Junkyard Jimmy Super Low Buck Build Thread

[Angelse68cal]

Awesome build

[hgs_notes]

Originally Posted by Angelse68cal

Awesome build

Thanks. I like it.

Not much to update here but I did buy a couple books (kindle editions) off amazon that I think are a huge help. I've learned more in the hour or so last night reading the trophy truck rebuild book than just about all my accumulated knowledge of these trucks before that. Tons of good info on how they are built and why they are done a certain way. I'm not building a trophy truck obviously but the design principles and much of the execution are similar on a lot of my build.

Monster Garage Trophy Truck Chassis Rebuild -... Welding for Off-Road Fabrication - Kindle edition...

[hgs_notes]

I bought a crossover steering set up today. Its something I know I'll need and I think I found a good deal here...

http://www.ebay.com/itm/251637875298...%3AMEBIDX%3AIT

Just need the DOM tube, which I can get much cheaper locally, and then decide what to do for a pitman arm. Should use a dropped one for better geometry but I want to wait and see where things actually line up. And also if I use my current 4wd steering box or swap to the 2wd box. Maybe I don't have an option for that, but they are easy enough to find.

I have an idea I'm working on for all of the frame brackets for the links. I spent a lot of time measuring and laying under it looking and thinking. I've got a drawing of the frame frome my chassis manual and have marked off the important dimensions. Next I'll draw up my idea and try to mock it up. If it works I'll start gathering materials.

A couple things I've figured out so far is that I will probably need to change to a cable type shifter or a direct linkage like Lokar sells. I used it on my C-10 and it works good. And shorty headers. The passenger side header is directly in line with the front driveshaft and yoke of the D60 differential. Its about 2" further back and 1.5" outboard of the D44 yoke. So the cost of this transformation will be higher just for those 2 items.

Just an idea of whats on my shopping list:
Tubing (for steering arm, track bar, links, bumpers and cage)
Rod ends/bushings
Plate steel (for brackets, gussets, etc.)
1 matching tire (Dick Cepek FC-II 35x12.5x17)
4 - 17" 8 lug wheels
Coilover shocks with springs
Bump stops
Drive shafts (length to be determined)
Brake lines
Limit straps
Headers
Shifter
Fuel cell
I'm sure there's more, theres always more.

Total spent so far $5060 with the steering kit.

[hgs_notes]

Here's the basic idea of where I'm going with this. The idea anyway, pending actual test fitting, etc.



The middle section in tan would be a fabricated piece wrapping the frame with the body mount and link mounts built onto it. The inside of the frame rail will be reinforced. The rear upper links would be incorporated into a new cross member with a driveshaft hoop and tie into the fabbed frame section that I'm calling a cradle for now.

Triangulated rear 4 link. Parallel front 4 link with a track bar.

Lots to still figure out.

[Dieselwrencher]

The design and drawing look great.

[Ol Blue K20]

Nice drawing, I hope it goes smoothly.

[hgs_notes]

Originally Posted by Dieselwrencher

The design and drawing look great.

Originally Posted by Ol Blue K20

Nice drawing, I hope it goes smoothly.

Thanks guys.

Parts showed up. The main piece here looks even better than I expected.


Comes with everything I need for the crossover steering except the tube for the drag link.

And the last piece I needed to get my TIG welder up and running got delivered last week. The foot pedal amptrol...


I finally had time yesterday to try it out. I did some checking and its been 16 years since my last TIG weld, and it shows. Looks like I have to relearn just about everything all over.

Its not really a big deal as far as this project is concerned. Most of the welding can be done with my MIG welder. Pretty much all of the cage anyway. On the thicker plate work I can get everything tacked up and hopefully my skills make a comeback by then. Worst case is taking the parts to a friend of mine that gets paid to be a damn good welder. Was kinda planning on him doing the welding on the axles in any case.

Still waiting on dies for the bender, and money. Once my tax return hits the bank I'm gonna order some tubing, and other steel to get started. It's March, the weather forecast is finally starting to show a warming trend and I'm past the worst of my workload crunch I've been stuck in since the beginning of the year.

S&%$@ getting real.

[hgs_notes]

Still working on the design stuff, drawing it out, etc. But some things are pretty well set on how it will be done. So I started ordering some steel. On the bottom left of this drawing you can see how I'm going to build the frame sections. Basically I'm sandwiching the stock frame between 2 pieces. The frame is about 1/8" thick. I'm having a C channel made that is 2-3/8" x 5". Then I'm getting 3" x 6" x .25" wall tube. I will cut off one of the short sides and it will push up and wrap the frame and C channel. I can through bolt it all in place. A new body mount will go on the tube, and the frame ends of the links will get mounted to it also. Then I can tie the roll cage into it and it should be rock solid.


Today I got the driver side body mount off, removed the shifter linkage and the driver side header.






Nice open stretch of frame to work with. Plenty of room for the exhaust to route between the transfer case and frame. That rear body mount will probably be removed also.

I'm thinking I should replace the tranny crossmember also. Have it tie into the new frame rail pieces, like the new rear crossmember will. That rear one will incorporate the upper rear link mounts and a driveshaft hoop and stabilize the frame more.

I put on the shortened top I had so I work around it for roll cage fitting.

