The Resurection of 'The Beast' (1 Viewer)

[Southeast Overland]

Thanks to the I got a ton of work done today. I was able to finish patching up the tailgate so I can paint the tailgate ODG tomorrow. I installed two Yakima load bars, basket and paddle holder (for Hi-lift) and mounted two fire extinguishers in the cab. I test fit my swing-out spare tire mount and think it will work well - I definately am good-ole-boy fabbing this guy. I also felt bad because I never take pics so here are a ton-o-pics for your viewing pleasure.

Pic 1) Rack from below. It was dark when I took these three pics so you can't see them very well.
Pic 2) Rack from front. I mounted my Hi-lift for the time being in a Yakima paddle rack for the rear. I secured it with a mountain bike toe clip strap and a Yakima wheel tie-down. The front would have sat in a paddle rack but I couldn't get the nut in the sucker to come loose. A mountain bike toe clip strap and wheel strap were used to tie the front down also.
Pic 3) I trimmed the load bars pretty close to the rain gutter mounts to help with catching trees and limbs. I debated even putting a rack as if I flop this Piggie the rack would do damage but I am going to use it as a place to secure ropes for a tarp so when I reach camp and its raining I can rig up a tarp to stay dry under as I pitch a tent. I'm not going to put any weight up top except for the Hi-lift for the time being. If I didn't install the rack I would have to mount some eye hooks or something similar in the roof to attach tarp ropes to and felt this had a better chance of causing damage from wind.

 

[Southeast Overland]

Mo pics Mo pics Mo pics!

Pic 4) I welded up the last spot on the tailgate where I cut out rust. This pic shows a piece of 16 ga sheet that I cut to fit exactly in the hole. This was a pain in the keister.
Pic 5) Patch tacked in place.
Pic 6) Patch fully welded in place.

 

[Southeast Overland]

Mo pics yo!

Pic 7) Tailgate patch weld ground flat.
Pic 8) Tailgate patch weld area with POR Patch as a shallow filler.

ETA: I have already primed the patch area, sanded and reprimed to prep for painting the tailgate tomorrow.

 

[Southeast Overland]

And mo mo mo pics! (I'm in a goofy mood, can ya tell?)

Rear wheel swing-out pieced together.

Pic 9) Rear wheel swing-out IPOR DIY spindle and 2x2.
Pic 10) IPOR DIY wheel mount from front. Stick is taped in place so I can see how wide my spare is going to be so I won't block my taillight.
Pic 11) IPOR DIY wheel mount from the side. This is going to be niiiice. The was not around to hold the wheel mount in place so I don't have a good pic.

 

[Southeast Overland]

And even more pics!

Pic 12) I'm thinking about welding this bolt to the bumper to secure the swing-out in place. There is a 1 inch piece of steel that I will weld to the 2x2 to secure the swing-out to the bumper. Note black rubber stopper.
Pic 13) The rubber stopper is in place so the spindle weld will not have to support the whole weight bouncing around. This rubber piece is a stopper I picked up from True Value Hardware.
Pic 14) I drilled a hole thorugh the stopper with a 3/8 inch paddle bit and then drilled a hole the rest of the way through for a bolt. I recessed a washer into the stopper so the bolt won't pull through as easily.

 

[Southeast Overland]

Pic 15) I am going to weld two pieces of steel rod to the nut to make basically a big wing nut. DanKunz has a similar set up. I would have liked to have used IPOR's clasp instead of this ghetto-fab method but it was much cheaper and I hope it will work. I am going to cut about a third to half of the steel rod length off to shorten things up.

 

[yooper]

A buddy has a forklift which = automatic ramp. I am going to put new shocks on sometime soon and w/ the forklift we are going to figure out exactly what I need. I want to double check since I broke one of the shock mounts this spring.

The shock mount only broke because the PO isn't a very good welder....

 

[yooper]

I think McMaster Carr has some pretty inexpensive clamps that would work as a hold down for your swingout. I can't imagine having to take off a wing nut every single time I wanted to open the tailgate...

 

[Southeast Overland]

I think McMaster Carr has some pretty inexpensive clamps that would work as a hold down for your swingout. I can't imagine having to take off a wing nut every single time I wanted to open the tailgate...

