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  #51  
Old 07-05-2011
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Great minds think alike :)
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  #52  
Old 07-07-2011
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Well, still no doubler.... Called Duffy twice yesterday, and nothing. Still have the claim in through Paypal though.

I did do a little body work yesterday.... Holy **** sheet metal is thin.... I kept burning through it, so i slowed down, and used a **** ton of tack welds to piece everything together. I made the filler panels with scrap sheet metal and cut everything out with a 4 1/2" cutoff wheel... Man i miss my plasma...

Here are some pics:

What i started with


Here is after i got the 3 pieces i cut in place. I tacked everything first (no pic), then moved into the booger-the-****-out-of-everything step


^Boogies!! Yea i know they look like ****. Self taught here people...

I then took a 36 grit flap wheel and went to work...


^Got it pretty smoothed down, so i moved on.

There were a lot of holes and gaps that i had to fill in with weld (well i didn't have to, but i did anyway. You can see some in the pics, some you can't

This is the side towards the tail gate all boogered up


top and side towards bed boogered on


You can see some of the gaps here


Everything boogered in



It was after dark when i got this far, and i can't use the grinder after dark at my condo, so i have to wait until tonight after work to finish. I will grind all the boogers down, and shoot some Krylon yellow spray paint over it. Color matches pretty good, so it will be fine for the bed.
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  #53  
Old 07-07-2011
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try shaving tailgates, handles and tail lights..uber pain
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  #54  
Old 07-07-2011
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My dad is a wizard at it. Then again, his welder is setup to burn just sheet metal. And he has been doing it for like 20 something years.

I got it done, looks like **** right now, but wait until tomorrow, i'll get it looking good.
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  #55  
Old 07-08-2011
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HE SHIPPED IT!!! After 3 weeks and numerous phone calls and a paypal claim, I finally got the tracking number. Supposed to be here Saturday, so cutting the case Sunday and taking to a welding shop Monday. Also have to rip the steering box and pump out to send to West Texas Offroad to have rebuilt for Hydro.
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  #56  
Old 07-11-2011
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well, nothing showed up from Duffy yet, hopefully got to the house today. I did get my order from DIY4X, which by the way, kicks ***. They specialize in box body C/k10's and K5's, but they make a lot of fab parts too. I got 16 cross member tabs, 8 bushings, 8 bolts, 8 zurks, and 10 misc. gussets all for 140 bucks shipped. Was cheaper by like 8 bucks a piece on the crossmember kits than Ruff Stuff and even more from Ballistic. DIYBeadlocks.com are also cutting out gussets and tabs for a buck a piece.


finished the bed patch, and went to the carshow. On the way back, the passenger side window regulator crapped out, and the fuel pump quit working. Took the bed off to find i nicked one of the wires when i was cutting down the sending unit. So i ordered a new one.

Here are some pics

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Bed Patch

Beginning
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Big *** hole starting to get repaired
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All filled up and burned in
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Ground down enough for my likings
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Shot coat of Krylon Yellow
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Right after i finished, i drove to the show, and dirt got all in the paint, so now it really matches the rest of the bed. lol
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  #57  
Old 07-11-2011
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what was waiting on me when i got home....

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  #58  
Old 07-11-2011
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hey i recognize some of that...

hows the filler cup look?
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  #59  
Old 07-11-2011
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um, kick ***. Its going to look great on the truck in anodized black
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  #60  
Old 07-14-2011
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Well, its official... The deal for the new crawler has gone through...

Some of you might recognize it....

Here is a couple shots from the current owner. I will be picking this up the weekend i get home.


Attached Thumbnails
Josh's SAS thread-2011-02-13083843.jpg   Josh's SAS thread-frontflex.jpg  
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  #61  
Old 07-14-2011
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1350 Crawlbox build

To do this, you will need 2 main components...

Borg-Warner 1350M transfer Case


DD Machine Doubler Kit
(disreguard the Compressor and Jeep filler neck)

First thing to do is break open the 1350. Best thing to do is take the front yoke off and put the case in 2wd or neutral. To get the yoke off the front, I used an impact and a big pair of channel locks to hold the yoke while i spun the nut off.

