. I am going to cut holes in the boxed section just like I did under the truck, 2 3/4 " round, then measure and fab a rear fuel tank.

 

[73fj]

Major progress today.....she's a roller! Got a new bottle of mig mix, welded my Ruff Stuff shackle hangers and rolled it out in the sun, after tacking all the critical points, oh what a feeling! Also made a cross member to go across the hangers which will also double as part of my new fuel tank hanger, looks like I should be able to get at least a 30-35 gal tank back there.

 

[73fj]

Few more pictures, new frame is perfectly square and level, and added some gusset's to the front hangers