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Piffs Rebuild

Discussion in 'Builds and Fabricators Forum' started by piffey263, Dec 14, 2011.

  1. Jun 14, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Tarry:

    the reason why I used the used the old metal was the steel I bought was a tad thinner than the frame rails. This piece of metal I am using is the same thickness. I am not sure why, I researched on the forum about what some people use for plating frame rails and that is what I got. it was a little thinner than the frame rails so. I will give it a shot though on practicing on some extra steel I got.

    My plans where to mark and drill the holes, then weld in some 1"x.250 wall DOM to keep the frame from collapsing. I will probably do that with a arc welder because the other mig I got at full voltage at the moment. I got some 3/8 thick plate to go behind the box and will add a gusset or two with the left over 3/8 plate. Hmm, I could make the mount like a larger c-channel that fits over the frame rail. In addition to that I was thinking of strapping the front frame rails but not sure.

    That little bit about the spine count helpts
     
  2. Jun 15, 2014
    djcj3a

    djcj3a Member

    Ukiah, CA
    Joined:
    Jan 12, 2010
    Messages:
    206
    Looks good piff! I'm close enough, that If you need a hand, I could drag my 180 MIG your way for a day. Feel free to let me know if you need a hand. The box I'm putting in my Jeep is a 4-bolt 13/16-36 as Terry described. I picked up one of these: http://www.ebay.com/itm/290834051537?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

    This will allow me to extend off the box a bit, and then tie in with a 3/4 x 3/4 U-Joint. It will also give me a good spot to place a cross-member behind the steering box.
     
  3. Jun 15, 2014
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,784

    Pif, on that spaddering of the weld ( all the little BB's ) this product works will, just spray a little on the project prior to welding...........doesn't effect anything!...... and weld away. The spaddering is caused by incorrect heat & wire feed sometimes or proper or clean grounding or incompatibilities between the base metal and the filler material........with the later being closer to the root reason. Also keep the metal clean , wire brush it off both inside and out as any contamination from dirt and oil will effect weld quality and appearance............
    [​IMG]
     
  4. Jun 16, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Thank you I will keep that in mind and you know same goes to you. I got a friend that I frequently visit over that way so I'm over there at least twice a week. the welder that my buddy has, has the capability to run 220 and gas but he doesn't have the cylinder and hasn't wired the shop for it. He doesn't weld big enough projects. Although he should if he is going to put a dump loader on another vehicle.

    So with that coupling, are you going to have any support for it? I'm trying to picture it in my head, I guess it's not happening.

    Tarry:
    I got some of that stuff at the hardware store different brand it does work, I also dropped the wire speed to 1.5 instead of 2.5 and left the voltage alone. In addition did the zig zag welds instead of loop. The welds look like they are penetrating and are acceptable in my book. Thank you that stuff did help. I am not sure how much it helped but it really did.


    A friend of mine came over to give me a hand and after talking with him and a few people all weekend and researching. I think I will just do it right. Get the telescoping shaft from borgeoson. Then get corresponding u-joints. I am hoping to bring this down to Sacramento, so I want a little bit of safety.

    I will try and grind the welds down tonight and take out the old column and test fit today. Pictures tonight
     
  5. Jun 17, 2014
    djcj3a

    djcj3a Member

    Ukiah, CA
    Joined:
    Jan 12, 2010
    Messages:
    206
    No need for support I hope, it will only extend a 3/4" shaft through the crossmember ~3-4". after that a ujoint on a rod end. I'll post some pics once I get to that point. I am by no means a pro at any of this, just putting things together in hopes that it will work out for me. If not I will try, try again.
     
  6. Jun 18, 2014
    TexasBlues

    TexasBlues JEEP-Hockey-Holic

    Marietta, GA
    Joined:
    Jun 5, 2007
    Messages:
    529
    looking good Piff!

    it doesn't seem to matter who does what on this forum... the ideas and the work never seems to end...

    some might call that penance or purgatory..

    I call it

    FUN!
     
