DO NOT OPEN IN PUBLIC, YOU WILL BECOME INSTANTLY ERECT!!!

[truck-oholic]

Hope to finish the tube bender this weekend. In the meantime I got some small goodies for the front winch bumper and something for the front axle.

7/8 6.5 ton WLL d-rings

Daystar hawse fairlead winch isolator

Polyurethane washers I got from Ebay to take the slack out of the shackle at the tab. I would have preferred to get a thicker washer and run just one on each side but this was the best I could do at a reasonable cost.

35 Spline Spartan Locker for the Dana 60 front. Going to order up some Trailworthy Fab 35 spline drive flanges and some 35 spline chromoly outers to finish off the front axle assembly.

 

[truck-oholic]

Tubing bender base is welded together and ram mount is burned in.

Uprights and 45 brace should be welded on tomorrow and then this thing is operational!

 

[truck-oholic]

The Xtreme Offroad episode that the family was featured in just posted online. Here is a link for anyone that is interested. Our segment starts a little after the 10:20 mark.

http://powernationtv.com/episode/XO2015-16/diy-axle-setup

 

[truck-oholic]

Although I am not quite finished with the bender it is at least operational now. Still have a couple small details to take care of, paint it, and put it on lockable casters. This has been very labor intensive. I probably could have been done with my roll cage by now if I had just bought a pre-made unit but the cost savings paid for my high dollar Rogue Fab Versanotcher and it is a pretty bitchin tubing bender that comes with bragging rights so I would definitely recommend it to anyone that has more time than money or enjoys building their own tools.

 

[EPK5]

Thank you sir for taking the time to document your build. I truly admire your creative solutions and down to earth explanations. I am also building my K5 with young children in mind and appreciate your work.

 

[truck-oholic]

Thank you sir for taking the time to document your build. I truly admire your creative solutions and down to earth explanations. I am also building my K5 with young children in mind and appreciate your work.

Hey, happy to help any way I can. Glad someone is finding the info useful.

 

[truck-oholic]

Made a few practice bends after work to see how this is going to go

Wish I had a bigger compressor but the one I have will be OK, at least it's quiet

 

[jekquistk5]

http://www.pirate4x4.com/tech/bendin_tube/index.html


That made my life easier

 

[truck-oholic]

http://www.pirate4x4.com/tech/bendin_tube/index.html


That made my life easier

I will give that a read.

I am an industrial electrician and we bend rigid conduit with electric benders all the time so I am not starting at square one but most of our bends are 15,30,45, & 90 and we obviously never have to notch and cope.

We do a lot of offsets, 90s, kicked 90s, etc. but this cage design is going to be a test of skill for sure.

 

[Kay86K5]

http://www.pirate4x4.com/tech/bendin_tube/index.html


That made my life easier

That's the exact thread I read when I started building my cage. Used the techniques this spelled out. After a while, I was starting just to eye ball everything

 

[truck-oholic]

That's the exact thread I read when I started building my cage. Used the techniques this spelled out. After a while, I was starting just to eye ball everything

Well that is encouraging, your cage turned out pretty darn good

 

[NorCal69]

http://www.pirate4x4.com/tech/bendin_tube/index.html


That made my life easier

Ha, been awhile since I seen the jewel come up. That's exactly where I started. Now I pick up some grass, throw it in the air to see what way the wind is blowing, so I no where to stop the ram....all while drinking a beer.

 

[truck-oholic]

Felt like working on steering stuff today. Got the draglink cut and welded. Going to make a second pass on it both ends then grind the welds smooth to match the tie rod bungs. Also cut some 3/8" tabs for the hydro ram and welded those on with everything centered. Since I destroked the ram to 7" I have 3.5" throw each way.

Yesterday I installed my Spartan locker in the front and took all the stock brake stuff off since I am going to 3/4 ton brakes in the front for better response. I just ordered a kit from Lugnut 4x4 with all the parts needed. I also broke down the axle shafts since I am doing a 35 spline outer conversion. The front inner shafts I have are the non-neckdown version (thank God) so the 4340 35 spline outers I am putting in will bring everything up to par. Also putting in the cold forged Spicer non-greasable "life series" joints with full circle snap rings. Trailworthy Fab 35 spline drive flanges will finish off the front axle internals.

 

[truck-oholic]

By the way, is anybody else not seeing pics on the first couple pages of the build anymore? I am trying to figure out if it's just my computer or if there is some other problem.

 

[ryoken]

By the way, is anybody else not seeing pics on the first couple pages of the build anymore? I am trying to figure out if it's just my computer or if there is some other problem.

yeah, your pics in post #1 thru #36 are missing...

 

[truck-oholic]

yeah, your pics in post #1 thru #36 are missing...

Any idea what could be causing that? I am hosting everything on Facebook for convenience. It started out not showing a couple here or there as I have added pics over the past couple weeks and now there are large sections missing. Everything still shows up on Facebook.

 

[Kay86K5]

Well that is encouraging, your cage turned out pretty darn good

Thanks man. It's not perfect by any means, but I kinda like it that way, cause I know it was me that built it.

Every time I open your thread I am always impressed with the fab work. Keep up the good work

Ha, been awhile since I seen the jewel come up. That's exactly where I started. Now I pick up some grass, throw it in the air to see what way the wind is blowing, so I no where to stop the ram....all while drinking a beer.

Hahaha that is funny right there.

Like I said, after a while I just started to eye ball stuff. After you start getting your feet wet with bending tube, you start figuring it out pretty quick. I got to the point towards the end of my cage build that I would make one "eyeball" measurement with my measuring tape, and fire up the grinder

 

[truck-oholic]

Worked on front suck down winch some more while waiting on axle parts to finish the 35 spline outer upgrade.

Contemplating bending some tube to make a skid plate for the winch cable. Would go from outside of spring perch to outside of spring perch angled up for max clearance with 1/4" plate going across with trick tabs to make the plate removable for diff cover removal. Thoughts?

Where the vise grips are holding the cable I will be dropping some tabs and putting a sleeved 5/8" bolt across with welded washers to make another cable roller assembly

Tied cable end into the ORD engine crossmember using 1/4" plate and 5/8" bolt. Once the engine comes out again I will finish weld the rest of this.

This was a super awkward place to weld so . . .

I am going to do some 1/4" plate gussets back to the axle tube off the right hand pulley bracket to stiffen everything up.

Last but not least I also did some painting, which I absolutely despise

 

[truck-oholic]

Made my upper cable roller assembly tonight for the front suck down winch.

I think I am going to box the back of the tabs together with some more 1/4" plate

 

[truck-oholic]

Been a while since I've worked on this thing but I've been plenty busy in the garage. Finally welded the rock rings on the H1 wheels that Ian Johnson and I recentered on Xtreme Offroad back in May. Local guy I know is buying them and has been making payments for the past couple months. Anyway, he is ready to make the final payment and pick them up so I had to fire up the welder to give you guys some weld porn.