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Old January 21st, 2009, 08:55 AM   #181
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if I remember right I think you did something different with it??
No, I haven't finished that "flap" yet- probably will do a gusset that bolts to the inside of the frame like this-



The "flap" seems pretty solid as-is, but sometimes I get a little crazy on the dunes, so some extra insurance wouldn't hurt.
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Old January 21st, 2009, 09:01 AM   #182
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Did you ever finish up the front suspension? I looked back at the pictures and I dont see the final setup. Did I miss it?
Yeah, the front is all done-- apparantly I took pics of it on the ground before I did the steering, so no pics of everything together. Now I have the arms taken off to finish welding and paint. It does have 1 of 2 fenders on in my defense.

edit: found one pic of the front done, still off the ground, no tires on, suspension at full jounce.

Last edited by DUNE JUMP; January 21st, 2009 at 11:25 AM.
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Old January 23rd, 2009, 07:57 AM   #183
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Default Update 1/23/09

Some updated pics from last night. Sorry about the welding haze...




WOW, what a mess!!

The RH fender needs to be trimmed at the turn signal lens still.

The rear of the fenders will get trimmed to fit the door opening eventually so I can run my door skins. I pulled the hood/fenders back into the cowl about 6" and got rid of the cowl top closeout panel.


Next up I'm going to fab up a front bumper so I can mount my lights and grille.

Thanks to my father in law, I now have a sweet aluminum radiator to put in as well.
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Old January 23rd, 2009, 08:10 AM   #184
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I wanna know more about the front suspension.
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Old January 23rd, 2009, 10:30 AM   #185
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I wanna know more about the front suspension.
Ok, here's what I've got up front:

Lower arms are 2.5" .25 wall box with 2" sleeved into it. 1 1/4 heims at the frame end, poly bushings at the lower axle end.

Upper arms are 1 3/4 DOM. 1 1/4 heims at link end, poly bushings at the axle end.

Axle brackets are Ballistic Fab ones designed for coil springs, bought them before I got coilovers. Now they make all their brackets water-jetted :)

I ran a track bar to control lateral movement and planned it carefully to minimize bump steer. The upper mount is in line with the pitman arm and the axle mount is as close as I could make it to the drag link pivot on the tie rod. Track bar is 1 3/4 DOM with 1 1/4 heim at the axle and a poly bushing at the top. I had to put a little bend in it to get it to clear the pumpkin at full bump. The whole thought process for the front suspension is low and stable with maximum travel.

Steering is 1 1/2 .25 wall DOM with 3/4 heims and hi misalignment spacers setup to be almost maxed at full droop.

I'm running 14" 2.5 King Coilovers with 350/500 springs. This should put the effective spring rate at ~200 lb/in until the suspension compresses ~ 4" from ride height, then it bumps to the heavy spring (500 lb) to absorb the heavy hits (DUNE JUMPS) .

Im running poly bump stops and limit straps to catch the suspension during the last 2" of droop. Straps stetch, so this is accounted for with the mounting positions.

This will cycle 14" of vertical wheel travel, and the design allows for me to pull the drivers side upper link if I want for crawling to avoid all the binding inherant to a radius arm design when crossed-up.

I'm going to run this for a while and see how it handles, I may end up changing it to a 3-link if it doesn't work the way I planned.

All of the front suspension pics are on page 1 of this thread.
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Old January 24th, 2009, 11:26 AM   #186
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looking good
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Old January 27th, 2009, 08:06 AM   #187
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thanks bud-

I got out there for an hour last night and actually got my heater to work

I've been working on bumper idears, and realized I need a method of bending sheet metal that doesn't involve a hammer and a vise. I know harbor freight has a 30 dollar brake, but it uses c-clamps and looks pretty weak. Plus, I have a lot of odds and ends of steel scrap just waiting to be put to use, so I fabbed this up. It's pretty booty-fabulous, but gets the job done. I would score it a BF-2

