'88 K5 - Running Down A Dream

[imiceman44]

Getting closer, I've had a lot of interruptions so it's been hard to get going. I've got one plate basically done. I've just got to weld a shear pin in. I have learned that my drill press is definitely wimpy. It was laying down when I was trying to drill 1-in holes. I did do one with a hole saw and it took probably 15min. I wound up having to go to the neighbors and use his. Waiting on some big boy drill bits now or I would have gotten more done today. I also spent some time sitting and thinking and scrolling Facebook marketplace looking for drill presses

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Yeah I didn't bother with that small drill press, I went for big tall one.
Haven't had a problem doing anything in 25 years

 

[jimmyleetn]

Yeah I didn't bother with that small drill press, I went for big tall one.
Haven't had a problem doing anything in 25 years

At the time I was living in a duplex with a tiny garage and it was all I could afford. I've owned it longer than any big tool I have. It's been 10 years ago or more when I bought it. I've been looking at new ones too, there are some really neat ones out there and also some very expensive ones.

 

[jimmyleetn]

Alright, front driver and passenger floor plates are done. I spent a lot of time today working on my metal bender. You can see it in more detail on the "got any new tools discussion." I had to use a 1-in drill bit for one of the plates because I had already got it too far to pilot it with a hole saw. These bits were $38 on Amazon. I'm pretty happy with them for what they are. Could they handle everyday use, probably not, but use here and there with oil and lots of pilots to step yourself up, for sure they can handle that.

 

[nvrenuf]

That bender is sweet!

 

[jimmyleetn]

Didn't get much time today, I was able to tack in the middle pipe for the b pillar hoop. Worked on the passenger plate a little bit more, it didn't fit great after putting that shear pin in but it's in there smooth now. I think I've got that hoop fit in there about as square as I can get it. It's a hard thing to measure so I had to do the eye test some as well, but if you've been following along, I'm sure you know I went way into the weeds on that lol. Anyways, here's the mock-up.

 

[nvrenuf]

Lookin good!

 

[jimmyleetn]

Got the B pillar hoop tacked and the seat belt brackets tacked. The metal bender has its nuances, but worked like a charm with a little muscle. It was hard to get the angles perfect. The passenger side fit way better than the driver, but that won't matter once the full top is on. I actually have the DIY4x seat belt brackets, they're just to big and bulky and do not fit great. Plus, making my own stuff is more fun. Tomorrow I should have time to get the seat belt brackets completely finished (still gonna beef them up a bit) and get the B pillar/bedsides brackets made.

 

[jimmyleetn]

Progress is progress I guess. These two lower brackets burned up my day. The whole entire thing was weird. I was making the passenger side bracket and it didn't fit great so I tried it on the driver side and it fit perfect. From there I tried to make not one but two more passenger side brackets and I guarantee you I have every bit of 3 hours in trying to make at least one fit flush against the roll cage. I'm sure anyone that drove by I could see the smoke that was coming out of my ears from the amount of brain power it took to make that thing fit. I ended up using a pipe wrench and part of my metal bender to twist the metal. It was a complicated use of brute force. Still not sure why that side was so difficult.

 

[jimmyleetn]

Made gussets today. They weren't too hard to make and once they're fully welded and dressed they'll look super nice. The B pillar is tacked in and done other than welding the final beads of course. Also, my shop time will be way less. Work starts Monday and I can't get out there tomorrow. Didn't get as far as I wanted this summer, but oh well, the frame wasn't even under the body two months ago so I can't complain. I think I can still get the cage done in a month or two, but my pace will be a lot slower.

 

[kennyw]

I have one comment on your gussets. It is best not to taper to a sharp point, instead, square off the end so it is slightly larger than the weld. Otherwise, your weld can create a place for a crack to initiate.

 

[jimmyleetn]

I have one comment on your gussets. It is best not to taper to a sharp point, instead, square off the end so it is slightly larger than the weld. Otherwise, your weld can create a place for a crack to initiate.

