4307's Canadian Taco Build
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4307
Adventurer
I know first it was photo bucket now image shack, I'll take care of it.
Exceeded band width again. sheesh.... the price for epic format. LOL
Can some one fill me in if my own website would be beneficial, in dealing with large amount of pics and text? I upgraded photo bucket but would it be better to invest in my own web site?
you can either respond on the thread or PM.
Exceeded band width again. sheesh.... the price for epic format. LOL
Can some one fill me in if my own website would be beneficial, in dealing with large amount of pics and text? I upgraded photo bucket but would it be better to invest in my own web site?
you can either respond on the thread or PM.
4307
Adventurer
Found this stored in a box, while routing through stuff.... might as well throw it in the kit.
Secondary / Backup / Air Mattress, Air compressor.
I bought this compressor for $25 at Costco a couple years ago, does the job, not the fastest in the world.... but runs like a champ up to 140psi, @35L/min.
Secondary / Backup / Air Mattress, Air compressor.
I bought this compressor for $25 at Costco a couple years ago, does the job, not the fastest in the world.... but runs like a champ up to 140psi, @35L/min.
4307
Adventurer
OK.... I tend to jump around between different project's, multi tasking and waiting for eureka moments... and money.... LOL, no I don't have A.D.D.
Anyway... I've been working on the rear leaf spring and shackle hangers getting them ready for the 63'' Chevy rear leaf spring swap.
I could have bought a kit, but I'm on the cheap and I love to fabricate...
The hangers are made from scrap steel, from my bumper build, and 13'' piece of 3.5'' x 3.5'' box steel.
Here are the main steps of the build.
First.... Front hangers...
Material... 3.5'' x 3.5'' x 13'', 1/4'' wall box tube
The design for the front hangers are designed as a reinforced ramp.
This series of pics shows the diagonal sectioning, cut on the band saw.
I drew a few more cut lines.....
The below pic shows a rough rounded, corner contour. The contour was rounded using a table disk sander. The second pic shows the rounded corner.
The second pic shows a cardboard template, for the re-enforcement plate. The plate will box-in, the ramp part of the hanger. The ramp is to protect the leading eye of the leaf spring, from rocks and obstacles that may get in the way. Its more of a rock crawler feature, but what the heck, can't hurt.
After fitting the template, it was time to put it to 3/16'' plate steel, left over from the bumper build. The plate was cut, corners notched to match the inside width of the hanger.
Anyway... I've been working on the rear leaf spring and shackle hangers getting them ready for the 63'' Chevy rear leaf spring swap.
I could have bought a kit, but I'm on the cheap and I love to fabricate...
The hangers are made from scrap steel, from my bumper build, and 13'' piece of 3.5'' x 3.5'' box steel.
Here are the main steps of the build.
First.... Front hangers...
Material... 3.5'' x 3.5'' x 13'', 1/4'' wall box tube
The design for the front hangers are designed as a reinforced ramp.
This series of pics shows the diagonal sectioning, cut on the band saw.
I drew a few more cut lines.....
The below pic shows a rough rounded, corner contour. The contour was rounded using a table disk sander. The second pic shows the rounded corner.
The second pic shows a cardboard template, for the re-enforcement plate. The plate will box-in, the ramp part of the hanger. The ramp is to protect the leading eye of the leaf spring, from rocks and obstacles that may get in the way. Its more of a rock crawler feature, but what the heck, can't hurt.
After fitting the template, it was time to put it to 3/16'' plate steel, left over from the bumper build. The plate was cut, corners notched to match the inside width of the hanger.
4307
Adventurer
Unfortunately, I don't have the pics of the bolt holes being drilled, so I'll explain what I did.
The hole locations are pre-determined. First I drilled the guide holes using 3/16'' drill bit. After drilling the guide holes I used the 3/16'' bit as a gauge to make sure the holes line up to one another on either side. Next I used a 9/16'' bit to drill out the proper size holes for the mounting bolts.
A dry fit on the leaf spring, was in order to make sure the new hanger rotates, and is free of side to side play. It was a perfect fit, couldn't be happier.
Welding will be the next step to complete the front hangers. I'll hold off until the rear shackle hangers are complete and ready for welding. I'll do all the welding in one shot.
The hole locations are pre-determined. First I drilled the guide holes using 3/16'' drill bit. After drilling the guide holes I used the 3/16'' bit as a gauge to make sure the holes line up to one another on either side. Next I used a 9/16'' bit to drill out the proper size holes for the mounting bolts.
A dry fit on the leaf spring, was in order to make sure the new hanger rotates, and is free of side to side play. It was a perfect fit, couldn't be happier.
Welding will be the next step to complete the front hangers. I'll hold off until the rear shackle hangers are complete and ready for welding. I'll do all the welding in one shot.
4307
Adventurer
Rear shackle hangers.....
Again, the shackles hangers are made from scrap, from the rear bumper build. The only thing I bought, that was extra, is 12'' of 2'' O.D x 1.5'' I.D. (1/4'' wall) DOM steel tube for mounting the Energy brand bushings.
Piece of scrap....
Measuring and drilling, guide holes, for a 2 1/8'' hole saw.
To make sure the hole location line up on either side of the stock, I used the drill bit as a gauge to determine the accuracy of the hole locations.
The 2'' x 12'' DOM tubing, is cut to 2.5'' in length.
The scrap stock with the 2 1/8'' holes, are cut with the band saw to create a tube saddle.
The 2'' O.D. tube sitting in the saddle, has a little play, of 1/8''. The little bit of play allows me to position the tube square in the saddle, to be tack welded, securing it for final welding.
