The "In over my head" build thread

[SeventyOne]

Frame is basically ready to go out to the powdercoater but I have some concerns before I send it.

I will be running a 700r4 and will be moving the engine forward 1 7/8" to accommodate the extra length. I will also be using the DIY crossmember. Should I find the exact location of the crossmember before I send it out for coating? Basically mock up the engine and tranny then tear it down once I know the new location? Or just measure and drill then send out the frame?
-Reason I ask is because yesterday I attempted to mock up the drivetrain and ran into issues across the board: frame seemed to have "shrunk" slightly (frame rails are closer together than before) since the tranny x-member holes are tough to get aligned. Then, the 700r4 seemed to mount differently to the crossmember compared to the Th350 - the mounting holes on the end of the tranny seem rather small in diameter. Maybe I need 700r4 specific mounts/bolts?

Also while mocking up the DIY engine crossmember I tried putting the poly bushings into the tube and they are extremely tight and the bushing won't seat fully in the tube - to make matters worse I can't get the bushing out now. So I can't mock up the engine, and later I need to remove it so I can get it coated but can't. Awesome.

At this point I stopped from severe frustration and daylight running out...

Maybe I ran into all these problems because I am trying to reassemble some 40 year old parts with some new and some aftermarket parts? If anyone has some words of wisdom here I could really use a little advice from those that have been here before. I know there's a lot going on in this post but any help is appreciated.

[SeventyOne]

Ok so I solved part of issue - I completely forgot that the trans-to-tcase adapter is the part that actually bolts to the mounts on the trans x-member - I'll have to bolt that to the 700r4 first.

Now I just need to figure out why the DIY crossmember is not fitting right and try again with a mockup.

Advice from my above post it still welcome : )

[SeventyOne]

Update: 4/12/11

Getting all my chassis junk picked up for powder coating tomorrow

Frame
Transmission Crossmember
Transfer Case Torque Mount
Core Support
Bumper Brackets

In other news I'm looking for a trans and engine builder.

I think it will be a HUGE momentum and morale booster to get some CLEAN parts to work with and start assembling rather then disassembling.

Pics to come when I get them back from the coater!

[SeventyOne]

Update: 5/6/11

Got my junk back from the powder coater.

Before:



After:





Started getting the suspension assembled. These are Alcan springs. 6" front lift and 2" rear lift + 4" ORD shackle flips w/ 4.5" DIY4X shackles. I hope when I get some weight on the springs the shackles get better angles. Front is negative and the rear is straight up and down...



This thing is going to be huge...
I didn't have enough daylight to get the rear together but soon enough!

In other news:
I should be getting a sick little rebuilt 700r4 and the engine for the build (specs to come) before Memorial day. My brother (there's a pic of him elsewhere in this thread) is on leave from the Marine Corps that weekend so I am hoping he will have time and can help me spin some wrenches on this thing!

[y5mgisi]

Dang that frame came out clean!

[Jtrux]

I just read your build, looks good. On a side note about the lugs having a "loose" feeling, I wouldn't see any issue in running it like that since the friction between the rotor and wheel surface will negate any play in the stud, especially concerning the miniscule amount you mentioned. The stud doesn't actually hold the weight of the vehicle anyways, just the friction between the two surfaces BUT it looks like you found a good solution to your problem and i'm sure you won't have any issues. Look forward to reading about some more progress!

[SeventyOne]

Update 5.8.11 - A bolt-on affair

Man I love new parts! Toughest part of getting the suspension back on the frame are the damn poly bushings! But I guess if they aren't snug and tight they aren't doing their job.

Anyways - here are my shackle angles with no weight on the frame...should I be worrying?





Here's the chassis with the suspension and both axles under it. Tires are 37" MTRs for those not familiar.



Frame height at the belly - It's going to be big...



End of the day snug as a bug next to it's better half



I need to get trans crossmember in place but I am having problems getting the bolt holes to align. It's as if the frame is more narrow now. Anyone have any ideas to "spread the rails" while I get the bolts sinched down? I was thinking of cutting a 4x4 post wider than the rails are currently and tapping it in between the rails to get them to spread slightly - trick is not to scratch the powder coating... thoughts?

[cvalcore]

if you dont mind me asking how much did it cost to get the frame powder coated?

[SeventyOne]

Frame alone would have been $600. Not bad in my opinion - the thing is spotless. I got all the brackets, crossmembers, core support, shackles and mics junk for a little more than $900.

[jaros44sr]

how about a scissor jack and a 4x4??

[SeventyOne]

Ya maybe that could work...

Sorta like... [-X-]
if the [ ]'s are the frame rails, the -'s are 4x4's and the x is the jack to spread...

Now I gotta find a scissor jack - oh wait maybe my car has one.

I'll update later...

[jaros44sr]

Originally Posted by SeventyOne

Ya maybe that could work...

