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Norcal69's Common Sense Build.

Discussion in 'Builds and Fabricators Forum' started by Norcal69, Sep 11, 2014.

  1. Apr 10, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Nope! Just a heavy side shift attachment and soft jeep springs..... This is my loading dock forklift hence the solid rubber tires. It's quite a bit overkill as it is rated at 6k lbs....
     
    ITLKSEZ likes this.
  2. Apr 13, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Finally got my rear shock mounts done. Modified a bracket from Ruff Stuff.

    [​IMG]

    [​IMG]

    [​IMG]
     
  3. Apr 16, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Back on page 15, I build a custom transmission cross member. This gave me 3" of increased ground clearance and raised the transfer case to within 1/2" of the floorboard. Of course one thing leads to another..... and now the fan is only 3/8" to the radiator core. When I installed the aluminum radiator I tried a multitude of flex fans, but non of them pulled enough air keep the jeep cool at low speed on a 110 degree day. Road speeds were just fine, but sub 15 mph and we got a little hot. I gave in and installed this noisy solid fan and for 3 years I haven't had any issues. With the engine idling, the steel fan would hold a shop rag up against the front of the grill. The steel fan is noisy due to the increased air volume and there was a very small, but noticeable amount of drag. Now that the steel fan is too close to the radiator I am going to give in and install a shroud. The shroud should allow me to install a lower drag/ quieter flex fan.
    Here is where the fan ended up after raising the rear of the drive train.

    [​IMG]
     
    47v6 and Muzikp like this.
  4. Apr 17, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    New fan and shroud. My brother is going to tig some flanges onto the outside for attaching to the radiator. The fan is basically flush on the front with the water pump mounting and 7/8" toward the rear. With a short spacer I should get the optimum half in half out spacing. When I ran this fan before The engine revved noticeably faster and was much quieter than with the current steel fan. I think that with the shroud it should work great.

    [​IMG]
     
    47v6, 3b a runnin, txtoller and 3 others like this.
  5. Apr 17, 2019
    IRQVET

    IRQVET Bubbaification Exorcist

    Tallahassee, FL.
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    Feb 5, 2015
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    680
    Looks like the same fan I have, its a tight fit.
     
  6. Apr 18, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    It is especially tight with the thick 3 core radiator I am using.
     
  7. Apr 18, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    I pulled the radiator last night to work on attaching the shroud. I am very happy I chose to do this! When I installed the radiator I was very careful to check for clearance/ rub areas all the way around. Apparently I missed this spot. I carry JB weld in the jeep for trail fixes, but this little spot could easily have turned into a 4 hour trail repair...... o_O

    Almost rubbed through.... I'll have my brother tig this up.....

    [​IMG]


    For the fan shroud.
    Once the rad was out the rest was pretty simple. There is a lip on the side of the radiator for the factory dodge fan shroud.

    [​IMG]


    VERY CAREFULLY removed the lip and ground the remaining material down flush with the core.

    [​IMG]


    Now I have a clean slate for my brother to tig some shroud mounting ears on each side. My brother is certified in every type of welding, pressure vessels, master machinist and a industrial fabrication/ engineers apprentice. I made the mounting ears for him to tig onto both the shroud and radiator. I'm almost positive he will overthink what Ive done and come back with something capable of finishing the Baja 1000...... :rofl:
    I mean this kid is a certified wack job..... his serpentine belt idler pulley broke on his chevy truck. Rather than go 5 miles to the parts store where they stock them, he turned his own out of aluminum. Cut a groove inside so once the bearing is pressed in a snap ring could be used for added safety; even turned all the ribs for the serpentine belt........ :rolleyes:
    I have high temp rubber trim for every edge and surface where the shroud can come in contact with the radiator.


    [​IMG]
     
    ITLKSEZ and Focker like this.
  8. Apr 18, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Sep 10, 2018
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    You better be nice to that brother. Anything he needs. :beer:
     
  9. Apr 19, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Like it never happened......... I removed the piece that caused the damage to the lower tank.

    [​IMG]
     
  10. Apr 19, 2019
    IRQVET

    IRQVET Bubbaification Exorcist

    Tallahassee, FL.
    Joined:
    Feb 5, 2015
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    680
    I have a 3 core as well, its crazy tight. I always fear if the motor flexed it could send the fan into the radiator.
     
  11. Apr 22, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Mounting ears welded to shroud.

    [​IMG]

    Flange welded to radiator. I guess he was afraid that it could break off....... :confused:


    [​IMG]

    You can see the scrapes on the shroud from the water pump snout. I slid the assembly in and marked the center of the fan. 1" was added to the radius for flex clearance.