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Good to know. I should be able to fix that without removing them, although only two tacks hold them in place so no worries there. What height would you recommend there where you drew the yellow line? An 1/8in or a 1/4in? I'm hoping to sneak in there and work a littler when I get home today.

 

[kennyw]

AWS welding standards say MIN 1/16" of material from your weld to the edge of the plate. So if your welds are about 1/4" leg fillet welds, you want the height of the vertical section to be approx 5/16" min.

Here is an example of the result of having a sharp corner, you can see the weld undercuts the gusset and creates a place for a crack to form.


Here is a good example, large flat at end of gusset that is larger than the weld. This allows for the weld to wrap around the end cleanly without structural issues.

 

[kennyw]

Looking at this pic, you may want to do the same to the other end wrapping around the tube as well.


If I were to design this gusset, I would make it a lot larger as well covering the bend in the plate. Currently, that bent tab is going to fold at the existing bend before anything else.

 

[jimmyleetn]

Looking at this pic, you may want to do the same to the other end wrapping around the tube as well.
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If I were to design this gusset, I would make it a lot larger as well covering the bend in the plate. Currently, that bent tab is going to fold at the existing bend before anything else.
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Looks like I'll be back to the drawing board. Fortunately, I have plenty of 3/16 stock leftover.

 

[imiceman44]

Looking at this pic, you may want to do the same to the other end wrapping around the tube as well.
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If I were to design this gusset, I would make it a lot larger as well covering the bend in the plate. Currently, that bent tab is going to fold at the existing bend before anything else.
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I have been thinking about this for a few days and didn't want to say anything but you said exactly what I was thinking on making the gusset wider and go further past the bend

 

[jimmyleetn]

I have been thinking about this for a few days and didn't want to say anything but you said exactly what I was thinking on making the gusset wider and go further past the bend

Don't be afraid to critique. Most of what I know is self taught. I don't really have anyone looking over my shoulder making sure I do things right so I welcome the helpful comments and suggestions especially with something that's all about safety like a roll cage. I've got better gusset built in my head, just gotta find the time after work to get it made. I may just use one in the center of each bracket like what was drawn above instead of two like I did originally. Even with one gusset, it'll still be way more stronger the brackets that came with the kit that have no gusset.

 

[jimmyleetn]

Well I had a little bit of a setback. I started mocking up the family bar portion of roll cage and learned I had taken too much out of that middle bar in the b pillar hoop. The family cage portion was going to be too close to the heads of the passengers in the rear. It's a crazy world we live in though, I can buy DOM tubing off of both Amazon and eBay at a competitive price. I wouldn't have made this mistake if I had rewatched some of those YouTube videos of them installing this cage because I forgot about the ratchet strap trick for the b pillar hoop. Right now I may take another quarter inch out of it but I think I've got it pretty close. My biggest concern at this point is that if I take out much more, I'll be back where I was before, and if I leave the gap's too tight up at the top of the bed rails rails the bedside interior panels won't fit. While I waited on the tubing to arrive I started on the plates one afternoon when I got home early. They shaped up pretty good.

 

[jimmyleetn]

B-pillar round two. It got so wild today I even used the 20 ton press. There is a slight twist in the hoop that it had out of the box. In order to get it in their square I had to attach the seat belt brackets and use a series of clamps to get it in right. I'm hoping this time I'm done. Next up are the bed side brackets and then the family cage. I can't add gussets to the seat belt brackets just yet.

 

[Jake_C_]

May have missed something in this discussion, still planning a full vert conversion on this build? The top b pillar to roll bar brackets got me wondering. Nice fab work on the roll bar.

 

[jimmyleetn]

May have missed something in this discussion, still planning a full vert conversion on this build? The top b pillar to roll bar brackets got me wondering. Nice fab work on the roll bar.

Yes, full vert conversion is still the plan. I got to a stopping point before school started back (I'm a teacher), but once the roll cage is finished the conversion is the next step. I appreciate the compliment on the b-pillar, it was way more work than I expected. Those top brackets will clear a full vert top and give me just enough room to keep my 3 point seat belts up front. I'm starting to get the itch to get started again, but probably won't be deep into it until mid May.