Project "Dream Truck"

[abadsvt]

Well i went downstair right after you gave me that idea. I cut off the factory alluminum mounts and then pressed out the rubber and the remaining alluminum. Then i remembered i bought a set of rubber inserts for my old cantilever suspension set and was curious if they were similiar sizes. Turned out that they we almost perfect. I had to lightly sand it a little to make it fit but i couldn't believe it. What luck! I only have 2 sets and i need 4 but i am sure i can order some more. Also the rubber bushings had the metal sleeve that goes inside. I didn't press it in because i wanted to double check and make sure that it is "thick" enough. I think it might be .120 but might be just one size down from that. Here are a couple pics of the one side i did. Also a pic of that metal sleeve. How thick do you think the metal sleeve should be? Thanks again

Josh

[abadsvt]

Well i got the other side done. I think it looks much cleaner.

Josh

[Frizzle Fry]

Nice! That sleeve looks like it's more than enough for the job.

[abadsvt]

Well i got a little creative on the upper control. I wanted something clean and not so big like the factory mounts. So i was talking to my father when some how we got on to the conversation of his mill and how i never have used it before and would like to learn. So he gave me a quick run down on how to use it and i went to town. I want to grab all sorts of steel and mill it down now to something cool. So this is what i ended up making. I took some 1 1/4 solid cold rolled steel pipe and cut it down to length. Then i drilled and tapped it for a 9/16 fine thread bolt. After i got done with that i started using the mill to achieve the shape i was looking for. After a while of using the mill i was done. Then i finished by drilling the two 1/2" holes. I drilled and tapped 1 1/8 of usuable thread for the 9/16 bolts. Here are some pics. Like always if you see something that i forgot or could modify please let me know.

Josh

[abadsvt]

a couple more. I was very camera happy.

[FnLow69]

looks way cleaner, nice job.

[BigSky71]

Note to self [me]; buy a lathe and a mill and learn how to use them...

Looking great man, love your work!

[abadsvt]

Well i roughed in the mount for the control arm this morning. I think i like it. I am not sure how to finish the lower part that goes at an angle. I am not sure if i want to blank it off like it did with the other setup or just add another gusset in the middle. Also i didn't add the inner support gusset on the inside of the bracket because i was going to have the shockwave mounts tie into the bracket to reinforce the bracket and give the shockwave a nice solid mounting piece. Next weekend i will hopefully get the shockwaves installed in the front so i get that all finished. Here is a few pics and hope you guys have a MERRY CHRISTMAS!!!!!!!

[IvelDesigns]

great work man. some day in the distant future I'll have the room for all of the toys/tools you have.

[poorboy]

Josh actually does not have a huge shop. He works out of his 2 car garage right now.

[pcorriveau951]

any more progress? great job like the new upper control mounts.

[abadsvt]

Originally Posted by pcorriveau951

any more progress? great job like the new upper control mounts.

Actually i got alot done. I have been waiting to post some pics until i get it all done. Maybe this weekend i will snap a few pics. By next weekend i should have all the suspension done, frame pretty much completed except a few little things, and i should have the motor, new extended torque tube, and the rear end all installed.

Josh

[Rokcrln]

Josh your frame is looking very well thought out and built! Who did your torque tube for you and if I may what kind of $ are they charging for it? I have been toying with some C5 ideas but teh tube is the one area I have not yet looked into.

Kevin
LFD Inc.

[abadsvt]

Originally Posted by Rokcrln

Josh your frame is looking very well thought out and built! Who did your torque tube for you and if I may what kind of $ are they charging for it? I have been toying with some C5 ideas but teh tube is the one area I have not yet looked into.

Kevin
LFD Inc.

Thanks kevin for the complements!! I extended the torque tube. I will have it finished today. It was a big job and ended up taking alot more time than i thought but came out PERFECT! I made a jig to hold the bellhousings inline and square. The hardest part was milling out the two bellhousings from the tube without running anything. I was going to take some pics of the new tube today and i will explain a little more. I am not extending the alluminum driveshaft though. I am going to have a carbon fiber driveshaft built to replace it. A new driveshaft is going to run around $600. It is looking sweet and completely different than what i am used to seeing which i love. Anyways i will talk to you soon.

