Builds HDJ79 build #2: 2022 double cab with FTE (2 Viewers)

[roma042987]

There is a shift position sensor on the top of the h152 case. I won’t be using it so I capped it off with an m16x1.25 stainless plug from Amazon.

Joywayus Internal Hex Head Pipe... Amazon product ASIN B07MSDCL7Y
View attachment 3255427View attachment 3255429

I've been ordering a ton of those plugs from that supplier myself in different sizes to cap off different things.

 

[bottombracket]

@roma042987 clogs all day every day

 

[davegonz]

I need a new pair.

 

[roma042987]

I've been ordering a ton of those plugs from that supplier myself in different sizes to cap off different things.

I feel like there should be a joke coming out of this. "how do you spot a surgeon outside of work...."

 

[bottombracket]

Honestly, it’s the most comfortable shoe I can wear. I’m on my feet so much in the OR… Sanita clogs just work for me and keep my lower back pain to a minimum. So I wear them all the damn time. I have at least 4 pairs.

 

[FJBen]

Honestly, it’s the most comfortable shoe I can wear. I’m on my feet so much in the OR… Sanita clogs just work for me and keep my lower back pain to a minimum. So I wear them all the damn time. I have at least 4 pairs.

Starts googling for scheel mann clogs….

 

[roma042987]

Honestly, it’s the most comfortable shoe I can wear. I’m on my feet so much in the OR… Sanita clogs just work for me and keep my lower back pain to a minimum. So I wear them all the damn time. I have at least 4 pairs.

I feel the same way about my Redwing shoes. Years ago I started having back pain when I used to spend alot of my time on my feet at work. Don't remember how I came to the conclusion but turned out it was the cheap ass shoes I was buying. I bought a nice pair of red wings and back pain went away. I'm on my probably 4th pair of the same shoe. Money well spent and they last a few years.

 

[tucker74]

You seem to have 4-5 of everything man, I know where I’m heading when I want to do a diesel swap

 

[davegonz]

You seem to have 4-5 of everything man, I know where I’m heading when I want to do a diesel swap

LOL! In the Rivian?

 

[bj70bc]

disel swapped rivian would be the most hilarious s*** ever

 

[bottombracket]

Got a care package from @orangefj45 yesterday.

Heaviest pickles ever.

 

[bottombracket]

Ok, not pickles.

It is a locked 80 rear third and some @TRAIL TAILOR axle shafts (and a rear hub rebuild kit because Georg THINKS OF EVERYTHING) for the double cab.

Adding in an actuator from @Deathvalleypaul and I’ll be ready to go.

I have a spare locked front axle and I can convert my rear to locked now.

Nate approves.

 

[tucker74]

LOL! In the Rivian?

I still have two Cruisers, tho they don’t get driven much currently

 

[bottombracket]

@tucker74 let’s fix that. Been too long since I’ve seen you, or the Blackjack 40.

Last night I had to get out the cutoff wheel to get the second exhaust ring out of the back section of the manifold. Should be pretty well cleaned up now and ready for blast and ceramic this week.

 

[bottombracket]

Today I attacked the swirl flaps and I take spacer. I got to use my two favorite tools at the same time: Kroil, and my screwball screwdriver. I broke off half the tiny screws holding the flaps onto the actuators. Figures.

There are six holes that will need to be filled. I was thinking 1/4 NPT stainless plugs. The hole diameter is 11.5 mm, but there should be enough meat at the bottom of the hole to drill through and successfully tap (1/4 NPT uses a 7/16” drill bit, ~11.1mm).

Other thoughts? Tight plugs from a 12HT? Air rail plugs from a 2F?

TIG is the backup option but I don’t want someone to warp it.

 

[bottombracket]

Updates: Bill was in town for a week, and we finished the single cab rolling chassis. That meant emptying the shop and swapping places of single versus double. Lord, I need to clean up more often. @teleskier ’s Go Jacks made the job tolerable.

Double cab was up to bat.

 

[bottombracket]

Bill burned in the frame to motor mounts. We used two VDJ79 right side mounts, left seems to be unavailable. Each took some massaging.

Note: you can reuse the left sided (short) HDJ100 motor mount. I got FT motor mounts from Stedman, using only the right side.

I got new FT isolators and covers.

 

[bottombracket]

The front crossmember and transmission crossmember took a little doing.

The age old solution for 79-on-80-frame has been to line up the rear single cab body mount with the middle body to frame mount on the 80 frame, and build forward.

Guess what? Double cab is off about an inch in both dimensions. The cab mount is 1” wider and also 1” further back, which pushes the entire body 1” forward. We found that out after the fact while lining up the front tubular crossmember.

I obtained 48” of .250 2” DOM tube and the factory mounts, hardware, and isolators. The radius was off, and Bill came up with a slick adaptation, notching and flaring the mount to adapt to a 2.25” pipe. Note that the crossmember is eccentricly drilled through the frame. Which I’m ok with because everything here is about adapting to fit.

Correct inner frame gussets were also used.

Using a sleeved double tube also gained a little height, pushing the crossmember closer to center of 80 frame.

 

[bottombracket]

Burned in.

 

[bottombracket]

Transmission crossmember:

Since the cab was now pushed forward 1”ish, the transmission mount needed to move 1” laterally and 2.5” forward. Some square tube made it possible.

The outside had to be clearanced for t case fins. Needs to be cleaned up with a grinder but it all works.

I don’t know if I’ll stick with this or switch to a Slee skid plate/crossmember- that is a really elegant solution that @AlbertoSD used on his FT 80 conversion.

At the end of the day, we had fan centered in fan shroud, and shift tower centered in the cover plate. Rolling chassis achieved!

Not too shabby for 3.5 days in safety sandals. Bill rocks. I’m grateful for his friendship, and skill set.