Re: Project: Tow-Rat (Lil' Blue)
 

Ditto, thanks!

Re: Project: Tow-Rat (Lil' Blue)
 

made some shocking progress this evening

https://i.imgur.com/GtK3zFa.jpg
https://i.imgur.com/rwHXhi7.jpg
https://i.imgur.com/PBLPzqn.jpg
https://i.imgur.com/Zr6TILa.jpg
https://i.imgur.com/lBOQJ26.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

got the carrier bearing mounted finally now that i knew the angle of the trans output. the sucky part is that i have to knock the bearing races out to fully weld it.

i do have some drive shafts i can start cutting up for temporary bits for the first test drive and sorting everything out.

https://i.imgur.com/eo6ZzrA.jpg
https://i.imgur.com/HG7OcxG.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

one thing i really want this to be is reasonable to drive for long distances on the highway. that's going to require a new rear gear to really get there, but I'm starting with noise and heat. while researching mufflers and killing drone on big exhaust for the 12v, the ONLY thing that everyone agreed on was that these resonator/mufflers are the best thing going. even adding another standard muffler after it for a great note that is actually more quite then factory in the cab. but it looks super screwy :lol:

my next issue is getting a 5" exhaust to go anywhere reasonable. i have always planned to run it down outside the frame on the passenger side with a side exit in front of the running board. the running board might now get scrapped for a 2nd muffler, but i'll save that for later. the real issue is going to be getting the exhaust around the frame, tire, shock, and body! if building this frame again, i'd move the 45deg section back by 3" to gain enough space to turn a 90 in plane with the ground and then turn a 90 straight up inside to the turbo. as it stands though, i have 5.5" between the floor and frame. i was thinking maybe i would just run a 4" down to the rocker, but now maybe i can crush a 5" down to a 4" tall oval locally there. we'll see, this will be a project.

https://i.imgur.com/KY3xwI8.jpg
https://i.imgur.com/dUEakxT.jpg
https://i.imgur.com/jp56AGs.jpg
https://i.imgur.com/dNPiZri.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

this next bit of fab is going to make a few of you twitch :lol:

off road fab'd some drive shafts for test fitting and set-up this weekend. but will also most likely start driving on them too. section out or in whatever length you want, clamp with angle iron on 2 sides to keep the tube straight and weld it back up. jump around a lot and to the opposite side each time to keep from warping it, grind off the top of the weld to minimize extra weight working against the balance, but leave the weld proud for extra material at the joint for strength.

i have actually had very good success doing this with perfect balance at 80mph, and living years under jeeps being beat off road. just not the prettiest, or well accepted solution.

had to make a little clearance on the fwd shaft to the crossmember. held a sharpie on a pc of 1/4" plate and spun the shaft to get about 1/2" clearance. if the chassis twists enough to get that to contact, the solution isn't more clearance but adding a roll cage ;) this shaft is 1410 joints, and will eventually just get a new professionally balanced pc.

the rear shaft helped me set the rear pinion angle and check it thru travel. at full droop i set the pinion 2deg below the shaft to allow for a little motion up under torque loading. at full compression the pinion is only 1.2deg below the pinion, so ride will be somewhere in the middle. axle perches are officially tacked in place, making the axle DONE and ready for final weld/paint. this shaft is a junkyard 1350 cv, eventually i'll get a new 1410 cv unit and have to change the yoke on the axle at the same time. that's probably also a good time to get better gears and limited slip installed.

i'm quickly running out of things to fab and procrastinate doing the floor ...

https://i.imgur.com/lbqUawe.jpg
https://i.imgur.com/ss1XqM0.jpg
https://i.imgur.com/T2irvS1.jpg
https://i.imgur.com/e046RrI.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

"made some shocking progress this evening" :lol:
Who makes that resonator? It looks very neat. Took me 3 try's to get the exhaust on my little diesel in my jeep the way I wanted, ended up making my own muffler, straight through baffled.
Making driveshafts like that works surprisingly well.

Re: Project: Tow-Rat (Lil' Blue)
 

FTE Diesel

https://www.ftediesel.com/store/pc/v...p?idCategory=7

it's the only muffler/resonator i've come across that didn't even have troll haters. some go with only that, some use a muffler with it, but the word on the street is that it's nothing but good things. i figured it's worth a shot!

today i actually ordered a muffler to go behind it too. I got the "Resonator / Muffler 5" Aluminized", but figured i should take it further. on the passenger side i probably won't run any bed side step at all in favor of the muffler/side pipe setup. being a long bed, and moving the fenders back another 10-12" should give me lots of room to play with. then i can use a chunk from the pass side board to weld into the drivers side to extend it far enough to cover the whole span cab to fender.

Re: Project: Tow-Rat (Lil' Blue)
 

so here is the 2nd most recommended muffler to quite a diesel, a Donaldson muffler. now i went with a shorter version though since i don't quite have the room, so 20" body vs the 44" most ppl get for a ram. this is an M090595 with 5" in and out.

straight thru design, but then you can see the baffle right smack in the middle. i guess if it's too quite i can just start drilling holes in that. :lol:

the rear fenders are about 13" wide, and this can is 9" dia plus at least 1" off the bed side, so i'll still be at least 3" inside the fender lip with this side pipe. don't forget that i'm making the whole bed wider to get around the duals vs just wider fenders.

https://i.imgur.com/SdLhxcq.jpg
https://i.imgur.com/CWD6Ux0.jpg
https://i.imgur.com/6M2vtv0.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

while i've been plotting exhaust and ordering parts, i've also started to figure the trans tunnel. i think i'm going to commit to the bent plate vs rolled look.

https://i.imgur.com/wuhhkFO.jpg
https://i.imgur.com/9vBWs7E.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

The nice thing about a bent plate trans cover is that it is easy to mount stuff to it if you want, like cup holders.

Re: Project: Tow-Rat (Lil' Blue)
 

Got a new toy in the mail today! I had the swag press brake, but just got the adapter for tight bends. I think this is going to be good.

The sheet is 16g CORTEN i had left over from building the house, so its nice n solid. I was thinking about where to put a bead roll or 2 and its just noooot needed. The floor structure bridge will be plated over and under to box it.

https://i.imgur.com/ZBfU4eA.jpg
https://i.imgur.com/FZV4csN.jpg
https://i.imgur.com/8tiemYN.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

I must have been asleep for sometime or something. This build got really serious real quick.

Nice work!

Re: Project: Tow-Rat (Lil' Blue)
 

haha, thanks!

just curious, where had you left off?

Re: Project: Tow-Rat (Lil' Blue)
 

Getting a little better at this sheet metal thing. I'll fill the floor flat across to the tunnel, and will be a huge flare going fwd around the bell. Lucky me, i was able to read my own sketch :lol:

https://i.imgur.com/rGB7ojp.jpg
https://i.imgur.com/XKVbh2z.jpg
https://i.imgur.com/zwe22iq.jpg
https://i.imgur.com/9pZO3NE.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

finally got the throttle pedal i ordered like 2 months ago. There was NO way my size 13 boot was going to fit between the tunnel and the brake pedal where it was. Relief cuts, reversed the bends to get the pedal arm on the other side of the column n i think we are golden. I actually like the mirrored look better to!

https://i.imgur.com/JTC2uAF.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

Agree! Looks good like that.

Re: Project: Tow-Rat (Lil' Blue)
 

Pedals look good. Nicely spaced. Steve

Re: Project: Tow-Rat (Lil' Blue)
 

I love everything about this build. Hopefully I run into it one day. I'm pretty sure I've seen that YJ before. Bantam perhaps... maybe Rausch Creek.

Re: Project: Tow-Rat (Lil' Blue)
 

thanks! with any luck you can see the truck towing the YJ at RC some time "soon"! the YJ has been to RC for sure, but i've only taken the 6.0L TJ to Bantam. last year was the first season for the 40 n beadlocks on the YJ too, the 12 years prior she was on 36" IROKs and some generic AL wheels.

