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77K5. The IronMaiden...9/2 headed for Blazer Bash 20!

jack of all trades build, overland, dunes, rocks, trails
Overview Gallery Discussion
The coolers are LONG brand, sold by Speedway motors.
The sandwich adapter is a bolt on type, a sleeve goes up through the center, and screws on the existing threads in the block adapter, then the filter screws on the bottom of that sleeve. By getting this one, I can index it where I want the ports to be.
 
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Man I take off to run for parts and some errands (day off today), I get home the power is out....for about 6 hours....dug out the generator, got that running to get the shop powered up and worked out there most of the evening....come out of the shop and the neighbors lights are on....yeah...

So this is what I got done:

re-routed the fuel line and put in a stainless ball valve:

misc044.jpg




I need to rework the hole in the frame when I get the fuel line out:

misc040.jpg




Made a bracket to bolt to the frame and cradle the valve:

misc041.jpg




Then made some locater brackets for the fuel tank, as it is driven up into the opening it self centers on these re-cylced brackets:

misc042.jpg



Can you guess where these recycled K5 parts came from? Hint, there is only about 1/3 of the original bracket left here.

misc043.jpg
 
Are those part of the original leaf spring mounts?

And what is the purpose of the ball valve, a safety cutoff for the fuel supply?

Looks good Dave, I like it.
 
Those are the old rear bumpstop brackets, they were just laying in the scrap bucket, and I thought the curved part would work great for where it is now. I'll probably add a gusset to the middle, when I get the frame boxed up.
The rear bracket is some exhaust tubing that I cut for the saddles on the exhaust brackets, it was a left over piece I flattened out somewhat. I will use a pad similar to a tank strap pad between all of the brackets and the tank when its installed.

The ball valve is just a little anti-theft device. You know like when you turn off the petcock on your motorcycle and then 1/4 mi. down the road it dies on you, and everyone hollars "turn on the gas".:dunno:
 
I use swagelock fittings at work, I don't even want to think about how much that Stainless valve cost you.
:eek1::eek1:
 
Don't even think about it...I have no idea either.

I'm going to try the Walbro in tank pickups:



It says they are 3" diameter, which is just enough to squeeze it through the opening in the tank.
I'll try 3 of them, 2 in back one in front, and one with a bleed hole.
I really couldn't find a decent "clunk" system, or the parts that I thought would work without fail. These seem to be a proven design.
 
Got a new sandblaster today...referred by Paul (Ryoken).
Its a Harbor Freight, 40lb unit. works good, way better than siphon type I used to have.

Ironmaiden131.jpg




used it on the tank today...then got a coat of zinc and paint on it too.

Ironmaiden132.jpg




I started on the brake system also. these lines from G&J aircraft are the Gold....they are 30" long on each side, and the drop is 24".

Ironmaiden126.jpg

Ironmaiden127.jpg




Welded on a tab for the mount of the upper hose end.

Ironmaiden128.jpg





Used some retainer tabs with a grommet in them to hold the lines in place.

Ironmaiden129.jpg


Ironmaiden130.jpg
 
blazinzuk said:
I can think of other purposes it may serve too :D:D:D:D:D:D:D
Click to expand...


I can just see it now.

Erik: " Dave I bet you 20 bucks you can't make it up that hill"

Dave: " you are on watch this!!"

Dave: ( gets in truck starts it gets halfway up the hill engine dies, tries starting to no avail)

Erik: "give me my 20 bucks"
 
max 02 said:
Nice work! I like the anti theft, good idea.
Click to expand...
It might slow someone down for a minute or two, just enough time to grab the shotgun!

blazinzuk said:
I can think of other purposes it may serve too :D:D:D:D:D:D:D
Click to expand...
Speak man....

toner91 said:
My brother has one just like that. Man that thing makes a mess! Do you blast in a booth?
Click to expand...

I just blast outside, way to messy to do indoors...its almost as bad as grinding metal.
jekquistk5 said:
I can just see it now.

Erik: " Dave I bet you 20 bucks you can't make it up that hill"

Dave: " you are on watch this!!"

Dave: ( gets in truck starts it gets halfway up the hill engine dies, tries starting to no avail)

Erik: "give me my 20 bucks"
Click to expand...
:doah:

Payupsucka....I know it'll happen too Jess.:haha:
 
jekquistk5 said:
I can just see it now.

Erik: " Dave I bet you 20 bucks you can't make it up that hill"

Dave: " you are on watch this!!"

Dave: ( gets in truck starts it gets halfway up the hill engine dies, tries starting to no avail)

Erik: "give me my 20 bucks"
Click to expand...

I would NEVER do that:haha::whistle:

I have already revealed too much
 
Eric and I will be working on it from Wed to Mon.
The plan is to build up the cage, rock sliders, boatside, engine compartment cage, shock hoops, bumpstops and mounting, and whatever else come along to complete those items. Also high priority is figuring both axle pinion angles so I can complete the welding on the rear and make any necessary adjustments to the front.
Also get the rear Gauntlet bumper mounted!!!!!!!!