Once it is off, just simply remove all the bolts from the outside (15mm) and pull the top off.


^Note: The picture above shows the chain removed already. To do this, you will have to take off the snap ring from the gear that drives the front shaft. Its a PIA, but once it is off, the chain, shift rail, and the large shaft come right out.



Once you have these out of the way, open up your DD kit, and grab the smaller shift fork.


Put it in the hole where the old one came out.


Next you will have to address the pressed in stub on the side of the case.


You can try and pull it out or whatever, I just took a 4 1/2" cut off wheel to it. Then i took the grinder with a well used 36 grit flap wheel around the lip to clean up any crap, but not staying on any spot so i wouldn't eat into the metal.


Our next step is to lay the doubler plate on the case half you will be using and use 3 of the grade 5 bolts included in the kit to hold the plate.


Break out your handy dandy marker and mark where you want to cut. I gave a little slack that i cleaned up with the grinder, but we will get there.


Then i used my grinder with the cut off wheel to cut most of the case. There are ribs that go farther than my wheel did, so I simply broke out the sawzall and finished the cut.


Next is to "clean up" the cut until you are satisfied.

^Note: I again used my well worn 36 grit flap wheel to handle all my grinding needs. Although it took a little while, the end result is great.

As you can see, there is a rather large hole that i highly doubt will keep fluid in the case. To address this hole, there are 2 alluminum blocks included in the kit. Just an FYI, they don't fit. At all. You have to cut down about 3/8" and do some finish grinding to get them to fit.


Here is where a decision needs to be made. With me running this in my truck for a couple months then pulling it and installing in the new crawler, I don't want it to leak, so i opted to take the crawlbox to a weld shop here in town and have them weld the blocks into the cut down case. You can also follow my other buddy's lead and just use Form-A-Gasket


Once i get the CB back from the shop, I will edit this post to show the rest of the process.
Attached Thumbnails
Josh's SAS thread-1005or_03_-guide_to_common_transfer_cases-bw_1350_transfer_case.jpg   Josh's SAS thread-6ff67449.jpg   Josh's SAS thread-faa13b63.jpg   Josh's SAS thread-80488a0f.jpg   Josh's SAS thread-d7aa45e7.jpg  

Josh's SAS thread-5ea80164.jpg   Josh's SAS thread-7dd6aff2.jpg   Josh's SAS thread-01511178.jpg   Josh's SAS thread-b9b190a0.jpg   Josh's SAS thread-c3c20046.jpg  

Josh's SAS thread-c3957d04.jpg   Josh's SAS thread-514642cd.jpg   Josh's SAS thread-87cf9e40.jpg   Josh's SAS thread-doublerassy007.jpg  
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  #62  
Old 07-18-2011
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well, while the T-Case is at the shop being welded up, I went and worked on D doing a lot of the little things that i have been trying to not pay attention to. With me turning this one back into a DD after the Rubicon, I want to get as much knocked out as possible.

First, the A/C. The A/C hasn't worked for almost 2 years, so i replaced everything in the system other than the condensor. Heater Core, compressor, lines, and acumulator. Now it works like a charm.

Second was the rough running.... I had no idea what this was. I assumed the new top end had smoked the bottom end of the engine and i would just have to limp it until KY. I was wrong. When i pulled off my gangster-*** Autozone intake tube, i noticed that the radiator hose clamp had cut a hole in the tube. So i figured, this might not help, but it sure couldn't hurt to cover up that little hole. Slapped some electrical tape on, WAH-LAH!! Runs better now than EVER.

3. Jeep thingy. The one I snagged at the JY was plastic, and my buddy Mike from KY sent me one that he had that was alluminum. I like it better, so i took the old one out, put the new filler neck in, and painted the alluminum Jeep Thingy hammered black. Mounted everything up and very pleased with how much better it looks.

4. Passenger Window Motor. The passenger side window motor went out, so i had to replace it. After getting the new one in, I realized the old one was held in with rivets. So i ground them done, knocked them out, and installed the new motor. When i was installing the glass, i over tightened one of the bolts i used to put it all back together and shattered the glass. Dumbass. So i had to go to the border and get a window, then get it installed.

