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'72 K5 - Greg's @MightAsWellK5 Build

This is the build description. I will improve this later. (GB)
Overview Gallery Discussion
Don't be a fool.....stay in school.

:)


Check back again next year, you should have another couple hours of new reading by then.

:usaflag:
 
dood, the shifter bracket is sick.... nice...

I need to order my cable shifter next week from NWF.....
 
2008.09.14 - !UPDATE! - THE PLANS HAVE CHANGED...

And that typically means that the budget just got ruined too. :D But in this case, there will be some savings in certain areas to offset other areas where costs have increased.

Here's the deal...

As I pondered my next steps with the truck it became more and more clear that if I truly build this truck in 2 Phases (the current 1-Ton phase, then the Mog Axle phase) I'm going to end up building a LOT of things twice. Specifically, crossmembers...parts of the chassis underneath, the link mounts will change to accomodate the higher axletubes of the portal axles, the transmission will change from an auto to manual, etc. etc.

The thing specifically that has been on my mind is the costs associated with integrating the Mog axles to the build. I've already spent some serious coin on the axles and special CNC'ed portal boxes but there is still quite a bit of money left to spend....since I need to have the housings narrowed and have the front pumpkin moved from the left side (driver's) to the right side to match the front output of my Atlas. Integrating the T56 (6-speed) means custom bellhousings, a clutch pedal, hydraulic setup, custom output shaft and adapter, and finding a way to get the shifter far enough forward to come out of the center tunnel somewhere in front of the driver (not behind me!) :eek1: It's all possible to do.....but it will take plenty of time and money to accomplish. Not to mention that I'll have to REDO many of the things I'm already solving now.

Enter the newest player in this little "Might As Well" story: The Mog-9 axle. :thumb:

The Mog-9 is basically just a set of 404 Mog portals with a Ford 9" centersection instead of the traditional Mog dropout centersection. This allows for a change in gear ratios from the stock 3.54:1 to whatever you want. Initially, this didn't appeal to me because the last thing I wanted to do was go even DEEPER with my axle gears....but as I looked around I discovered that there are quite a few ratios that are higher (numerically lower) than 3.54:1 on the Ford 9". In fact, there are a total of 6 ratios less than 3.0:1 available!! What does this mean?

It means that instead of a set of portal axles with a 7:56:1 overall ratio, I now have a way to build a Mog 404 axle with an overall ratio of only 5.33:1. That's a huge deal because with a ratio like that I don't need a 50% overdrive ratio from the T56 (6th gear) to drive this thing down the highway. In fact, according to my calculations a 4L80E transmission with a 25% overdrive will be PERFECTLY MATCHED to this setup and will provide me with 2200RPMs at 65MPH, and only 2500RPMs at 75MPH!! :saweet:

My life potentially just got a LOT simpler now. Instead of doing a complete transmission swap from Auto to Manual to accomodate the Mog axles, I can build the driveline ONCE with a 4L80E and be done with it. Remember, the 1st, 2nd and 3rd gears in a 4L80E are identical to a TH400 so even if I don't do the axle swap immediately, I'll still have the ability to run the transmission in 3rd gear on the highway with my 4.10 axle gears (14BFF) and have awesome RPMs.

The 6-hole pattern on the back of a 4L80E case is identical to the TH400, so all that bracketry I've already built off the back of the TH400 can be re-used too. The only small issue is that the case is about 1.5" longer than the TH400, so my Atlas shifters will be a bit too far back with the current bracket I've built. It should be a simple matter to rework that bracket to move them forward 1.5"...I should be able to get that done in an afternoon.


All of this is based on a number of assumptions, and I still have quite a bit of research to do to validate that this will all work the way I expect it to. I also need to do a real side-by-side comparison of the costs to see if this is a lot more expensive than my original plan. My guess is that it will add some costs, but will save me a lot of conversion time and will allow me to skip the entire (Phase 1 / Phase 2) build strategy, and simply continue forward immediately with integrating the Mog axles into the current build. :thinking:

The lucky thing (if you can call it that) is that I'll have a pretty decent pile of premium parts that I can sell off to help finance this part of the project:

  • D60 Front Axle
  • 14BFF Rear Axle
  • 0 Mile TH400 built tranny
  • T56 Viper Transmission
That pile should bring in a few dollars to help keep things moving along.... :deal:
 
The 'Burb is 2WD..... and I intend to keep in that way.

