My first project vehicle

[That One Guy]

Started on my roof rack today. I used a sleeving method to connect the four corners. The second picture shows the farthest the last piece was from it's connection. Our bender's degree stop dial doesn't work for crap, so it took a LOT of fine tuning to get them all just right. Sadly, that's 72 dollars laying on the floor right there, and that's only 40% of my tubing. It's gonna be spendy. And HEAVY.

 

[That One Guy]

Got almost all of the support pieces inbetween the deck and upper rail welded on. Just need to cut one or two more. The last three tubes are gonna be waiting for me tomorrow, so I should have the majority of this done by Friday. Looking at alternatives to expanded steel. Any ideas? Oh and almost got in a fight with some naerdowell too. Wasting my shop time....:violent-smiley-031:

 

[trailrunner]

Well, it depends what you are looking for? Do you want the same kind of drainage and openess? If so, you have a tough time beating expanded steel. You could do sheet metal, drill holes, and use dimple dies. Another option could be High density Poly-ethylene (I think thats what its called) which is basically like the material used in cutting boards. You could drill holes in that to make it lighter. Though, I'm not sure that either of those options would be significantly lighter or cheaper.

 

[That One Guy]

Not to mention the extra few days it would take to drill all those holes. Well, I guess that's what I'm stayin with. I got most of it done today. Pics tomorrow.

 

[MrBeast]

Dude, cool project, I like it when people do something retro.

 

[That One Guy]

Thanks! I do too, easier to work on and look really cool. Kinda rare to see em too.

 

[That One Guy]

Alright, need to go to Ranch & Home and get a couple more of those giant steel hinges, cut out some 1/8th inch steel for the sunroof door, get some expanded steel and mount it to my van. Oh yeah, and paint it. And add my spare tire carrier. Lots of ands.

 

[That One Guy]

Pics. Still not done. The rear is about 1" taller than I would have liked.

 

[That One Guy]

Soooo now I need to buy a starter. Bummer. Does anyone know of any places with good prices on heavy duty starters?

 

[Keyblazer]

Rockauto, or AutohausAZ are my faves.

 

[That One Guy]

Thanks! I like Rockauto's prices.

 

[1sweetvan]

That is a serious looking roof rack, I like it. What material (size &kind) are you using?

 

[That One Guy]

Thanks, 1.5 inch OD pipe (not tubing, because it's about half the price) so in the catalog I think it's 1.25 1/8" wall cold rolled steel pipe. And for the 5 light enclosure tubes, it's just some 1" scrap steel.

 

[That One Guy]

Okay, so more to think about... My van is a 5 lug, and I was going to get F-250 axles so I could switch to stronger 3/4 ton axles with 8 lugs because I want H1 wheels and I want the extra strength of 44's. But I was talking to my Dad and I brought up possibly buying just the front axle, and (this was the question part) possibly getting new axle shafts with the Ford 8 lug pattern for my Chrysler rear to match.

Question 1: Is it possible to buy axle shafts for my Chrysler 8.75 with a different lug pattern?

Question 2: Should I just buy an F-150 front axle so they'll both be 5 lugs?

I can't stop thinking...


Edit: I think it's the 8.25... If so, is the 8.25 comparable in strength to a D44?

 

[dsw4x4]

That one guy,
Here your answers
Question 1: Is it possible to buy axle shafts for my Chrysler 8.75 with a different lug pattern?

Yes Moser will build whatever axle you want for any application.
However you can usually find a dana 60 rear axle for a lot less money and the strength will be 5 times what that 8.75 axle will be. You will spend 3 or 4 hundred dollars buying axle shafts to beef up a weak axle.

Question 2: Should I just buy an F-150 front axle so they'll both be 5 lugs?
Options for the front axle are endless.

You can buy a f150 axle or a dodge 1/2 ton axle to swap in the front axle.
First thing you need to figure out is how are you going to use/build your van. If you are going to load it down with a full rv build and then use it to take you to far off destinations in remote areas then I would ditch all of the half ton gear and go one ton dana 60s front and rear. Or if your going to run big tires and wheel it hard, regardless of the weight of the van I would still ditch the half ton gear. If you want a 4wd van to tow a boat or toy and get to an occasional camp spot in the woods I would say half ton would be fine. It seems around here 8 lug dana 44 front axles go for about the same as a good deal on a dana 60 front axle. If that is the case in your area I would hold out for a dana 60 again the strength will be a huge difference. I am doing a swap on my work van and I really need the 4wd to get to my house in the winter and that is about it so i am going to go with a 44 if I can find one cheap enough if not, I am going to put a 60 in the front. But either way i am ditching the 9inch for a 60 in the rear.
Derek