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Varg In Jeep's Clothing

Discussion in 'Builds and Fabricators Forum' started by ITLKSEZ, Aug 20, 2015.

  1. Apr 14, 2019
    tomasinator

    tomasinator Member

    Joined:
    Aug 26, 2015
    Messages:
    212
    I can't wait to see if you cut pieces of metal matching each of the cardboard pieces and weld them into a tank or if you cut larger pieces of metal and bend them. If this was a Discovery Channel show, you'd send the tacked together tank "out for paint" and it'd come back beautifully smooth and spectacularly painted and ready to mount on a chopper. That's the part of the show I'd like to see -- transforming a tacked together tank into a work of art. They never show that. Hopefully, we'll get to see your pictures.
     
    ITLKSEZ likes this.
  2. Apr 14, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Sep 10, 2018
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    314
    Is there a trick to welding cardboard. Lol. JK. You continue to amaze me
     
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  3. Apr 14, 2019
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member Sponsor

    Denver, CO
    Joined:
    Jul 18, 2013
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    2,297
    Are you good with 11.4 gallons - volumetric space is limited under there, but I really appreciate having some extra fuel range. Maybe your planning on some serious fuel mileage from the Varg? I really have no idea what you are expecting...so maybe it isn't an issue.
     
  4. Apr 14, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    I have reason to believe I should get 20-22 mpg with this thing, so 220+ miles per tank should be achievable. That should be fine for my wife's commute to work. ;)

    I was on the fence with the idea of raising the section of floor under the seat (and the top of the tank) by 3" to gain an additional 3.8 gallons, but I can't convince myself the funky floor and the extra work is worth less extra fuel than a jerry can can provide.
     
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  5. Apr 14, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    Maybe I'll set up my helmet cam in time-lapse mode to capture the process.
     
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  6. Apr 15, 2019
    62CheepJeep

    62CheepJeep Member

    Spartanburg SC
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    Sep 10, 2018
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    I found this Pro-Series Cardboard Welder on EBay
     

    Attached Files:

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  7. Apr 15, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
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    I spent some of the morning making this out of scrap.

    [​IMG]

    It's an insert for my press brake.

    [​IMG]

    It brings the mouth of the shoe closer together to make tighter bends, and also allows tighter clearances between two bends.

    The bottom bend was made without this insert (and is what prompted me to finally make it), and the top bend was made with it. I ended up flattening the bottom bend and redoing it to match the top.

    [​IMG]

    This morning's progress:
    I'm making the bottom section (any parts that could contact rocks) out of 1/8" and the rest out of 14g.

    [​IMG]

    The 20" tight bends in the 1/8" stock was the absolute limit of my press. I thought for sure something was going to let loose. I was hiding around the corner operating the control. :worry:
     
    fhoehle, Twin2, Bowbender and 6 others like this.
  8. Apr 15, 2019
    TIm E

    TIm E Member Sponsor 2019 Sponsor

    NW Arkansas
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    Mar 2, 2017
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    630
    Like an x-ray technician! :clap:
     
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  9. Apr 15, 2019
    Cap-n-Cray

    Cap-n-Cray I want to do this again.. Staff Member Sponsor

    Bainbridge...
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    Did you have on your lead shorts... :lol:
     
  10. Apr 15, 2019
    73 cj5

    73 cj5 Not ready for the junkyard yet Sponsor

    MS
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    I try to stand beside the press at work when removing wrist pins. Problem is one hand has to hold the connecting rod... catch-22
     
  11. Apr 15, 2019
    Muzikp

    Muzikp Sponsor Sponsor

    Sacramento Ca.
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    Your wife's commute must be pretty gnarly :p
     
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  12. Apr 15, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    You're back!
     
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  13. Apr 15, 2019
    Buildflycrash

    Buildflycrash Member Sponsor

    Gulf Breeze FL...
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    Seems like someone might bounce this jeep more than a grocery getter!
     
  14. Apr 15, 2019
    tomasinator

    tomasinator Member

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    What kind of fuel level sensor are you going to use? Were you able to scavenge the sensor out of the donor Volvo's gas tank?
     
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  15. Apr 15, 2019
    Roverguy

    Roverguy New Member

    Union, Maine
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    I’m thinking a 5/8”x5/8” x 22” piece of hickory or oak would work to check the fuel level....
     
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  16. Apr 15, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    That's my dump truck's gauge! An old broomstick that fits nicely behind the seat.

    I'll be modifying the sending unit/pump that goes with the engine to fit in this tank. These have a small in-tank feeder pump that feeds the main external high-pressure pump.
    Stay tuned.
     
  17. Apr 16, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    Wasted the morning.

    The original Volvo tank was plastic, and I cut it up for fenders on the hippo. I no longer have it to measure the opening for the drop-in unit to seal against. I took a stab at it and was off by about 1/16" in diameter.

    I started by turning a chunk of hickory on the lathe to match my guesstimate.

    [​IMG]

    I cut a 3/4" x 15" strip of 14g to wrap it.

    [​IMG]

    [​IMG]

    I welded it together, filled the screw holes and hammered it round again, then tacked it to scrap to grind the inside perfectly round. It just happened to be the exact size of this grinding wheel.

    [​IMG]

    All for nothing because it doesn't fit. It passes the first seal, but the second one is bigger.

    [​IMG]

    I think I'll make the next one out of 1/8" instead. It'll be a lot harder to work with, but it will be less sensitive to warpage, and I'll be able to grind a taper into the top to funnel-in the seal.

    I'll be back at it this weekend.
     
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  18. Apr 22, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
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    You'll find inspiration in the strangest places...

    We don't have cable or satellite or anything. So when we go on vacation, all the tv channels are new to us. I got stuck staring at the Discovery Channel logo while escaping the 100 degree temps in Phoenix, and it gave me an idea of how to tackle the mounts for this gas tank. I made a jig for the press out of scrap that mimics the logo to form these little tabs.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
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  19. Apr 22, 2019
    FinoCJ

    FinoCJ 1970 CJ5 Staff Member Sponsor

    Denver, CO
    Joined:
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    how did you make the jig? Maybe my question is more around the two cylindrical pieces where the OD on the press fits the ID of the base piece, and of course allows for the proper thickness of the work piece...Are these common pieces (like dies for a bender) or did you custom make the whole set-up?
     
  20. Apr 22, 2019
    ITLKSEZ

    ITLKSEZ Volvophilic

    Post Falls, ID
    Joined:
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    It's all from the scrap pile. The OD of the die has to be the size of the ID of the shoe minus the thickness of the material you want to form, x2. I'm forming 1/8" plate.

    The form on the bottom is the "axle" from a HF snatch block. It's ID was (nearly) exactly 1/4" (.255") bigger than the OD of a piece of 1" pipe.

    I carved out an opening in a piece of cage tubing to mount it in, and welded another section of tubing to the top of the pipe to space the die away from the press a little, and I welded in some coins to stiffen the pipe to keep it from collapsing.

    1 hour billable. :D
     
    Last edited: Apr 22, 2019
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