crossmember replacement before and after

So in the past, Ive discussed the replacement of the front crossmember thats below the radiator and front bumper, and how we fabricated its replacement. While i was up working on the truck i got some pics of the original crossmember and will show the before/after effects.

73 grill bumper Kevin's truck project 016

Originally this should have been an L shaped crossmember. Below is what it looked like once we got it off the truck.

img_20160822_114525 img_20160822_114516 img_20160822_114537

Anything but straight. So we replaced it with something much stronger.

new front crossmember 001 front axle and crossmember pics 007 IMG_20160827_183306Its 2×4 rectangular tubing that has notches for the spring bolts that are reinforced with round pipe cut in half horizontally the crossmember is fully enclosed and will not let in water, rust, or derbies. bolts in with 24 grade 8 bolts to the frame, and has a class III hitch that is welded directly into it.

August Update

IMG_20160821_190821This August I was able to finally go up and visit my folks and spend some time working on the truck project again. The first order of business was removing the bed from the green truck to allow us to better see how fuel and brake lines were being routed, and setup for dual tanks.

 

 

 

 

 

IMG_20160827_183431We recently purchased the tail housing and output shaft for a C6 transmission that allows bolting the married transfer case directly to the transmission. It was bought sight unseen, and we were glad that the shaft is correct, and splines into the input of the transfer case.

We were able to pull out the transfer case from the orange truck as well as remove two of the cross members from it to mount things correctly in the new build. pulling out the cross members was much more time consuming than expected. Drilling out rivets is not as simple as you may imagine. They will need to be cleaned, and painted and re mounted, but for now we are going for test fittings. making sure everything lines up correctly, and mounts in the new frame right. As the truck originally had a smaller engine, a manual transmission and divorced transfer case, some drilling was required.

 

 

 

 

IMG_20160826_190414With the engine, transmission, adapter and transfer case in, you can see it goes from just behind the radiator, to back just short of the rear cab mounts, and is all connected as one piece. eventually things will need to come back out to be rebuilt but this allows us to measure for fuel tanks, run brake lines, setup steering and a ton of other things.

 

 

 

 

 

IMG_20160826_190449We had a custom built gas tank created, that will fit between the frame rails at the end of the bed. It will hold 20 gallons once done. We still need to add in the fill neck, and fuel line outputs and float. We will also be building a side tank that will hold between 20 – 22 gallons once done, and upgrading from the manual fuel tank switch to an electric solenoid switch.

 

 

 

 

 

IMG_20160827_183223While hard to see in this picture (try clicking it so its bigger) you can see the beginnings of new brake lines on the axle, and new brake and fuel lines in the left side frame rail. Its getting all new brake and fuel lines (as well as new or rebuilt more or less everything)

 

 

 

 

 

 

 

 

 

 

The newest addition to the fleet.

Because what this project needs? Is another truck! A 73 Camper Special with deluxe trim, A/C, dual tanks etc. The body panels on this truck are far straighter than on any of the others. This will be the starting point for the body of the new truck. Hmmmmn. Now how to get it back to blue?

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Decisions decisions.

So over Christmas break, we pulled the springs off the front axle from the 73 truck to clean up and put the new bushings into, so we could mount the front axle from the 78 truck. That was the plan anyway.

After blowing apart the first spring, and pressing out the bearings, we found out that 1. the springs had been binding, and as such they wore groves into the leaves above them. These range from a light wear, to ones that are almost a quarter inch deep. On springs that are only about a half inch thick each leaf that makes them dangerously thin.

I called a few spring shops, and the options to repair are simply adding a new leaf and re setting the correct spring arch. Nothing would be done to fix the existing wear. Obviously that will not fix the problem nor meet with my goal of functioning like new once completed. Therefore new springs will need to be purchased. For the meantime, we will simply re use the old springs until we are ready to rebuild the axles. At least that way we can get the frame into a rolling state, and start mounting the power steering pump and steering linkage etc.

The original front cross member that goes between the front springs was so bent out of shape, that it litterally bent and cracked the frame, in multiple places. We decided it was not worth re using.

My trucks theme song.

While working on the springs, and having a haze of rust dust swirling in the shop, I couldnt not think of this song. I think it so apropriate for this project. Its all about sheding the rust, waking up, being better and stronger than before. I think this is gonna be the official song for this truck.

The video is a bit… weird. but listen to the lyrics.

Lyrics

Whoa, oh, oh
Whoa, oh, oh
Whoa, oh, oh
Whoa

I’m waking up to ash and dust
I wipe my brow and I sweat my rust
I’m breathing in the chemicals

I’m breaking in, shaping up, then checking out on the prison bus
This is it, the apocalypse
Whoa

I’m waking up, I feel it in my bones
Enough to make my systems blow
Welcome to the new age, to the new age
Welcome to the new age, to the new age
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive

I raise my flags, don my clothes
It’s a revolution, I suppose
We’ll paint it red to fit right in
Whoa

I’m breaking in, shaping up, then checking out on the prison bus
This is it, the apocalypse
Whoa

I’m waking up, I feel it in my bones
Enough to make my systems blow
Welcome to the new age, to the new age
Welcome to the new age, to the new age
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive

All systems go, the sun hasn’t died
Deep in my bones, straight from inside

I’m waking up, I feel it in my bones
Enough to make my systems blow
Welcome to the new age, to the new age
Welcome to the new age, to the new age
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive
Whoa, oh, oh, oh, oh, whoa, oh, oh, oh, I’m radioactive, radioactive