Wrenching items will be whatever is on my build list to complete, from where I'm at on the list at the time. So whatever someone feels comfortable working on, but basically I'm here right now:


Weld on mounts for Spring limiting blocks (for trailering to limit suspension travel)


Figure oil coolers mounting

Fabricate oil cooler lines


REMOVE DRIVETRAIN/STRIP FRAME


Clearance around pass side header

blast and zinc coat inside of frame rails

Weld up frame boxing kit

Sandblast exterior frame

Clean and seam seal any double layered plates

Paint frame


Body back on frame​

Check floor mods for raised fuel tank


Clean underbody and paint

Rock sliders

Mini Boat side


Cage installation

Shifter mounting

Seating


Seat belts

Cup holders

Driver reachable storage


Grab handles




Major component completion​

............Rear 14BFF axle:​



Final weld rear shock mounting​



Final weld rear spring perches​



Paint rear axle/springs/all brackets/shackles etc​




Install truss/Antiwrap mounting plates​


Install pinion guard​






Finish weld Antiwrap bars, and add gusset​





....................Front Dana 60 axle:​


check wheel studs for proper fit​


check all lugnuts for proper application​

figure shock mounting​




..................Engine:​


Align crankshaft pulley​


Install temp sender​

Install oil cooler adapter​


Install oil pressure sender​


Valve cover venting​


Vacuum advance source ​

make vac.mech advance adjustments​





.....................Transmission:​


TH400, install trans temp sender unit and other mods needed​


Torque convertor cover mounting holes​


Shifter cable hookup​


Check pan seal​


Install dipstick tube​


......................203/205 Doubler:​

Dis-assemble the 205 for replacement of the front output, add a spacer, replace the shifter rails w/ ORD rails for triple stick, drill and tap for a sightglass oil level tube.

Drill and tap for 203 sightglass oil level tube


Fab and install transfer case venting system

Locktite everything doubler related.





Misc. items​


Route Hydroboost lines


Figure trans temp guage placement and needs


Fab and install axle t/c venting system


Fabricate battery mount

Install battery master shutoff

Install remote starter solenoid

Run Battery cables

Mount front winch bumper

Install and wire Windstar fans

 
76zimmer said:
Eric and I will be working on it from Wed to Mon.
The plan is to build up the cage, rock sliders, boatside, engine compartment cage, shock hoops, bumpstops and mounting, and whatever else come along to complete those items. Also high priority is figuring both axle pinion angles so I can complete the welding on the rear and make any necessary adjustments to the front.
Also get the rear Gauntlet bumper mounted!!!!!!!!

Wrenching items will be whatever is on my build list to complete, from where I'm at on the list at the time. So whatever someone feels comfortable working on, but basically I'm here right now:


Weld on mounts for Spring limiting blocks (for trailering to limit suspension travel)


Figure oil coolers mounting

Fabricate oil cooler lines


REMOVE DRIVETRAIN/STRIP FRAME


Clearance around pass side header

blast and zinc coat inside of frame rails

Weld up frame boxing kit

Sandblast exterior frame

Clean and seam seal any double layered plates

Paint frame


Body back on frame​

Check floor mods for raised fuel tank


Clean underbody and paint

Rock sliders

Mini Boat side


Cage installation

Shifter mounting

Seating


Seat belts

Cup holders

Driver reachable storage


Grab handles




Major component completion​

............Rear 14BFF axle:​



Final weld rear shock mounting​



Final weld rear spring perches​



Paint rear axle/springs/all brackets/shackles etc​




Install truss/Antiwrap mounting plates​


Install pinion guard​






Finish weld Antiwrap bars, and add gusset​





....................Front Dana 60 axle:​


check wheel studs for proper fit​


check all lugnuts for proper application​

figure shock mounting​




..................Engine:​


Align crankshaft pulley​


Install temp sender​

Install oil cooler adapter​


Install oil pressure sender​


Valve cover venting​


Vacuum advance source ​

make vac.mech advance adjustments​





.....................Transmission:​


TH400, install trans temp sender unit and other mods needed​


Torque convertor cover mounting holes​


Shifter cable hookup​


Check pan seal​


Install dipstick tube​


......................203/205 Doubler:​

Dis-assemble the 205 for replacement of the front output, add a spacer, replace the shifter rails w/ ORD rails for triple stick, drill and tap for a sightglass oil level tube.

Drill and tap for 203 sightglass oil level tube


Fab and install transfer case venting system

Locktite everything doubler related.





Misc. items​


Route Hydroboost lines


Figure trans temp guage placement and needs


Fab and install axle t/c venting system


Fabricate battery mount

Install battery master shutoff

Install remote starter solenoid

Run Battery cables

Mount front winch bumper

Install and wire Windstar fans
Click to expand...


Grab handles 1" tube?
 
Is that all? No prob! LOL!

Out of that entire list, you know what I'm most interested in seeing???

Your plan for cup holders! I use those wide base coffee mugs and always have my mug up on the dash above the heater controls. So consiquently, there is a damn neer permanent coffee ring on the dash and coffee splash and run down the windsheild.

Yes, so outstanding build, now lets see your cupholders! LOL!
 
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