E350 pre-build wisdom (and hello)

[SHAFT]

The biggest challenge of this conversion is staying organized, well fueled (eat food), and focused. I found that documenting my build progress each day helped to keep me focused and organized. (and even reminded me of a few things that I missed) You might want to assign someone to force you to eat. I won't stop working to eat unless told to by an adult...

Wise words.... Staying organized isn't my forte, especially after receiving all those beautiful UJOR parts. I've struggled with staying on track and not just buzzing around the garage like a hummingbird. The diet of soda, beer, paint fumes and party pizza doesn't help either and i'm the only "adult" in the house. thanks for the input and for your "Vandiana" build documentation. Reference it prob once a day!

 

[SHAFT]

After work today was spent picking up parts and such. Assembled and painted the UJOR steering knuckle yesterday. Front pads and rotors acquired today which means i've now (finally) got all the parts for front axle reassembly.....
having my kit and (finally) tires really hammered home the scale of the project.

one thing i've also run into is the slight moment of panic when i look into the bucket of front axle hardware: i only remember where about a third of that bucket goes. I'm notorious for killing my memory with brake cleaner fumes so hopefully i've taken enough pics:ugh:

Goal is to have front and rear ends reassembled and ready to go by sat as adulthood will pull me away from the project for a few days.

 

[SHAFT]

Hmmmmm

SITREP: I still haven't met my goal for the axles. Rear is basically ready but the front's been fighting me. Ive run into this:
Driver's side is back together (minus brakes), spins and functions fine. Passenger side however, is bound together so tightly by the crush washer deals and the cir clip (these guys)

that the unit bearing spins the inner axle and pinion yoke without a hub installed in the bearing. Install order: round-hex-round-circlip. (I know i'm missing one of the metal washers in the picture but i couldn't get it out of the unit bearing due to grease stiction)

This does NOT seem right to me and i've pulled the unit bearing off the knuckle TWICE over the last two days trying to figure out what's wrong. Take one of the washers out of the equation and it functions perfectly but that's not how i wanna do it. It's like the axle shaft shrunk 1/16th of an inch........

Anyone have any insight into this? Will it work itself out after a mile or two or is this wishful thinking?

You guys are wise that's why i'm here......

 

[ujoint]

New unit bearings? Did you replace the big vacuum seal that attaches to the stub shaft?

 

[SHAFT]

New unit bearings? Did you replace the big vacuum seal that attaches to the stub shaft?

Yes new unit moog unit bearings and new giant vacuum seal.

 

[SHAFT]

Too long without an update on the van, here's where we're at:
Front axle finally done and functioning normally. Visiting co-worker idiots were heard to remark "that's a nice from end". I don't necessarily need a pat on the @$$ every five minutes, but hearing that made me think about the condition of that thing when i bought it out of a yard, and where it is now= MOTIVATION.....


Worked on front spring hangers when i could over a couple days and, well, i'm glad to be past that.

PICS:


Realize these are a bit before and after. Turns out drilling into my frame removed my enthusiasm for grabbing my phone and increased my desire to sit and shake my head....sorry.
What i will say is that i found it easiest to drill all the outside with the 3/16" and then jump right to 3/8". I had a small level from a TV wall mount that i safety wired to the top of the drill. My frame was pretty close to level with the ground so it REALLY helped to keep me in the ballpark.
From there i went straight through and scored the inside frame with the 3/8". I COULD NOT get the 3/16" bit to cut the inside without doing this first. Jumped up to 1/2" inside and out and then opened up the outside to 5/8 and 3/4 from there (super fun)
i also found it easiest to completely finish one hole and get it bolted up to help hold the hanger in place...
After that, exercise my lackluster rattle-can skills and i'm a little farther along.

 

[SHAFT]

Still waiting on springs but i've got stuff to do before then so planning to drop and cut my fuel tank tomorrow. Question is, what works best for the cutting. Tools on hand: Recip saw, grinder with cutting wheel, Dremel tool. Thinking grinder at the moment. Thoughts?

 

[bknudtsen]

I think most folks use the grinder. I would score the line with a metal scribe, then lightly trace the score with the grinder to get a nice visible groove going, followed up by the final pass.

https://www.youtube.com/watch?feature=player_embedded&v=OiWs7g5i0ZM#t=606

 

[SHAFT]

chop chop. the 1mm cutting wheel on my grinder zipped it right off.

currently at the boat shop being welded

 

[bknudtsen]

Noyce!

 

[SHAFT]

Cap welded and primed to stop the rustin' until after i POR 15 the inside of the tank and then paint the outside...

...progress.... now if i can just get some springs before the rain comes.....

 

[tgreening]

Not sure how long you've been waiting, but it took about 60 days to get mine. Waiting is a bugger, but they will come.

 

[Gravity]

My springs were ordered back in early June along with the kit/axle that I've been staring at out in the garage - hoping to see them soon so i can dig into the De-Quig project the next few weeks

 

[ujoint]

Spring lead times have been ridiculous the last few months. There was a major steel shortage and that backed everything up. He's been cranking them out but its taking some time to catch up. I just sent him an email with all of my open PO's asking for a build schedule so we can get some solid answers.

4 or 5 sets did ship this week so thats good.

 

[SHAFT]

Guess what was waiting for me when i got off the boat today....

waiting for me in the parking lot...thanks Chris. Loaded them up in the Volvo for the trip home, then threw them in the van as the garage is quite full at the moment.
Soooooo happy to see em. ball is truly in my court now. Thinking that i should get into the actual build now since i've already got the fuel tank out.
gotta find a plasma cutter, for real now....