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IFS to 1 ton Truggy

Discussion in '1st Gen. Builds (1995-2004)' started by esxcli, May 2, 2019.

  1. Feb 25, 2020 at 5:38 PM
    #41
    esxcli

    esxcli [OP] Keyboard Warrior

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    I decided to skip working on the truck yesterday. I have stress fractures in L3 and L4 from a lackluster amateur career in kickboxing. My wife's yard work pretty much made me useless on Monday. That's the sacrifice I was talking about I suppose.

    Wanted to get the steering box mounted up today, but I can't get it far enough forward without hitting that repurposed front cross member. So, off with their heads!

    A little bit day by day. My daughter needed her bike water bottle holder fixed, so that ended the day.

    IMG_20200225_172236.jpg
    IMG_20200225_172246.jpg
     
    MY50cal and slander like this.
  2. Feb 28, 2020 at 9:32 PM
    #42
    esxcli

    esxcli [OP] Keyboard Warrior

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    So, after much deliberation, I think I have placement of the box where I need it. Got everything tightened up, going to tack, shave the sleeves and get the box mounted to get it off the floor.

    I need another set of hands but daughter is sick and not strong enough to hold the gearbox in place. Hate how slow going this is. Tomorrow should be more productive.

    Go straight axle, they said.

    IMG_20200228_172616.jpg
     
    POSTacoMike, MY50cal and Nimble9 like this.
  3. Mar 2, 2020 at 7:11 AM
    #43
    esxcli

    esxcli [OP] Keyboard Warrior

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    Quick update. Steering box in! Now comes the truss work for the front, WFO crossmember, and sorting out 3 link geometry.

    Neighbor told me I look like a hillbilly building zombie response vehicle. Lol, not even mad.

    IMG_20200229_155851.jpg
    IMG_20200229_162603_783.jpg
     
  4. Mar 2, 2020 at 2:25 PM
    #44
    PanDa_

    PanDa_ Active Member

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    Nice Build! Are you going to keep it Auto when it's finished? Also, Where did you get those headlights?
     
  5. Mar 2, 2020 at 2:32 PM
    #45
    avw4x4

    avw4x4 Well-Hung Member

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    ...loading....
    What truss are you using for the D60?
     
  6. Mar 2, 2020 at 3:41 PM
    #46
    esxcli

    esxcli [OP] Keyboard Warrior

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    A hybrid of the ruffstuff d44 (found for 20 bucks locally) with some alteration and 2x4 rectangle stock for the length of the tube. I figure I'll weld the tubes to the cast first, then do the truss, reassemble and button up.
     
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  7. Mar 2, 2020 at 3:44 PM
    #47
    esxcli

    esxcli [OP] Keyboard Warrior

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    Thanks. Yep, keeping auto. My YJ was standard and eff that noise in the rocks on a side hill.

    Headlights were gifted from a buddy who borrowed it for a week and couldn't stand the stocks. Amazon special. If you get them, get the relay with them, otherwise the brights don't work
     
    Running Board Man likes this.
  8. Mar 2, 2020 at 3:51 PM
    #48
    avw4x4

    avw4x4 Well-Hung Member

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    ...loading....
    Amped to see where this goes :cheers:
     
  9. Mar 2, 2020 at 4:39 PM
    #49
    esxcli

    esxcli [OP] Keyboard Warrior

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    slander and avw4x4 like this.
  10. Mar 2, 2020 at 5:16 PM
    #50
    slander

    slander Honorary Crawl Boi

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    Ahhh the mighty orb of traction! Nice!!
     
    gunn_runner and esxcli[OP] like this.
  11. Mar 3, 2020 at 6:36 PM
    #51
    esxcli

    esxcli [OP] Keyboard Warrior

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    Mile Marker hubs in
    Truss half welded in
    Tubes burnt to pumpkin (I hate cast)
    WFO crossmember shit staring at me.
    Ric Flair Wooooooooooooo! Done for the day.

    IMG_20200303_183229.jpg
    IMG_20200303_164535.jpg
    IMG_20200303_183209.jpg
    IMG_20200303_183406.jpg
     
    avw4x4 and slander like this.
  12. Mar 3, 2020 at 10:02 PM
    #52
    esxcli

    esxcli [OP] Keyboard Warrior

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    I lied, got ancy and banged out some more like an addict. The cast is hard to run a nice bead on, so I'll flap disc and take it in smaller sections.