Hmmm - wasn't thinking about having to get into the tailgate - only thinking about getting the tire off...

 

[Trollhole]

Steve call me around 9:30 tomorrow I'll be around all day working on the pig and can weld your carrier together.

 

[Southeast Overland]

Scratch the Hi-lift on the roof rack - there is a spot for it to mountn on the IPOR DIY carrier - knew that but wasn't thinking yesterday.

 

[yooper]

Scratch the Hi-lift on the roof rack - there is a spot for it to mountn on the IPOR DIY carrier - knew that but wasn't thinking yesterday.

That makes more sense. A PITA to climb up top to get it. You can also mount it on the front bumper, but it tends to get really dirty there...

 

[yooper]

If you search for "latching clamps" at http://www.mcmaster.com/ you will see the ones I was thinking of...

 

[GXO]

I use the stud/wing nut attachment method on my rear bumper and it is actually VERY nice. It takes no effort to spin it off, and I put a magnet to hold the nut on the bumper while it is open. The best part is that you can always tighten it up so there is no slack in the system and the tire carrier system stays put.

 

[Southeast Overland]

Weeeeee! My swing-out tire carrier is all welded up. I still have a few small things to figure out but it works! A big thanks to Trollhole for the welding assistance today. I know my 110 would not have been enough.

The whole spindle, arm, wheel mount welding went just fine. The large hole drilled in my bumper at my HAMOM <<<clears throat>>> was not a problem!

What we did run into is a TON of play in my bumper once the swing-out was welded up and the tire mounted. This is due to four missing bolts on the underside of the bumper that secure the bumper to the frame. I believe the rescue of a Heep by the PPO caused this. For the time being we tack welded the bumper to the frame on the underside and it tied everything together nicely for the ride home. I am going to get a step bit and drill the holes back out and rebolt everything together this week. If it wasn't for needing to straighten the rear bumper at some point in the near future I woudl fully weld the bumper to the frame and be done wid it!

Before Upstate Cruiser's Blueridge Parkway ride next weekend I need to fab up some type of license plate mount with illumination for inside the rear wheel. I have to be able to run power to the wheel area and open the swing-out without having to unhook the line and also need to be able to easily disconnect the plate and light mount from the wheel in case I need the spare. This is going to be a busy week at work so it will be challenging to get everything done in time. Painting the tailgate and the swing-out will probably have to wait until sometime next week. Also will need to weld a stop to keep the swing-out from swinging-out too far and some type of catch to hold the swing-out open.

Now for the pics!

Pic 1) Rear view
Pic 2) Passenger side view
Pic 3) Close up of weld on spindle. I haven't cleaned anything up yet.

 

[Southeast Overland]

Couple more pics.

Pic 4) DIY mount welded on to 2x2
Pic 5) Open
Pic 6) Wing nut close up. I have not yet welded the wings on.


I think my 2x2 swing-arm is not thick enough. I need at least 2x2x3/16 and I'm pretty sure mine is thinner. Looks like I might be cutting and rewelding...not happy. CONFIRMED - am picking up some 2x2x1/4 tube tomorrow morning and will have to weld on a new cross arm - won't be that big of a deal. Spindle will remain welded as well as bolt on bumper.

I opened this creature up and sat on the far end of the 2x2 and the sucker was pretty stable. I get some slight play in the 2x2 and some slight play in the bumper. I will have to make the bumper rock solid before I add another swing-out on the driver's side for a dual Jerry can rack that I'm working on.

 

[Southeast Overland]

Snapped two more quick pics. Front and rear view. The e-brake does now work but my wife is scared that my Piggie is going to run over her wee little Jetta so to make the I still throw that wheel chock underneath.

Oh - and ignore the Heep. Its up for sale!

Pic 1) Front view
Pic 2) Rear view

ETA: 35" MTRs & 36" Swampers both measure 34"

 

[yooper]

 

[n2666s]

Steve, awsomeappologize for the phone interruption while you were welding; got my tail in a bind with the rear tailgate gear!

Lou

 

[Southeast Overland]

Steve, awsomeappologize for the phone interruption while you were welding; got my tail in a bind with the rear tailgate gear!

Lou

Thanks Lou! No prob on the call - I didn't know you called until later and speaking of I need to check VM...the Piggie is coming along!