Again, the shackles hangers are made from scrap, from the rear bumper build. The only thing I bought, that was extra, is 12'' of 2'' O.D x 1.5'' I.D. (1/4'' wall) DOM steel tube for mounting the Energy brand bushings.
Piece of scrap....
Measuring and drilling, guide holes, for a 2 1/8'' hole saw.
To make sure the hole location line up on either side of the stock, I used the drill bit as a gauge to determine the accuracy of the hole locations.
The 2'' x 12'' DOM tubing, is cut to 2.5'' in length.
The scrap stock with the 2 1/8'' holes, are cut with the band saw to create a tube saddle.
The 2'' O.D. tube sitting in the saddle, has a little play, of 1/8''. The little bit of play allows me to position the tube square in the saddle, to be tack welded, securing it for final welding.
4307
Adventurer
End caps, to box-in the saddle are cut from 2'' width stock.
The Energy Bushings, didn't quite fit in the DOM tubing. I spent a little time machining the inside of the tube, to get a proper bushing fit.
Before and after pics....
The bushings inside the tube, are spaced apart, leaving a 3/16 '' space between bushing ends. This gap will allow me to incorporate a threaded zerk fitting on the out side of the tube, to inject grease inside the tube, between bushings. The zerk location will be out of harms way by rotating the bushing tube to one side, before welding.
The inner sleeve will have 4 - 1/16'' holes drilled, equally spaced around the center line of the sleeve, to allow the grease, under pressure to lubricate the inner sleeve and mounting bolt. Kind of a experiment of sorts. The zerk location will be out of harms way by rotating the bushing tube to one side.
Drilling the tiny holes in the inner sleeve, will not effect the structural integrity of the sleeve, the sleeve is just a friction barrier between the bushing and bolt.
I thought about buying grease-able bolts. I found standard fine thread bolts for 1/5 of the price locally.
Here is a pick of the leaf hanger and shackle hanger. Not complete, but gives you a idea of what they look like together.
Incorporating a grease zerk.....
I started off by drilling a guide hole with a 1/8'' bit, then re-drilled the same hole with a 7/32'' drill bit.
I used a 1/4'' 28tpi tap. to cut the thread
The Energy Bushings, didn't quite fit in the DOM tubing. I spent a little time machining the inside of the tube, to get a proper bushing fit.
Before and after pics....
The bushings inside the tube, are spaced apart, leaving a 3/16 '' space between bushing ends. This gap will allow me to incorporate a threaded zerk fitting on the out side of the tube, to inject grease inside the tube, between bushings. The zerk location will be out of harms way by rotating the bushing tube to one side, before welding.
The inner sleeve will have 4 - 1/16'' holes drilled, equally spaced around the center line of the sleeve, to allow the grease, under pressure to lubricate the inner sleeve and mounting bolt. Kind of a experiment of sorts. The zerk location will be out of harms way by rotating the bushing tube to one side.
Drilling the tiny holes in the inner sleeve, will not effect the structural integrity of the sleeve, the sleeve is just a friction barrier between the bushing and bolt.
I thought about buying grease-able bolts. I found standard fine thread bolts for 1/5 of the price locally.
Here is a pick of the leaf hanger and shackle hanger. Not complete, but gives you a idea of what they look like together.
Incorporating a grease zerk.....
I started off by drilling a guide hole with a 1/8'' bit, then re-drilled the same hole with a 7/32'' drill bit.
I used a 1/4'' 28tpi tap. to cut the thread
4307
Adventurer
The zerk fits nice and tight.
Here are a few pics of the the outside and inside of the Bushing eye.
If you look inside the inner bushing you will see the gap between bushings. This gap will hold the grease.
The next pic shows the inner bushing sleeve. I drilled 4 - 1/16'' holes around the center of the sleeve to allow grease to lubricate the inner sleeve and bolt.
I think the grease zerk and sleeve holes will do the job. Time will tell.
Here are a few pics of the the outside and inside of the Bushing eye.
If you look inside the inner bushing you will see the gap between bushings. This gap will hold the grease.
The next pic shows the inner bushing sleeve. I drilled 4 - 1/16'' holes around the center of the sleeve to allow grease to lubricate the inner sleeve and bolt.
I think the grease zerk and sleeve holes will do the job. Time will tell.
4307
Adventurer
OK.... Shock Hangers.... to mount my Bilstein 5125's.
I'm going with the stock, shock mounting positions, instead of mounting them / \.
In order to do this, I need mounting hangers welded to the axle tube, so I made my own.
Again I used 3/16'' scrap steel.
The next pic shows the rough cut hanger held together with a 1/2'' bolt (not the bolt I'll be using) The piece of copper tube is used as a jig spacer to give me the proper width when welding, another piece of 1''x1'' square tube will be cut to the same length as the copper tube. The square tube will be used as another spacer, to keep the brackets square, when clamped, for welding, to avoid distortion or shifting.
The rough cut pieces were rounded using a bench disk / belt sander.
A couple more pics of the hanger bolted together, to show a more refined product....
The unfinished hanger bolted to the shock....
More to come......:coffeedrink:
I'm going with the stock, shock mounting positions, instead of mounting them / \.
In order to do this, I need mounting hangers welded to the axle tube, so I made my own.
Again I used 3/16'' scrap steel.
The next pic shows the rough cut hanger held together with a 1/2'' bolt (not the bolt I'll be using) The piece of copper tube is used as a jig spacer to give me the proper width when welding, another piece of 1''x1'' square tube will be cut to the same length as the copper tube. The square tube will be used as another spacer, to keep the brackets square, when clamped, for welding, to avoid distortion or shifting.
The rough cut pieces were rounded using a bench disk / belt sander.
A couple more pics of the hanger bolted together, to show a more refined product....
The unfinished hanger bolted to the shock....
More to come......:coffeedrink:
