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K10: Built HP60/241-205 Doubler/tons of tube

I went and bought all the fluids for the truck tonight. Gear oil for the axles and 205 and ATF for the range box and to top off all I've lost out of the back of the 700r during the build time.

Had a little energy when I got home so I started on the patch panels. Cut up and welded in the one in the center next to the shifters. I'm going to make a small patch to fill in where the stock shifter hole is tomorrow night then figure out what to do with the big hole under the seats. I'm thinking of making something removable for the area where the pivot for the shifters is so I could slip the shifter handles off in the cab and drop the cases straight down for future install/removal.

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My sliders are welded to the cab floor and then to the frame and it would have been a lot of work to move all that. This will be fine, lower the better yeah? :)

Yeah, that makes sense. I am just a fan of the 1" body lift because it makes it much easier to work on the trucks underneath.

Martin
 
I got more done tonight. I decided the floor doesn't matter a whole lot so I'm shifting gears and getting other stuff done. I can dink around with the floor with whatever time I have left before our trip.

I picked up some fittings and put together a way to be able to fill the clocked 205 with enough fluid to make it happy. Plus now it's an easy site tube.

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Then I filled the range box (that was fun but it's good to go), the 14 bolt, the 60 and topped off the 700r a little. I'll fill it completely once I get it drive-able and can run it to get things warm.

I ran a line for the ARB, it's not permanent but it's what I have for this next trip and should be fine. I'll get a nice line made up for the future though.
I put the 5mm tube inside another tube to help protect it and zip tied it in a bunch of spots except right at the end to let it have some slack.

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Also decided tomorrow night I'll start on the 205 support setup and I think it's going to be a one sided deal. I'll box the frame and just go off the driver's side frame rail since it's so close to where I'm supporting it with it clocked up.

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Thats a good idea. No need to run a whole xmember to get in the way.
When are you guys officially leaving for pismo?
 
You guys just don't know any better. :)



My sliders are welded to the cab floor and then to the frame and it would have been a lot of work to move all that. This will be fine, lower the better yeah? :)
oh good i thought i was the only that had done that. have you had a chance to wheel it like that yet or no?
i'm curious how it will work. hopefully will help stiffen up the cab with the rollcage.
 
Thats a good idea. No need to run a whole xmember to get in the way.
When are you guys officially leaving for pismo?

My parents are leaving Tuesday the 24th and my sister and I are rolling out sometime Wednesday depending on both of our work schedules and what's going on with the truck.

oh good i thought i was the only that had done that. have you had a chance to wheel it like that yet or no?
i'm curious how it will work. hopefully will help stiffen up the cab with the rollcage.

Yeah I've wheeled it like this. It made things a lot quieter because the cab isn't squeaking all the time now. I haven't had any cracks show up between the sheetmetal of the cab and the top face of the sliders where they're welded either.
 
Yeah I've wheeled it like this. It made things a lot quieter because the cab isn't squeaking all the time now. I haven't had any cracks show up between the sheetmetal of the cab and the top face of the sliders where they're welded either.
SWEET.that gives me the warm and fuzzies about mine now.
i think i asked you about this already but are you coming to blazerfest this month? it seems stupid to ask bcuz reading your post above and now looking at the calendar, BF is saturday and your pismo trip is wednesday.
 
SWEET.that gives me the warm and fuzzies about mine now.
i think i asked you about this already but are you coming to blazerfest this month? it seems stupid to ask bcuz reading your post above and now looking at the calendar, BF is saturday and your pismo trip is wednesday.
I posted on norcal last night that I wasn't going to make it. Just not enough time/money to do it with the Pismo trip. Plus I am committed to something this and next Saturday.
 
I posted on norcal last night that I wasn't going to make it. Just not enough time/money to do it with the Pismo trip. Plus I am committed to something this and next Saturday.
oh gotcha.
well you'll have to come over to HH sometime later this year. i'd like to see your rig in person.
 
I started working on the 205 support tonight. Ended up getting about half way done then calling it a night and jumping in the pool. 108* today took it out of me at work.
I did get to fire up the bender and run the first piece of tube through it. Figured you guys were tired of the same old pics of the truck so here's a movie of the first of many bends this little guy will have to do. :)


I'll finish it up tomorrow after work. Then Friday night all I have to do is trim the front fenders and grease everything and it'll be ready to head off to get some d-shaft parts and exhaust work done next week.
 
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I feel your pain it was 105* up here. Managed to work on my truck for about an hour before I ran back to the AC inside. Keep up the progress the end is near. Cant wait to see this thing out in the dunes and on the trails
 
Thanks for posting the video of that bender in action. I've never seen one of them actually doing it's thing. That was cool. In my mind I always pictured them going a lot faster though. Haha. You know how with a manual bender, sometimes you have to kind of overbend the tube one or two degrees because it will bend back a little when you take it out of the die? Do you have to do that with yours? Or is that only on cheap benders?
 
Thanks for posting the video of that bender in action. I've never seen one of them actually doing it's thing. That was cool. In my mind I always pictured them going a lot faster though. Haha. You know how with a manual bender, sometimes you have to kind of overbend the tube one or two degrees because it will bend back a little when you take it out of the die? Do you have to do that with yours? Or is that only on cheap benders?

As far as I know there is some spring back with all of these types of benders. It will depend on the material as to how much though. I went a few degrees past and it seemed to spring back a couple when I pulled it out.
 
I worked on the little support piece for the back of the 205. I set it all up so when it goes together you have to use a floor jack and put a little pressure on the 205 to get the last bit of the bolt hole to line up on the upper mount. Figured that way it would actually take a little of the weight off the adapter and front poly mount.

I'm really not sure on this one. It came out how I pictured it in my head but now that it's done I'm not sure I like it. It should be functional though.
The factory crossmember it's tied to is pretty beefy. It's tied to the side of the frame rails in a couple spots then there are big legs that gusset it to the bottom of the frame rails on both sides. I used 1/4" plate and gusseted it.

Parts...
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Got the welder dialed in pretty well tonight...
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All in place...
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Tomorrow after work I'm going to swap to the longer u-bolts, grease the front end and trim the fenders and then it's off for driveshaft and exhaust work next week.
 
I say anything more then stock is good. Gm left that heavy beast hangin all by the adapter. Looks good Avery, it won't move with those stiff poly bushings.
 
I was trying to figure out how to load this sucker up on the trailer with no driveshafts and just broke down and bought a winch. I had a couple 4wp gift cards from my birthday so I used them to pick up this little Warn 1700. It's marketed for uses like this and being a Warn I'd guess it actually pulls what it's rated for. I looked into some Harbor Freight stuff figuring what the heck they're cheap and it's just the trailer but read so many mediocre to bad reviews I just couldn't pull the trigger.
I even read some that said parts stripped mid pull and the drum let go. That's just something I'm not willing to risk.

So if any of you are in the market for a little trailer winch I'd highly recommend this one, it's really well built and seems to be a great value. I'll give a review once we see it yank the truck up on the trailer this weekend.

I have to pull a trailer up to the mountains for my church tomorrow for the big kids camp this week so tomorrow afternoon/evening is shot but I'll try to get some stuff done first thing in the morning. :)

Here's the winch. I picked up some 20' 4 gauge jumper cables and soldered/heatshrunk/taped the wires to the leads off the winch. I tried it tonight and it works great. This way I can use it with multiple vehicles. I'll build a base that slips into a hitch and weld a receiver tube on the front of the trailer.

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