Re: Project: Tow-Rat (Lil' Blue)
 

ok, finally stopped procrastinating and got to work on the new doghouse for the #6 cylinder. lots of trial work with the markers before i finally settled on something i liked.

made the firewall cuts, measured twice, then bent myself a 6.5" sidewall to the doghouse. fit it, realized i had measured wrong, and had to cut in half since i didn't want to waste that much steel. got it welded back together and that little panel had a little warp in it. i hate sheet metal. and i really could have taken a tiny bit more out of it, but oh well. she fit pretty well.

https://i.imgur.com/n95rs0Q.jpg
https://i.imgur.com/rIgQDj8.jpg
https://i.imgur.com/WtOx9Bs.jpg
https://i.imgur.com/n2criUn.jpg
https://i.imgur.com/igcgbVS.jpg
https://i.imgur.com/Ctdnsas.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

so before i swung that massive chunk of cast iron out of the frame, i had measured about where i wanted to cut the tunnel on the dog house back plate. nothing like trusting in your notes and making holes! the back plate has a 6.5deg bend (same angle as engine tip) in it as well, trying to pull the face fwd and give my boot a little more room. i need to test fit with all the pedals and seat in place, but i could actually do like a 1" chamfer up that whole corner if needed too. i'll finish the rest of the tunnel first.

should have enough room on the exhaust side for an aftermarket manifold and full blanket to keep the cab cooler.

https://i.imgur.com/VK4baEV.jpg
https://i.imgur.com/b5wh5Rw.jpg
https://i.imgur.com/CKy2eFi.jpg
https://i.imgur.com/XDm9vxQ.jpg
https://i.imgur.com/32vnZzP.jpg
https://i.imgur.com/Bi3m2C4.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

my biggest win was that the engine/trans were able to swing in together at the same time! that trans is STUPID heavy and i have zero interest in trying to put it in from the bottom. i'd probably pull the cab. my tunnel cut lined up nice, and i'm buring it all in solid now.

https://i.imgur.com/o3jmUcN.jpg
https://i.imgur.com/kjy7sYR.jpg
https://i.imgur.com/gVLytud.jpg
https://i.imgur.com/PhijXY1.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

The firewall turned out good.


I just put 40s on my YJ this year as well. Hopefully I can get it on the trail this weekend finally.

https://drive.google.com/uc?id=19mbL...kLCW3bOCOVixWX

Re: Project: Tow-Rat (Lil' Blue)
 

NICE!!!

now there are 3 of us, time to schedule a trip.

Re: Project: Tow-Rat (Lil' Blue)
 

I like the look of your fire wall and it's a bonus that you can get the motor and trans in all together. Definitely set the seat and peddles in before you finish up the trans hump.
40's are the new 37" guess I'm really getting to be the under dog with my 33". Back 26 years ago when I lifted my Jeep 35" was big.

Re: Project: Tow-Rat (Lil' Blue)
 

the most fun i've ever had off road still was on 31s in a junkyard XJ though. didn't care if it never made it home, just full send. AT's that we grooved into MT's, welded diff, jumped on the doors till they ripped off :lol:

Re: Project: Tow-Rat (Lil' Blue)
 

What an awesome build! I also love every part of it. I've always wanted to build one of these trucks I just already have too many projects. That carrier bearing is so bad ass. I have 2 other suggestions for mufflers. First, is the spinny muffler. A 2nd turbo about 75mm or so. That quiets them down and adds that boost stuff you wanted before earlier in this thread. :lol: Or, a Jones aero turbine muffler. Takes up less room than those Donaldson units and are stainless. A little more money but they work really well and don't drone. 4" exhaust is fine. 5" is over kill and a PITA to fit in builds like this. Let's face it, this is a 359ci, not an 855. :lol: Most pick ups with 5" have it for looks only.

Awesome fab work and that computer aided everything you have from modeling to cutting everything is so cool. When I build my crew cab 67-72 I want to do exactly this. Build a custom frame that suites the truck's needs.

What plans do you have for the engine? What are you planning on doing to the IP and do you have a fuel plate or something else? I've installed a couple of AFC Live's and really like them.

Re: Project: Tow-Rat (Lil' Blue)
 

That's a nice firewall fit around that engine!

Re: Project: Tow-Rat (Lil' Blue)
 

Thanks!

aaalllllll the tack welds

https://i.imgur.com/ZiwZyso.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

:metal:

i also fully support the 2nd spinny muffler! my usual term is spiral muffler, but i now actually have one that better fits that description ... weird. my goal with this is to only build it once, and if i can fit 5" now i know i never have to re-do it. i can also get less restriction with quieter dual mufflers in 5" cuz i do hope to make more power than that 855 eventually while still being able to have a conversation while driving. same power, same air!

i'm willing to share my CAD if anyone wants it.