  7. Jun 21, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    djcj3a: Having trouble seeing it, but I got the steering shaft and joints ordered so I should be able to understand what is going on for mine.

    Texasblues: Thanks! Hope you and your family been doing good,
    that is so true, I am glad I have been seeing some amazing ideas so I can apply them to my own jeep.
     
  8. Jun 21, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    [​IMG]

    Started on the steering column, out with the old.
    [​IMG]
    [​IMG]


    Pulled off the exhaust manifold to get the steering box out, noticed this crack on the back side. what was weird is that, two bolts where hand tight.
    [​IMG]
    [​IMG]


    Upper bearing was completely shot it moves all around... no wonder the steering is so bad.
    [​IMG]
    [​IMG]
    [​IMG]

    Moving it out of the shop for the day, its hard work with no steering wheel
    [​IMG]

    Quick check with the new steering column out of a 1975 DJ5
    [​IMG]
    [​IMG]

    Moving the bracket, the 75 column measures 31 inches but the support is wrong place.
    [​IMG]

    My bad...... I should of turned down the voltage, then I turned it too low. I was making a mess, all I wanted was a tack really quick. Note to self do not rush things.
    [​IMG]
    [​IMG]
    [​IMG]


    started making a piece to hold the bottom of the column, I know its bigger than needed. It will serve two functions, hold column and reinforce that area, its bent and warped there.
    [​IMG]
    [​IMG]

    rough idea of what I am doing right there, stole the clamp off the old ross box. I cut a tube then realized the clamp was there.
    [​IMG]


    I got collapsible steering shaft, and two u-joints that should be here Tuesday. I have the new pulley mounted, head tapped for the power steering pump. Still need a new belt for it.
    I probably should of split this up.
     
  9. Jun 21, 2014
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,784
    Pif................when your welding on a piece like the steering column tube that is thin wall and the support bracket that is a heavier metal set the welder to the thicker piece and just direct the point of arc / wire over towards the bracket corner at an angle.......meaning the weld puddle should be around 75 %+/- aimed towards the heavier piece . Once the puddle grows enough it will flow over to the lighter tube and attache itself...........this of course should be just a tack and the whole process is over in a few seconds so as not to create allot of heat, basically it's a pull the trigger count to two and stop.....do it in 3-4 places on the bracket to the tube allowing a little cooling time between each side by alternating from top/bottom or side to side and you should be good to go............also both pieces of metal need to prepped meaning paint & rust free , take a small grinder or wire brush and clean them up to bare metal.
     
  10. Jul 2, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    [​IMG]
    [​IMG]
    [​IMG]

    Got all of the parts now, I been adjusting things before I make up the mount for the power steering box. Need to notch the cross member, because I want to move the box up.
    More work tomorrow now that I have hex keys for the u-joints and hole saw bits.
     
  11. Jul 2, 2014
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,784
    Pif , You Having fun yet?
     
  12. Jul 2, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
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    1,214
    lots of thought involved in this, but its enjoyable. I try and do it best I can and make sure I don't get the wrong parts.

    example, measure a u-joint wrong had to send back. column mount of my way didn't work so went another way things like that are good learning experiences.

    So yes lots of fun :) I think my wallet disagrees.
     
  13. Jul 3, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Started working on the power steering bracket,
    [​IMG]

    First three holes went well, the hole saw bit started making the holes smaller and smaller :(
    Which is too bad cause I liked the holes bigger so it allows adjustment and penetration with welder.



    [​IMG]
    this is the last hole and it was off by 1/16.. so sense the step bit couldn't enlarge it I welded it shut and tried again.

    [​IMG]
    [​IMG]
    [​IMG]


    I tried a space then figured I couldn't get it close enough, so the bolt you see is a transfer punch I made on the grinder.


    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    and... It fits :)
    [​IMG]
    [​IMG]

    Will weld up the spacers tomorrow, front and back then grind the back down so it will fit flush on the frame. I will wait for trimming down the bracket tell its time to weld it to the frame. Now to put in the spacers in the frame, the quick check I did tonight I think I got enough tubing for three holes which means I need to get more in Ukiah some time this week.
     