Plus, I recently sold my trailer so using it as a "tow vehicle" is nothing that's going to happen in the short term.


:usaflag:
 
Sure sounds like this is a better approach - not having to redo alot of stuff which requires alot of time and effort is worth alot IMO.
 
2008.09.21 - !UPDATE! - GOING FORWARDS SOMETIMES REQUIRES GOING BACKWARDS...

It's not the "fun" stuff, but with Fall weather settling into New England it was time to start preparing for colder weather....and to take the manspace to the next level in terms of organization and utility.

The main problem I've been struggling with lately is storage space. I seem to have TONS of small bins with takeoff parts, cans of solvents, small fasteners, etc. And with only one small metal shelving unit to store them on, most end up packed away in bankers boxes never to be seen again....or parts end up strewn about the shop, which drives me completely nuts.

My fastener bins are currently sitting on top of my LP gas heater, which won't work much longer. In the next 30 days or so, I'm sure it will get cold enough that the heater will need to be fired up...so I needed to come up with alternative storage. Since I've built an adjustable-shelving unit a few times before I knew what I'd need to do....so I made a trip to the local lumberyard, bought some 2X6s and some pine shelving and started making sawdust....

DSC01256.jpg


I cleared the one large wall I've got, and began laying out the vertical supports. Each board has a series of routered 3/4" slots every 6 inches...this allows me to add shelves as needed to accomodate whatever stuff I accumulate. For now I have just set them up with 12" spacing which is generally pretty useful.

DSC01257.jpg


Here is a shot as of a few minutes ago.... All of the individual shelves are in place, and I've got a coat of polyurethane on everything....about half has two coats, later on tonight I should be able to do the final coats on the parts that need it.

DSC01263.jpg



Also, as I expected....this "downtime" in the project has allowed me to start gathering more tools that I'll need for later on.

Here is a very small (but expensive) box of Jancy sheetmetal saws in 3/4", 1", 1.5", 2.0" and 2.5" sizes.... to match the 5 sizes of flare hole dies I already own.

DSC01264.jpg



By tomorrow morning, the shelving should be dry enough for me to put this box (among other things) in it's rightful place in the shop.

Sorry I don't have a sexier update for you all, but this is the reality I'm up against.....and also, I'm saving up for the next expensive set of parts I'll need to move forward (Spidertrax axle housings, 4L80E tranny, hydro-assist for my bender, etc). :yikes:



:usaflag:
 
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I can`t wait to have my own garage. After seeing what you, and others, have done with your man space, I`m inspired to make a sweet one of my own. :bow:
 
*subscribed*

Greg, I want to thank you for all of the documentation you have provided in this thread. Much of the sheetmetal replacement that you have done, I will be doing on my '74. Thanks for taking the time to share your experiences with us!!
 
Screws top and bottom into 2x4 blocking.

Bottom blocking goes into the sole-plate on the foundation wall, and up top it screws into the ceiling joist.

Serious tech. :deal:


Actually, tonight I've been working in the shop putting all my "stuff" on those shelves... some of which has been in boxes since I moved from CA about 4 years ago!! :yikes: It has been an interesting process, and I've made some pleasant discoveries along the way.....parts I thought were long gone, have resurfaced and are now organized so that I'll be able to lay my hands on them when the time comes.

No pics yet....you guys don't get "in process" shots of me cleaning up, just the money shot once it's all done. I've got enough Chinese takeout and enough energy for about 1 more hours-worth of cleaning tonight. Expect a photo update in the morning.....


:usaflag:
 
I did it the hard way....I clamped a metal guide down for EVERY individual slot that I cut.

Yes, it took a long time.


:usaflag:
 
Wow!

You are the great, nice build, write up.... if I wasn't at work I would be out working on my truck now. You are inspiring! Keep up the work!
 
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