Sorta like... [-X-]
if the [ ]'s are the frame rails, the -'s are 4x4's and the x is the jack to spread...

Now I gotta find a scissor jack - oh wait maybe my car has one.

I'll update later...

I would only use 1 4x4, less chance of it slipping...

[ X-]

[SeventyOne]

Your idea would have worked better I suppose but the scissor jack did the trick. Trans crossmember is bolted in with new stainless hardware without much fuss - Thanks Jaros!

[SeventyOne]

Worked on the truck a little more tonight.

The calipers I bought months ago were starting to show some surface rust and since I'm in the chassis build phase it seemed fitting to get them painted up and ready for installation.

Here's a side by side sorta before and after shot:



The paint is a silver engine enamel that looks just like the cast metal of the calipers. Wasn't intentional but I like it.

I then put in the transfer case torque mount (minus two bolts...)



Then I got to thinking about the hardware I will need in the future since new shiny hardware is sooo much nicer than old, rusty, greasy crap...Does anyone know where you can get new Th350 Transmission mount bolts? These are the bolts that go through the crossmember and into the adapter that is sandwiched between the trans and tcase.





They are 1/2" x 13 and about 5-5.5" long. The guy at the hardware store said the looked like starter bolts...Anyways - any thoughts on where to get some new ones? (Yes the one pictured is tweaked/bent)

In other news my engine builder called to inform me my 383 is out of the machine shop and being moved to the assembly room...

[SeventyOne]

Anyone know anything about the bolt in my last post? Where to get replacements or will standard bolts work fine. The stock ones have the beveled end though...

Tonight I disassembled the NP205 transfer case completely. Wasn't all that difficult. We'll see now the re-assembly goes when I get the rebuild kit. In the mean time I can get the case and other parts cleaned up and painted.

I pick up my rebuilt 700r4 on Saturday and my engine could be ready next week sometime...I am buying parts up left and right. It's like I was in this bottleneck waiting for the frame to get done and now it's like a free for all!

[Burt4x4]

Go too OSH and buy G8 bolts. I also used nylon lock nuts on everything.
Lookin good. Your shakels/springs should be fine with all the weight in them. Any reason you didn'i upgrade your front rear shakles? ORD makes a beefy set..I guess if yer not gonna wheel hard you'll be fine

[elzombo]

Let me know how the NP205 rebuild goes. I have been thinking about buying a rebuild kit and doing it myself, but I don't want to open it up and realize that I'm not sure how to put it back together. The dis-assembly always seems to be easier than the re-assembly.

[SeventyOne]

This truck won't be built for hardcore wheeling so I didn't see the need for the shackles. Down the road when I swap to a D60 and do crossover steering I might...

There's a great write up I found regarding the NP205 rebuild. Step by step instructions with pics. I figure If I get lost I can refer to that and an exploded view diagram to get it back together. It's just gears, bearings, shafts, and seals right??

I'll post a link to it when I get it back together with some pics.

[VA72C10]

Nice build! Looking great!!!!

[SeventyOne]

Update 5/14/11 - We're moving now!

Picked up my 700r4 from the trans builder this morning. Real good guy and super knowledgeable. He also hooked me up with a 5 pinion rear planetary gear set w/o charge! Can't wait to get this beast behind the engine!







Here's all the internals of the NP205. I spent about 4 hours today going through the bags and cleaning parts - bolts, cover plates, bearing retainers, etc - to get them ready for the assembly. POR15's Marin Clean is AMAZING at getting 40year old dirty greasy sludgy crap off these parts. It did seem to tarnish the aluminum parts though - I'm not too worried becuase 1: their clean, and 2: it's a Tcase...who cares...



This last shot shows the top of the case where the plugs and shift rail ball bearings sit. I wanted to show this because when I came to that part in the disassembly the top of the case had so much crap caked onto it I couldn't even find these holes! Nasty...



Case should get fully cleaned and masked for paint tomorrow. Seals and new bearings should be coming soon from NorthWestFab.

[SeventyOne]

Nothing much to add. Just boring stuff like painting the transfer case........oh and my engine will be delivered tomorrow....

[Baketown Scotty]

Are you using the stock transmission cross member with the 700R4?

[el3m3nt3l]

build looks great. same color as mine.

[SeventyOne]

Update 5/18

Here's what was delivered yesterday...








383, roller cam & rockers, aluminum heads, Edelbrock Performer RPM intake.

BaketownScotty: Yes, I and using the stock trans crossmember in the stock location. I had the trans built with the Advanced Adapters output shaft so it will bolt up to the NP205 behind it. The extra length that the 700r4 has over the Th350 will be accounted for by moving the engine and crossmember forward.

el3m3nt3l: Yes I really like the stock green color but I don't think it will end up being painted that color in the end...

[VA72C10]