    Screenshot_20200303-193318.jpg
     
  13. Mar 3, 2020 at 10:45 PM
    #53
    slander

    slander Honorary Crawl Boi

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    I'm surprised you didnt stick weld that cast. Did you preheat?
    Disclaimer- I am not a cast welding expert.
     
    esxcli[OP] likes this.
  14. Mar 4, 2020 at 8:12 AM
    #54
    esxcli

    esxcli [OP] Keyboard Warrior

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    I watched a shit ton about welding cast from other people just doing shit, but I was still leery. So I hit up a few buddies who are pro welders, and asked their advice. Here is the synopsis of the responses.

    If it is the only structural bit, use a 7018 rod and make at least 3 passes. However, it is really there for structural support as the main strength comes from the sections welded to the tube (which was 70-S6). The caveat to this is, preheat and allow to cool evenly. Cast steel will cool faster than the mild steel of the tube. Hence the fiberglass blanket. So here is what I did.

    Flap disk everything clean and shiney.
    Map gas for 10 min or so on the cast and tube, 2/3 of the time cast.
    Got everything to about 400 F
    Ran small beads
    Hit the cast with the torch again
    Covered it with blanket and wrapped to hold it
    Let it sit for an hour
    Repeated process
    Started welding, realized I didn't turn the gas back on
    Cussed
    Burnt my forearm turning on the gas
    Cussed more
    Started welding, but at this point I was getting impatient so ran connecting beads.
    Was at the wrong angle for the front, so it came out less than stellar.
    Threw the blanket back on and said "fuck it, I must be getting tired"
    Blew out the black boogers, cooked steak and asparagus, then went to sleep.

    Ultimately, I think I agree with you, stick welding that part might be the best idea.
    I think I might go back and run some 7018 rod tonight. I honestly think it's good to go, but I hate how ugly that front came out. :)
     
    slander[QUOTED] likes this.
  15. Mar 4, 2020 at 8:15 AM
    #55
    esxcli

    esxcli [OP] Keyboard Warrior

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    Lol, I won my first fight via lowkick. Dude was taller than me and I didn't have enough experience to get around his long ass jab. To misquote one of my favorite movies.

    "I could only win by removing the leg or destroying the thigh."
     
    jeff b[QUOTED] likes this.
  16. Mar 4, 2020 at 8:20 AM
    #56
    Running Board Man

    Running Board Man Well-Known Member

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    Why?
     
    esxcli[QUOTED][OP] likes this.
  17. Mar 4, 2020 at 8:36 AM
    #57
    esxcli

    esxcli [OP] Keyboard Warrior

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    It got dirty and took 2 hours to completely pull, clean, and reinstall. It sits back behind (in front of) the rack and pinion and was awkward as hell to get out without pulling the diff. When I got it back in 4x4 would lock with a handheld vacuum pump, but wasn't giving enough pressure to do it through the switch, so I never actually tracked down the issue.

    My personal thing is... I dislike anything vacuum actuated because all it takes is one stick on the trail to completely remove your ability to shift in and out of 4 wheel. What I ended up doing was moving the collar over, put a hose clamp to keep it locked, reinstalled the actuator, capped the vacuum lines and ports, and allowed the transfer case to decide if I was in 4x4 or not.

    Worked like a dream.
     
    Yetimetchkangmi likes this.
  18. Mar 4, 2020 at 8:43 AM
    #58
    ozpall

    ozpall Well-Known Member

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    awesome, here is my 1 ton taco i built 12 years ago (dang time flies) and now all the parts are going into my 48 willys.SmartSelect_20200304-104002_Instagram.jpgSmartSelect_20200304-103919_Instagram.jpg
     
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  19. Mar 4, 2020 at 8:56 AM
    #59
    esxcli

    esxcli [OP] Keyboard Warrior

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    HELL YES!

    So, I need to fabricate a link mount for the rear. Did you end up keeping the carrier bearing in? My thought is, I can go straight across under the carrier bearing and not worry about it coming in contact with the driveline. Since they will be equal length for top and bottom, there shouldn't be any binding... I hope.
     
  20. Mar 4, 2020 at 8:58 AM
    #60
    tmar_taco

    tmar_taco Well-Known Member

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    Roof Rack, RTT, Leer 180 Cap, Pullout Kitchen, Airlift Kit, Removed interior plastic paneling behind rear seats to make room for electrical & pv system, Pioneer Bluetooth Radio.
    Kinda love the way this looks without the front panels.... very steam punk!
     
    esxcli[QUOTED][OP] likes this.

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