Josh

[abadsvt]

Well i got the motor, torque tube, transaxle all put together in the frame. The only that sucks is i am going to have to replace the oil pan. I was hoping i wouldn't have too but the motor needs to drop a little more to make everything level. So right now the motor, torque tube, and the transaxle are at a slight angle until i get a new oil pan. I extended the torque tube yesterday and today which was very time consuming. I made a jig that held the factory torque tube so nothing would get twisted or unlevel. Then i cut the alluminum tube and took it over to my fathers house to use his mill. I used his flycutter to cut the inside of the bellhousings to remove the pressed in and welded alluminum tube. I ended up having to flycutt .050" more so the new tube would fit on both sides. I wanted it to fit in the bellhousing without any slop or play so that took a little while. After all that was done I was able to weld it up. It came out perfect. I am hoping to send off the driveshaft next week to have the new carbon fiber drivshaft built.

I finished the front suspension yesterday also. I wasn't able to use my new designed control arm mount because i couldn't get enough clearance for the shockwaves. I ended up having to use the factory style mount and use 5/16" camber spaces to give me clearance for the bags. I could have used a shorter shockwave but i want all the lift i can get which isn't much. I think i will get right around 5.5-6". I ordered new poly bushings for all the control arms which are supposed to make a big difference in the handling compared to the rubber ones now. Tuesday i get them so hopefully i can get them pressed into the front control arms so i can hook up the passanger side upper control arm.

I still have to finish bracing up the front rails but wanted to see if how the new oil pan sits so i don't have to change anything. Also since the torque tube is installed i can modify the main rails tomorrow and get those finished.

Josh

[abadsvt]

A few more pics

[Frizzle Fry]

Nice progress. Finally someone with some info on extending a torque tube!!! You know we need more pics and details on that!

[abadsvt]

Originally Posted by Frizzle Fry

Nice progress. Finally someone with some info on extending a torque tube!!! You know we need more pics and details on that!

I didn't take any pics when i was taking it apart and putting it back together. I should have and wish i did but i was caught up in the moment trying to get it done. Its funny because before i decided to do it i could not find anyone online that had any experience with the torque tube. I have only found a 3 cars or trucks that have had them extended but no details anywhere. What kind of info are you lookin for?

Josh

[abadsvt]

Well i got a little more done today. I finished bracing out the center section of the rails. It is nice and strong now. I also couldn't resist putting on one of my wheels to see how it looked with the new frame. I LOVE IT. Hopefully tuesday i will get my part so i can put all 4 wheels on and see how it looks. I can't wait to get the frame off the jig and on to the floor. It will look completely different. Anyways here are a few more pics

[FnLow69]

Dang josh, looks killer. cant wait tell my frame gets that far.. also cant wait to see it on the ground...

[Rokcrln]

Looks great, love the wheels!

Kevin
LFD Inc.

[Frizzle Fry]

What are the specs on the tube itself and who did you order the shaft through?

[abadsvt]

Originally Posted by Frizzle Fry

What are the specs on the tube itself and who did you order the shaft through?

The torque tube is 5" OD 3/16" thick. The new tube i ordered ended up being about .0500 bigger than the stock tube. I extended the torque tube 13.75" from stock. I wanted the motor to be tucked into the firewall as far as it could go but still have access to things. I haven't ordered the driveshaft yet because i am shuffling my money around to keep progressing. When i do order it it will be through PST. If you need the number just let me know. I saved it in my phone so i wouldn't loose it. The carbon fiber driveshaft is going to be around $600 plus shipping. At least that is what i was quoted. Are you thinking a different route for your c5 project?

Josh

[abadsvt]

Tonight was a great night. I finished up the motor mounts so FINALLY the drivetrain is self supported. I know i have alot to do still but i really feel like i will be finished with the frame soon. I also got the new poly bushings for all of the control arms so i was able to put back the passenger side upper control arm and put my wheels on. Anyways here is the only pics that came out of the new motor mounts.

Josh

[GMracer]

I new around here big on a couple other forums, but I couldn't leave without saying how amazing this project is, keep up the good work.