5. Header Panel. When i took the truck to Maaco, they didn't remove the grille to paint the header panel, so it was still red. Which is ugly and annoyed me, so i took the grille out, used my "close enough Yellow" spray paint and gave the header panel a fresh coat.

After the header panel dried, I decided to put my FX4 grille back on instead of the chrome one. I like it. All black and yellow now, minus the lights, which i will do one of these days.


Drove the truck to work today, and it runs so much better than before. Hopefully i will pull better than 14.6 MPG now....

Here are some pics of the finished product....





Attached Thumbnails
Josh's SAS thread-a5d89617.jpg   Josh's SAS thread-c5bf8dca.jpg   Josh's SAS thread-d08318ce.jpg  
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  #63  
Old 07-21-2011
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Worked on the truck last night for ENTIRELY too long. Took some 3/16" hot rolled and cut it down to match the frame. This is entirely too thick for what i needed, 1/16" would have sufficed. Whatever. Anyway, with the fuel lines and wiring running along that side, i wanted to be sure i didn't burn into them, so i kept a spray bottle close and soaked everything with water. The welder did not like this. As you can see below, my welds look like **** (what else is new) but they penetrated good enough.

Anyway, i mounted the air tank on the frame. I type too fawking much:shaking:

Pictures.

My gangster welds


side shot


Then i took some sheet metal and mounted the air chuck or whatever its called.
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Josh's SAS thread-12af4fdb.jpg   Josh's SAS thread-19965c2c.jpg   Josh's SAS thread-223488f1.jpg  

Last edited by Josh40601; 07-21-2011 at 04:04 PM.
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  #64  
Old 07-21-2011
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Nice stuff, like the air tank setup.
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  #65  
Old 07-21-2011
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1/4 is thicker than 3/16 isnt it there bub? looks good though.
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  #66  
Old 07-21-2011
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yes. I know. I meant 1/16" you just caught it before i did
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  #67  
Old 07-21-2011
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looks grat. like the idea of the airtank fill hose! think ill have to make something similar if i can manage to do the flatbed i want!
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  #68  
Old 07-22-2011
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Thanks buddy.


Another update!

Just picked the doubler back up from the weld shop. Going up to my buddy's to build the crossmember and install the whole mess this weekend. There will be pics.
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  #69  
Old 07-25-2011
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also messed around under the hood.

The hood latch from the 05 edge was just bolted on the core support and was always flopping around, so i decided to permenantly attach it to its new home.


First i just tacked in on there so it would stop moving.


Then i burned everything in. was pretty thin, so i burnt through twice, but filled it back in. Still look like boogers, but at least they're penetrating...


Ground it down, slapped some satin black on it. Called it good
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Josh's SAS thread-22e126c2.jpg   Josh's SAS thread-7ab10201.jpg   Josh's SAS thread-26b07999.jpg  
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  #70  
Old 07-25-2011
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Update~

Well, i had a busy *** weekend...... DOUBLER IS IN!


Now that is out of the way, time for the fun....

This thing was a bitch. It didn't want to go in. At all. Fought me and my buddy every chance it got.

Here is the end product as of today...


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Josh's SAS thread-d0544afb.jpg   Josh's SAS thread-94d37636.jpg  
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  #71  
Old 07-26-2011
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List that i need to finish by Sunday...

1. New rear driveshaft DONE
2. speedometer cable ORDERED
3. move shifter forward DONE
4. cut hole in access panel
5. add skid plate to bottom of crossmembers
6. Fix Fuel Sending Unit.... Again.... DONE
7. hook up the air tank again

Last edited by Josh40601; 07-28-2011 at 08:57 AM.
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  #72  
Old 07-26-2011
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so what happens sunday?
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  #73  
Old 07-26-2011
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4 wheeling
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  #74  
Old 07-26-2011
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As you can see from above, the sending unit **** out on me again. This makes the 3rd time. I have a new one at the house that i am going to install. This is starting to really annoy me.
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  #75  
Old 07-26-2011
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Jealous of the doubler.......
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