so the 12V plan ... this will be a long and twisted road :lol: right now the plan is to basically use it as-is to get things up and running so i can drive it while i detail out the rest of the truck. then add n build it more to kind of document my way thru. i intend to fully instrument the thing with the Banks iDash so i can have all the data showing the good, the bad, and what changed. lets put it this way, i won't be satisfied until i can out-run my wife's daily driver (C7 'vette)

as for the AFC live, i'll actually be building my own. they are a precision air pressure regulator with a bypass switch and orifice valve. the regulator lets you set the max boost PSI that the pump will see, letting you set max fueling. assumes that the AFC spring was swapped out to match your max boost. the orifice valve allows you to slow down how quickly the pump sees this max pressure, giving the turbo's time to spool and making a high HP engine less violent on the street. the bypass obviously just lets all the violent happen ;)

Re: Project: Tow-Rat (Lil' Blue)
 

Yes sir. I've actually got a couple air metering valves I was going to set one up for my truck but they will be going on my wife's burb instead. You can still get some decent power out of that on the cheap until you go all out or at least start going up. Some timing, retorque the head bolts, (over torque LOL), a gsk after you verify its been tabbed, block the waste gate, and the fuel, and have fun.

Re: Project: Tow-Rat (Lil' Blue)
 

i would kill for a p7100 fueled square burb ... nice enough to just leave alone, not too nice that i feel bad driving it in the winter after a full undercoating/sealing.

Re: Project: Tow-Rat (Lil' Blue)
 

Looking good! I like when all the violence happens, it's exciting.

Re: Project: Tow-Rat (Lil' Blue)
 

Same here. I just don't know if I could drive it through the entire winter here because of the brine they put on the roads. I drove my 72 through 1 complete winter when I first got it done and it gets used during winter off and on since. That brine really took it's toll after the first winter and I even washed it. The zinc plated parts were the pieces that rusted first and the worst. Now it needs rockers. I built it to drive it but dang. :lol:

Re: Project: Tow-Rat (Lil' Blue)
 

They started using that brine here in PA over the last few years. It seems they really don't want us to have nice things.

Re: Project: Tow-Rat (Lil' Blue)
 

i LOATH the salt BS ... i always try and drive something i enjoy, but you literally have to have something sacrificial in the winter around here!! my current GMC is on it's way out for sure, already had to replace every last fluid line, the hitch, etc etc

i hate to sacrifice a square burb, but figure if i keep up on it i can at least 8-10yrs before a total restoration to start over with. and for the cost of a new truck i could just pay someone to restore it and still be way ahead of the game.

Re: Project: Tow-Rat (Lil' Blue)
 

They put that crap on the roads up here like there is an endless supply, then follow it up with a good dose of salt.

Re: Project: Tow-Rat (Lil' Blue)
 

sheet metal is so not my thing ... i had to stop the first night i tried to cap the rib before i threw tools thru the windshield. next day took a zen moment and went back to it. not perfect, but good enough to cover in bed liner! i went under the truck and welded it from the bottom so that i could round the edges similar to the stamped rib in the floor.

other progress didn't happen cuz i went n beat on the jeep. wedged myself between a rock and a tree for the first real cowl damage i've gotten. i'm sad, haha

https://i.imgur.com/1a29YcL.jpg
https://i.imgur.com/0hKIGWJ.jpg
https://i.imgur.com/paqnwuu.jpg

Re: Project: Tow-Rat (Lil' Blue)
 

Welding sheet metal is certainly not like welding structural steel. It turned out just fine for a floor that no one is going to see.

I got my Jeep on the trail for the first time with the front spool and the 40's over the weekend. Just some local stuff. I am going to work on the trails at Bantam Saturday, then wheeling SOR on Sunday.

Re: Project: Tow-Rat (Lil' Blue)
 

sat down last night to officially tackle the pc that's been giving me anxiety. first shot with cardboard was a total bust, so tried a new tactic. i covered the entire opening with tape, drew on my bend lines, then cut the tape along the edges. best part about the tape was it then stuck right onto my sheet. cut out, transferred bend marks, and BOOM.

so the sharp back corners of the doghouse are kinda bugging me. i'm debating cutting them out for a 1" 45, but really need to just round them like the floor rib and see how it looks after.

https://i.imgur.com/aM4Rfgj.jpg
https://i.imgur.com/rMsRySW.jpg
https://i.imgur.com/Ie1KGSc.jpg