[Vintage Windmills]

Good progress Mike, I like those proportions. Its always a little tough to sit down and do a drawing since it doesn't feel as productive at first, but it always pays off in spades! What program are you using to draw and get the dimensions with?

[hgs_notes]

Originally Posted by Vintage Windmills

What program are you using to draw and get the dimensions with?

mspaint

Dimensions by tape measure.

Using autocad would be nice but its been 20 years and now I can't even draw a line without relearning a new program. Had to go with the hi-tech old school.

Tore the front axle apart yesterday. One hub is shot. Bad threads on one spindle. Needs new seals all around. Otherwise it looks good. I will replace the u-joints since its apart. A big win for me though. The $200 axles remain the biggest bargain on this project so far.

[hgs_notes]

I've been chipping away at it slowly but somewhat steadily. Heres a cpl pics of axle parts laying all over...




I started cutting brackets off the axle that are in the way or no longer needed.


I ordered some bits and pieces that will help me out with the cage and transfer case mounting in the near future from DIY4X. I'm hoping its $118 well spent. Total spent up to $5178 now.


Those are cage mounts with anti sheer pins and yes I could have made them myself but the cost isn't bad and saves me time and drill bits and cutting wheels/blades. The items on top right are for the transfer case mount. Since I'm changing that crossmember for the tranny and the OEM transfer case mount is in the frame rail I think this will make a great substitute and strengthen it up.
http://diy4x.com/cart/index.php?rout...product_id=202

The first order of steel tubing and the channels I need for my frame sandwich should be ready today to pick up. It won't be all I need but a big start. I don't have a cost for that yet but will update later.

I ordered it thru a guy I know here in town that has a welding business. Free delivery and he has the nice big hydraulic brake for custom bending the C channels I need to fit in the frame rails. He goes thru a lot of DOM tubing himself but not for building on trucks/cars. He's also my go to guy for any major welding I'm not equipped or skilled enuf for myself.

https://www.youtube.com/watch?v=_VrFV5r8cs0

[hgs_notes]

I still plan on getting this frame reinforcement for the steering box...


And my rear cross member for the upper link mounts and driveshaft hoop will be similar in design to this set up from Heidts...

[hgs_notes]

I got a bunch of steel to start cutting and burning. I got some bender dies. I got very little time.

Spent $400 on the steel channels, rectangular tubing, 2" DOM tubing, and heavy wall tubing for the front track bar and drag link. He really gave me a great deal. About a 25% discount on the DOM tubing from what I was quoted at the steel supply places. Only charged me about $50 to custom bend C channels and cut my stuff to length etc.

So total spent is now $5578 and I need to get busy in the garage.

[Ol Blue K20]

Discounts are always a good thing. Watching your progress, better get at it....

[hgs_notes]

Just so people know, the project is not dead. Just stagnant. Been overloaded with work, had to do some work to my C-10 to get it ready for power tour, bought a couple other trucks, and now I'm deep into trying to buy a farm place. This is turning into a next winter project with everything thats going on.

New place, assuming I get it, is 7 acres, has a nice big house, 3 garages, 2 machine sheds, plus a couple other storage buildings. I hope to build my dream shop in one of the machine sheds. The 3 car garage will be my shop until that becomes reality.

Wish me luck. I'm gonna need it. Lots of work to do at the new place, getting my current one ready to sell, and that damn job thingy takes up a lot of time too, but it's paying for all of this so I won't complain.

Later

[Low Elco]

Hell, I forgot about this thread! Gonna be neat!

[Ol Blue K20]

Keeping my fingers crossed and hoping you get the new place

[rustyrides]

I have that same gas tank as you

[Tynee]

Almost 2 months later, have you closed yet? When's the big move?

[hgs_notes]

Originally Posted by rustyrides

I have that same gas tank as you

Mine was completely rusted out.

Originally Posted by Tynee

Almost 2 months later, have you closed yet? When's the big move?

I closed on 8/21. Been moving and fixing ever since. I did post it on my C-10 thread. I haven't begun to move the garage stuff yet. The 3 car garage I will be using needs some roof repairs and electrical work done. The steel roof panels came on wednesday. The weather will cool off next week and hopefully I can get that done.

We are combining 2 full houses of stuff. It's been a challenge to say the least. I think if we get done by the end of the month we'll be doing good.




The new shop.


The future shop...


Another big machine shed I don't even have any ideas for yet.


These are pics taken earlier this summer. We had to remove a lot of stuff. Clean up truck loads of trash. Piles of appliances and rotten furniture. The house needs work (windows, doors, roof, siding) but is decent inside. The driveway is about 1/4 mile long and I can get to freeway speeds on it and drift around the 1 car garage. I have a separate building that I'm calling the small engine shop just for all the stuff like lawn mowers, motorcycles, ATV's, go cart, etc.

[rustyrides]

From what a few people told me is that it was made by hickey but not sure about that

[Bomp]

A big Congrats.
One of them shops has gotta be a paint booth.

[Tynee]

Congrats, that place has a ton of potential.
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[TennesseeZ]

That looks like the perfect place for you Mike, can't wait to see what you do with it!

[Ol Blue K20]

Lots of room for hiding toys Mike...awesome