2007 Silverado - Buy Once, Cry Once: 1-tons, 40's & a Custom Camper

[givemethewillys]

^ Thanks, sometimes an idea just works out. Pretty happy with how it turned out, especially considering it only cost $50!

This weekend I decided to tackle a few small fab projects.
First up was the rear winch mount.

Opted for this orientation. It positioned the release in an ideal position, and packaging was a bit easier.

Picked up some 1/4" & 3/16" plate and found some leftover 1/4" wall square tubing.

Frame mounts

I would love some better fab tools, but work with what you've got.

Final product

It's secured by 12 - 1/2" bolts to the frame and tied into the hitch with a couple of 9/16" bolts as well.

Next up was the rear sway bar mounts,

These worked out great, perfect 90* angle on the links and tons of room for flex

Rear brake flex line tabs

Finished up by prepping these cab mounts and welding them onto the frame. They are about 3" more forward than the factory location.

Great work! I'm by no means a fabricator, but have you considered adding some triangulation to your rear winch mount? It seems to me like it will want to bow and pull in your frame rails.

 

[Andrew_S]

^ That's a great question. The tubing is 3"x3" 3/8" wall and the box is made out of .250" plate, fully boxed. What I've done is really overkill for a 12k lb winch. It's also tied directly into the trailer hitch, which acts as another perpendicular cross member. I guess all that to say, if this thing were to budge, I've got some serious issues.

I've been trying to tackle one job a day, just to keep progress happening. Yesterday I repaired the drivers tilt head rest, the plastic detent had worn out completely.

Today was new fog lights for the front bumper.

This warn winch bumper came with these 4" ish cut outs for I'm guessing flush mount lights?

I really like the baja designs squadron lights but can't find anything comparable that fits this dimension. These are too small, only 3"

Hoping to find something like these, combo but in a 5" flush mount - anyone know of a good product out there?

 

[Andrew_S]

Yesterday,
Measuring for flat deck fender dimensions:

Todays mini project,

New to me heater controls,

Somebody tried to repair the LED's on my current one and completely botched it. I attempted to repair with 2 after market units and both failed out of the box...

Also swapped the cluster for some Denali trim options

Before

After

 

[Trektor73]

Maybe its the lighting, but that Denali cluster trim almost looks like Graystone Metallic.

 

[Andrew_S]

^ That's correct, it's a different colour surround and white needles.

Today's project was rear shock and bump mounts

These worked out perfect,

Checking for conflicts at full droop

6" droop and 8" of compression, by design. Lots of slack in the lines,

Knocked out the bump mounts next,

These turned out great

 

[YetiX]

Also swapped the cluster for some Denali trim options

Yesterday,
Measuring for flat deck fender dimensions:

Todays mini project,

New to me heater controls,

Somebody tried to repair the LED's on my current one and completely botched it. I attempted to repair with 2 after market units and both failed out of the box...

Also swapped the cluster for some Denali trim options

Before

After

I like the note from your kiddo.

 

[Andrew_S]

^That's going back about 6 months when he was not sleeping well and I was better off doing nothing than trying to work quietly* in the garage lol.
Got back on the front bumper and finishing it up, this took a lot of work. Made some frame mounts so the winch chassis is bolted in with 10 - 1/2" bolts directly to the frame. A lot of messing around but it's serviceable and turned out great. Also made up some lower tabs to retain the plastic lower cowl. Also fabbed up some upper mounts that tie into the stock location for the 1/2 ton truck bumper.

Happy to button this one up and call it good.

Next up, revisiting this t-case and clocking ring leak...

some evidence on the gasket

and that's a smoking gun, a few of the studs were proud of the mating surface for the gasket... Spun them all out and took an 1/16" off them

Cross member and trans mount prepped and ready to go up. This little motorcycle lift is the best tool ever.

Everything all back together

Fluids going back in, picked up a brand new pail to save over $300 in transynd that I just put in it a few weeks ago.

Pit stop to get some more pieces sandblasted

Finished up with some painting but I ran out.

Today's effort was righting this wrong. When I put this together with my setup bearings, it was spot on. As soon as I dropped in the new bearings, the pinion preload went from 30 in-lbs to 75 in-lbs. I was over it at the time and opted to revisit when I felt more energized.

I added .002" of shim to the pinion, and it was still super tight. I tried again, bumping it up to .005" total, and this time it was spot on, 35 in-lbs, the spec is 25-40in-lbs. I didn't take many photos as I was keenly focused on not messing up. This was just just before the cover was going back on.

Bench testing the locker, all good, no leaks. Went through and torqued everything and set the hub pre-load as well.

I stopped by the local driveshaft shop yesterday and ordered the front and rear shafts. I've got a plan for my rear driveshaft, and it involves modifying this cross member.

I swear this truck was in the sand dunes at some point in time.

Running around in the am to collect some supplies and then hopefully getting a couple of hours in the afternoon in. It's so stinking hot out here now I'm cooking in the garage.

 

[Andrew_S]

I really treated myself yesterday, picked up some new screens for my welding helmets.

It's the little things in life.

Spent a couple of hours at picknpull, this cherry little delica was on the scene.

Little side trip to the gravel pit,

Had to run over the truck scales to get my weights for ordering rear shocks.
3300kg - 7275lbs total
2290kg - 5049lbs front
1010kg - 2226lbs rear
This is currently missing a ton of parts, roughly 300lbs, and 350lbs in fuel.

Finished the day by wrapping up painting

 

[Andrew_S]

Today was a fun day, got started on the deck.
Picked up some 25' 2x3" .250" wall aluminum tubing this am.

I had given this a fair bit of thought previously, but now every cut counted @ $14/ft...

I need 6" of clear space below the deck to the frame to accommodate tire travel. Started by cutting up some risers for the mounts.

Next up was my primary frame, the deck would rest on, a little cart saves the day again.

One side fitted up,

Both sides fitted

A couple of dollars in aluminum shavings on the ground at this point

Cut up my front and rear deck rails. I had a pretty good idea of what this was going to look like, but I was relieved to see it in person and it be a fairly minor poke from the cab.

Ended with this, the mounts are all bolted down. Just need to start tacking everything together and cut up a few more cross members for the deck.

 

[xleratin]

Ive recently realized the game changer that using a metal blade on either a circular or mitre saw is....up until then...I always used a sawmill....but im an electrician...not a fabricator.

 

[Kingsize24]

Ive recently realized the game changer that using a metal blade on either a circular or mitre saw is....up until then...I always used a sawmill....but im an electrician...not a fabricator.

A wood blade works great on aluminum as well. 😉

 

[Andrew_S]

^Bingo, you can buy special blades, but in my experience, a fine-tooth wood blade does a great job.

Put in a few more hours over the last 2 days. Bevelled all of my joints to make sure I get good penetration with this thick-wall tubing.

Got everything mocked up and tacked.


Flipped this thing about ten times until I found all of the spots I missed.

Starting on the deck, to my surprise, the front to rear was only out by .05*. I'll take that win any day of the week.

After a bit more cutting and grinding, this thing is ready to be welded fully. The deck surface measures 92" wide by 102" long.

 

[YetiX]

Man, it's really starting to take shape now isn't it? Looking great!

 

[Andrew_S]

^ thanks, it definitely feels like a milestone

Spent 5 hours flipping this thing over a bunch and fully welding it out

Next up, we need to decide on some tail lights...

 

[Trektor73]

Progress is looking awesome. In the photos where you were finishing up some painting after the sandblasting, what does the rolling chassis with the nice meaty tires belong to?