  14. Jul 3, 2014
    tarry99

    tarry99 Member

    Northern California
    Joined:
    Oct 29, 2012
    Messages:
    3,784
    Pif, Remember before you mount the box & the bracket you should take a few measurements. One of which is: With the Pittman arm on and the box / arm at the straight ahead position ( which means the Pit arm will be facing rear) that you leave clearance between the intersect of the Arm and the Tie rod as the suspension travels up/down and the axle & tie rod travel for & aft at that moment. Depending on how yours is set up they will sometimes collide at that position during compression & rebound.
     
  15. Jul 7, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Thanks Terry, I took note of that.

    after playing with it and fine tuning it, I got a little farther.
    [​IMG]
    [​IMG]
    [​IMG]

    Still got more to do, like take everything apart and weld up the column, weld the 3.5 inch pipe into cross member, re-due a brake line (hit with grinder), new power steering lines, gusset and weld the mount to the frame, and shock mounts. I got to figure out what to do with my exhaust too (shop or do it myself). I will be out of town this next week for a job so I will get a lot of time to think about it.
     
  16. Jul 8, 2014
    djcj3a

    djcj3a Member

    Ukiah, CA
    Joined:
    Jan 12, 2010
    Messages:
    206
    Your welds look good! The plate you built is very similar to what I did, but I have the two upper bolts above the frame. Keep up the good work
     
  17. Jul 23, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Thanks Jake,



    I been busy with work and jeep, haven't had a chance to update.
    Being from a small area and only working on weekends makes it difficult to obtain some parts so I made one.
    [​IMG]

    it took three hole saw bits to make that plate. I need to start buying the hole saws at the steel shop the lenox brand works better than milwahki (spelling)
    [​IMG]
    Drivers side shock tower, with shock test fitted
    [​IMG]
    passenger side
    [​IMG]

    [​IMG]
    Everything is in, but need to work on the trailer for a bit. Tomorrow I will finish bracing the rack for my friends trailer than I will go through everything and double check that I didn't miss anything. I'm hoping to take the jeep on a test run this weekend, if my buddy comes up I will switch to some 33's also. We shall see.
    Jeep drivers weird with power steering I was able to go into town get coffee, shift, and drive without spilling.
     
  18. Jul 25, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Didn't get the front of the jeep apart yet,

    did work on this
    [​IMG]

    [​IMG]

    so when I had the motorola in, the jeep had 11.34 volts at idle (no fan, no headlights). Can't remember how much batter was when its off just its below 12 and above 11.
    I am surprised it starts, I knew the fan and ignition was taxing just not that much.

    jeep with new pick n pull alternator swap.
    pulls 13.4 with electric fan, headlights on, and MSD and pertronics with a upgraded coil. That works for me. quick check with jeep off, got 12.04 volts after swap instead of 11 something

    Alternator wired as follows:
    terminal 1 on alternator, charging light to dash.
    terminal 2 on alternator, battery terminal on alternator.
    battery terminal on back of alternator, positive terminal on Starter.
    ignition wire that was on back of Motorola, positive terminal on the battery. this one I didn't see mentioned when researching on the forum about 10si/12si swaps.
     
  19. Jul 26, 2014
    djcj3a

    djcj3a Member

    Ukiah, CA
    Joined:
    Jan 12, 2010
    Messages:
    206
    Looking good Piff! When I finally get mine done, I'd love to meet up and take a ride up Bartlett or Elk sometime.
     
  20. Jul 26, 2014
    piffey263

    piffey263 Active Member

    Medford, OR
    Joined:
    Oct 16, 2008
    Messages:
    1,214
    Yes that would be fun,

    I enjoyed Bartlett the last time I went,

    Never tried elk mountain, yet. Is that basically pills berry?

    Cow is close by also, all though not as pretty as Bartlett.
     
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