Builds My 40 Build... 20 years and Counting... Purists beware, this may hurt... :D

[bikersmurf]

Life has thrown our family some curve balls lately so the 40 hasn’t seen much love. Here’s something I’ve been working on. I’m adapting Sterling sway bar mounts to fit my Dana 70. Our Ambo has been our DD since April, and this is for its rear axle.

How the sway bar would fit if I had a Steering axle… shamelessly stolen from the web.

Closeup ou the stock configuration on a Sterling axle.

This is what the mounts looked like before I got creative.

 

[bikersmurf]

Although it’ll still take some tweaks and revisions. I really like that it’ll be tucked in tight once it’s done.

 

[bikersmurf]

 

[bikersmurf]

 

[bikersmurf]

 

[bikersmurf]

SAD

Sharpie Aided Design

 

[bikersmurf]

Right side is almost done.

I’ll need some fresh paper for the left side. Unfortunately the nearest tool stores don’t have it & it’ll be a while until I can get to Princess Auto (across town) that does have it.

So progress is on hold for now.

I have a Camaro sway bar to mount to the 40… but that’s a project for another year.

 

[bikersmurf]

All of the sway bars I’ve seen for E350/450 vans seem to hang 3-4” below the axle. I don’t particularly like that design and prefer the stock F350 pickup bar that’s up above the axle out of harm’s way.

Although it’ll be rare to need the extra clearance, the 4wheeler in me doesn’t like sacrificing ground clearance for any reason. For serious off roading the 10k 8’x21’x8’6” Ambo is too big. That’s what I have a 40 for… However, for camping and exploring logging roads, the “camper” has its advantages. It’s a great base camp to explore further out from on foot, bike, or 40. Power, fridge, microwave, and storage space are nice to have… especially for repairs away from home.

 

[bikersmurf]

Ready for test fit with the sway bar number 6. as much as I love custom fab work… it always involves a lot of test fitting. Fingers crossed it won’t be too stiff and lead to headaches.

 

[bikersmurf]

For anyone just dropping in, this axle isn’t on a 40. I thought I’d post here because we all like pictures and custom fab work. Personally I like to see solutions to problems that aren’t solved by having the thickest wallet.

So what do these mounts have to do with a 40 series… nothing. However, I’m hoping what I’m doing here will inspire someone else and help them solve there problems… or a very least, people can enjoy seeing the process. Wether it’s bending a class I hitch to make brackets, heating a stick shift to bend it, skid plates, or 1/2” rod to make mirror arm… the process is the same. All of these (and more) I’ve done for my build, and most I’ve not taken pictures of.

 

[bikersmurf]

Installed and fully functional. I especially like how the bar is nice and high up. I’ve seen some aftermarket sway bars that sacrifice 3-4” of ground clearance.

The sway bar is stiff enough to feel a significant difference without making the ride harsh. There’s 6000+ pounds on the rear wheels (per the truck scales) so it’s a lot like a loaded rig all the time.

 

[bikersmurf]

Looking at these pictures with all the surface rust makes me want to pull out the needle scaler and go to town. There are many areas where POR15 would probably do, but there are some where I’d want to knock everything loose off before painting.

It’s always a slippery slope… if clean the frame, then I’ll need to drop the fuel tank to clean that area… and if the tank is out I should clean up and paint the replacement tank. While I’m at it, one of the rear crossmembers is getting thinner in spots… so I should probably replace it at the same time. And hang my better spare, paint the rear axle… hey why not pull the box and body?

Well if the body is off, new glow plugs, fuel filter, newer injectors, new fuel pump, front main seal. Perhaps paint the block, and….

I’m exhausted already. Time to look away, put my blinders on, and try to find time to work on the 40. If it ain’t broke don’t fix it

 

[pjohnson]

If you give a mouse a cookie....

 

[bikersmurf]

If you give a mouse a cookie....

So true... unfortunately.


I'll admit I had to look up the reference... my kids are quite a bit older now.

 

[pjohnson]

I'll admit I had to look up the reference... my kids are quite a bit older now.

I read that to my daughter a bazillion times when she was little, about 35 years ago

 

[ijonesinsp]

I read that to my daughter a bazillion times when she was little, about 35 years ago

I read that to my daughter every night for a month last year. Oldie but a goodie.

 

[bikersmurf]

Small step in the right direction. Started it up after it has sat for 8+ months, it ran perfectly...

Stripped off the 30ish year old Rancho 5000 steering stabilizer that is pooched and in the way of the new pitman arm. Ordered a 10:1 tapered ream to be able to reverse the direction of the taper in the TRE so that I can mount that end of the "60 series" Monroe steering stabilizer.

While I'm waiting for the tapered ream to arrive I'll have to relocate the fixed end of the stabilizer mount... but it was too wet to mess around with that today so it'll have to wait a bit longer till I have some spare time to mess with that end.

 

[bikersmurf]

Came across this that’s new old stock. Not OEM, but it is very similar looking…

for about $30 I figured what the heck.

 

[Chungas Revenge]

Would you be able to send me a photo of the mounting points for your grab handle?

 

[archie73]

Came across this that’s new old stock. Not OEM, but it is very similar looking…
View attachment 3505117
View attachment 3505124View attachment 3505125View attachment 3505126
for about $30 I figured what the heck.

I’m curious on the ThermoKing heater. What’s that from? I need something compact like that for the cruiser and the f100.