    [​IMG]


    I knew I bought this thing for a reason. Still has the auction tag on the cord.......

    [​IMG]


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    Rubber belting in between the shroud and radiator. High temp rubber trim on the edges.

    [​IMG]

    The pictures make it look easy, But there were several installations and removals mixed in with a little hand filing..... I ran the engine for 45 minutes in my shop bay. 75 degrees outside in a dead air space. The temp never got over 185. I should note that the video was taken right after startup. Choke was still keeping engine idle up. Once the choke opens the rag still hangs right on the radiator. I am missing a pic of the slot that I cut for the alternator shaft/belt tension. In the video you can see light coming through the shroud in the location.

     
    Last edited: Apr 22, 2019
    Muzikp, Focker and ITLKSEZ like this.
  12. Apr 22, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Looks and works great. Excellent work.
     
  13. May 8, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    While I was working on my suspension I reworked my steering components and added a support bearing to the steering shaft. Adding the support bearing instantly alerted me to another demon as seen in the video below.



    This worn out steering column bushing produced the most annoying, teeth grinding..... point this thing into the next tree at a high rate of speed...... kind of steering wheel vibration. Racing open wheel cars made me kinda anal about those type of things..... Like we true our brand new racing tires kinda anal.
    Summit wouldn't give me any love since the column was 5 yrs old, so I came up with my own plan.
    When I removed the column this delrin type bushing fell out. It appears that this bushing rode inside of the thick steel sleeve that is pressed into the column.

    [​IMG]

    I picked up this setscrew collared bearing.

    [​IMG]

    The only issue was that the bearing OD is 2" and the column OD is 2". I turned this little sleeve .005 over 2" to press on and weld to the steering column; and .003 under size to press the bearing into.

    [​IMG]


    I started cutting with my tubing cutter but quickly realized that it wasn't going to get me far enough.

    [​IMG]

    [​IMG]

    I plug welded the reinforcement tube in several spots.

    [​IMG]

    I pressed the bearing into the sleeve and then the assembly onto the column. Tacked together.

    [​IMG]

    Welded up and locked down

    [​IMG]

    I had to make a new floor attachment plate to accommodate the new 2.25" column diameter. Pretty simple shaft collar welded to plate.

    [​IMG]

    I threw a couple bolts in for mock up and took it for a spin around the yard. Huge improvement! :beer:

    [​IMG]
     
    47v6, Rich M., Bowbender and 3 others like this.
  14. May 8, 2019
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    Nice work on that steering shaft....always love to find creative idea to solve problem :)
     
  15. May 8, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Great job. Good thing about 50% hearing loss. I only hear half of what bothers most. Lol
     
  16. May 10, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    I have come to the realization that a factory T98 or T18 floor cover is not going to fall into my lap..... With the rubicon trip fast approaching I knocked this transmission cover out this evening...... Hopefully by the end of the weekend it will be in sheet metal form....

    [​IMG]

    [​IMG]


    Ready to transfer to a sheet of 18 gauge steel

    [​IMG]
     
    47v6, supertrooper, Bowbender and 6 others like this.
  17. May 11, 2019
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    :clap:
     
  18. May 13, 2019
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    I don't know if you guys like the progress photos, maybe some people appreciate the procedure?

    Traced the template to steel sheet with a fine point pen, then drilled holes in all of the inside corners. It is hard to see in the pic. The holes help when cutting out the shape and make the metal more forgiving when bending compound angles in the brake. I drilled the holes with a 1/16" drill bit and cut out the shape with a jig saw.

    I don't have a lay out table here so I elevated the steel and used a t square to establish my bottom edge/ perpendicular lines where the sheet will be folded. Crappy phone camera doesn't show the lines.

    [​IMG]
    [​IMG]

    To the straight brake we go..... I won't bore you guys with every bend......

    [​IMG]

    Then the pan brake......

    [​IMG]

    If you look really close at the corner you can see how drilling a hole in the steel allows the fold to come out perfect.

    [​IMG]

    Tacked together. I had to make the final rearward sloping bend by hand on the work bench. It came out ok, I'll clean it up a bit.......

    [​IMG]
     
    47v6, tymbom, Twin2 and 11 others like this.
  19. May 13, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Very nice
     
  20. May 13, 2019
    Renegade ll

    Renegade ll Member

    Thayne Wyoming
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    Wow you do really good work. Looks great.
     
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