It's not done, but it is functional and serves it's purpose.
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Old January 27th, 2009, 10:36 AM   #188
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What guage sheet metal are you looking to bend i have acess to two breaks thats how i am bend my sheet metal. let me know and i could prob bend it up for you.
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Old January 27th, 2009, 10:51 AM   #189
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What guage sheet metal are you looking to bend i have acess to two breaks thats how i am bend my sheet metal. let me know and i could prob bend it up for you.
cool man, I may hit you up for that-- It's like 3/16 mild, so nothing too crazy. I may even make up a couple bending dies to use in my all-pupose bottle jack press
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Old January 27th, 2009, 11:11 AM   #190
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thats cool i have a 40 inch break here but the most i couls bend on it is like 18 i think
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Old January 27th, 2009, 12:55 PM   #191
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Originally Posted by DUNE JUMP View Post
thanks bud-

I got out there for an hour last night and actually got my heater to work

I've been working on bumper idears, and realized I need a method of bending sheet metal that doesn't involve a hammer and a vise. I know harbor freight has a 30 dollar brake, but it uses c-clamps and looks pretty weak. Plus, I have a lot of odds and ends of steel scrap just waiting to be put to use, so I fabbed this up. It's pretty booty-fabulous, but gets the job done. I would score it a BF-2

It's not done, but it is functional and serves it's purpose.
nawh - thats a "one" - if that

nice work, its looking good
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Old January 27th, 2009, 01:37 PM   #192
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sweet k5 i had 3 k5s but none as nice as urs
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Old February 2nd, 2009, 10:45 PM   #193
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thanks guys

side note- since it was warm Sunday we took the kids out, and the girls got to go offroading in their stroller. Daddy couldn't help it. It did well since it's a dually :)
Gotta start them out early!

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Old February 6th, 2009, 07:44 AM   #194
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Default Update 2/6/09

Ok, back to work on this beast. I have a new source of steel plate the side steps off the military tug truck are 3/16, and cut like butter with the plasma. I love the OD green





The box tube is 2.5" .25 wall, so it will make a good base for recovery points and someday... a winch

The plan is to trim up the fenders, then do some recycling with the old front bumper (cut off all old tubes and clean up) and use the main tube as the base of the new bumper and span the distance between the fenders. This will give me somewhere to mount lights and the grille.

I also need to build a new radiator mounting system for my new radiator, and new fan mounts to go with it.

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Old February 16th, 2009, 07:42 AM   #195
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Default Update 2/16/09

I spent an hour fabbing up what I thought would be a cool one-piece grille suround, headlight bezel piece, then I set it up front and hated it. Went up in the attic and got my grille and trim piece down, set it up there and thought it looked pretty decent. I tabbed the front to the fender/hood supports, and drilled the fenders for the lower attach points. Still have room for the Hella 4000's in the headlight openings, and still will probably make some trim pieces to fill in around the lamps.
I realize now that I need to get some more tubing and get that bumper fabbed up. I like how it's coming along though.







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Old February 16th, 2009, 09:27 AM   #196
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[QUOTE=DUNE JUMP;1533647]I spent an hour fabbing up what I thought would be a cool one-piece grille suround, headlight bezel piece, then I set it up front and hated it. QUOTE]


i think the culprits are still sitting on the hood


seriously though, its looking good - are the 4k hella's those big ass ones, not deep but large dia ?
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Old February 16th, 2009, 09:38 AM   #197
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[QUOTE=VonDirt;1533803]
Quote:
Originally Posted by DUNE JUMP View Post
I spent an hour fabbing up what I thought would be a cool one-piece grille suround, headlight bezel piece, then I set it up front and hated it. QUOTE]


i think the culprits are still sitting on the hood ?
---You mean these ---


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seriously though, its looking good - are the 4k hella's those big ass ones, not deep but large dia ?
Thanks
Yeah the 4000's are 9" diameter, not too deep, except in the middle they're probably 6-8" deep. I have the euro beam ones, so they have a nice flat output, no pencil beams for me.

I'm going to use some of my failed grille surround to make the headlamp bezels, should work out well. I'm just trying to keep the front [light] and simple.
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Old February 16th, 2009, 09:46 AM   #198
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Too bad that thing ain't ready yet! Sno Blind this weekend!
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Old February 16th, 2009, 09:52 AM   #199
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Too bad that thing ain't ready yet! Sno Blind this weekend!
how many open top rigs usually run it?
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Old February 16th, 2009, 09:54 AM   #200
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There have been a few, don't be a sissy, throw a coat on and some heat and run in the snow!
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