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Above 1200 Sq/FT Finally build my, long needed, shop
- Thread starter Michael B.
- Start date
Wokspaces above 1200 squarefeet.
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Michael B.
Well-known member
I have been cleaning and painting parts for a few weeks and today I bolted some of them on the frame.
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Michael B.
Well-known member
Lots of little parts getting cleaned, painted and installed. I hope to have the rear axle back this week 
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Michael B.
Well-known member
I also won a set of party lights at the office Christmas party last Wednesday. They’re Edison style LEDs.
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Michael B.
Well-known member
Yesterday I found out the carrier in the rear differential has excessive wear and the ring gear has rust pitting. Apparently letting the axels sit with the vent tube capped generates condensation. Fortunately I had a spare carrier in better condition. Unfortunately the gear ratio was different. So I’m going to need a new ring and pinion.
Then today I opened the front differential up to inspect it and found one of the spider gears chipped. Hmmmm, Merry Christmas
Then today I opened the front differential up to inspect it and found one of the spider gears chipped. Hmmmm, Merry Christmas
SilverJimmy
Well-known member
I’d run it! Everything else looks good, I’d even run the rear end. That’s just me, but I’m the guy who put a worn out forklift back together. It does run good tho….
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Michael B.
Well-known member
Loaded up and heading to the transmission shop.
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Michael B.
Well-known member
I have spent the last few weeks disassembling the front axle. Taking a Dana 44 apart is a new adventure for me. I have learned a lot. Mostly that these units are expensive to build.
Now that it’s apart I spent yesterday cleaning all the nasty parts and today I started sandblasting. I got about half of them blasted and painted. Next weekend I hope to get the other half finished.
I also bought and installed Green Hinges for all 3 of my roll up doors. Installation was very straight forward and they function as advertised.
Now that it’s apart I spent yesterday cleaning all the nasty parts and today I started sandblasting. I got about half of them blasted and painted. Next weekend I hope to get the other half finished.
I also bought and installed Green Hinges for all 3 of my roll up doors. Installation was very straight forward and they function as advertised.
jollygreengiant
Well-known member
What are these green hinges you speak of?
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Michael B.
Well-known member
The link above should help. There are also numerous YouTube videos about them as well.
jollygreengiant
Well-known member
The link above should help. There are also numerous YouTube videos about them as well.
You know it's kinda funny, I was thinking to myself recently that this site hasn't cost me any money lately which was quite odd. I guess it is a new week lol.
Thanks for the link. Seriously considering those for my garage door.
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Michael B.
Well-known member
Ummm…. You’re welcome?!
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Michael B.
Well-known member
The 14 bolt was finally finished. So I picked it up and moseyed over to the transmission shop and retrieved all of my stuff. The little truck was loaded down pretty heavy. I rode home bouncing off the bump stops.
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Michael B.
Well-known member
Finally some picture worthy progress.
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Michael B.
Well-known member
SilverJimmy
Well-known member
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Michael B.
Well-known member
Jimmy those are 16.5’s. I haven’t settled on tires yet and I know the options are slim. But there is more than one option for that rim size. I suggest going to a local tire supplier, if you haven’t already, ask them to search for availability. When I asked my local guy, he had a few options available. It was a couple of months ago, so I don’t remember the brand names. I think General Gabbers were on his list.
BTW, I’m looking for a 5th rim for my side mounted spare, if you know of any available I would appreciate the lead.
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Michael B.
Well-known member
I think I discovered some new shop music tonight.
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315K views · 12K reactions | Enlly Blue – Rust & Roses | Miswati
Enlly Blue – Rust & Roses
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Michael B.
Well-known member
I made a little progress this weekend. The upper and lower ball joint’s are installed. The u joints on the axel shafts are installed as well as the new rear brake lines.
I dropped the front axle off at the shop on Friday. He says about 2 weeks, hopefully that is an accurate quote.
When I was installing the u joints, I discovered that the “ears” on the inside right shaft are bent. Apparently I applied a little too much pressure during removal. Now one of the cir-clips can’t be installed. I’m reluctant to attempt to straighten it, as I think the metal integrity would be compromised. So a new one is on order.
View attachment 4078944View attachment 4078946View attachment 4078952View attachment 4078953View attachment 4078956
I dropped the front axle off at the shop on Friday. He says about 2 weeks, hopefully that is an accurate quote.
When I was installing the u joints, I discovered that the “ears” on the inside right shaft are bent. Apparently I applied a little too much pressure during removal. Now one of the cir-clips can’t be installed. I’m reluctant to attempt to straighten it, as I think the metal integrity would be compromised. So a new one is on order.
View attachment 4078944View attachment 4078946View attachment 4078952View attachment 4078953View attachment 4078956
jollygreengiant
Well-known member
Pics didn't load.
Can confirm. My 'net connection was sketchy when I first saw that post last night, I thought it was just me.
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Michael B.
Well-known member
Thanks for the heads up guys.
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Michael B.
Well-known member
I’m was a busy day in the shop. Three oils changes, a set of rotors/pads and a CV axle. Nothing picture worthy
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Michael B.
Well-known member
Well it’s one step forward and two steps back. Late this week my axle guy informed me that the housing has a hole in it. I was gob smacked honestly. He said something had come loose and was shoved through the housing after making a mess inside. The PO had epoxied the outside and RTV’d the inside. The epoxy had collected dirt and appeared to be a dirt clod until the pressure washer hit it.
So I have spent the weekend searching for a replacement. No luck so far, but I’m going to look at another one today.
So I have spent the weekend searching for a replacement. No luck so far, but I’m going to look at another one today.
SilverJimmy
Well-known member
Now is the perfect time to search for a 3/4 ton van rearend so the rear track will be the same as the front. I believe NAPCO also made the rear the same width as their front axles back in the day.
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Michael B.
Well-known member
@SilverJimmy , I already have a 3/4 ton 14 bolt, freshly built, in the rear. Plus it is intentional that 4x4’s have offset tracking.
SilverJimmy
Well-known member
Sorry, missed that the bad axle was a front. You’re going all in on making this a beauty!
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Michael B.
Well-known member
I ran a mission this weekend. I borrowed a mini skid on Saturday and this afternoon I retrieved the Dana 44 I found about 2 weeks ago but couldn’t get because of wet red clay.
The mission was a success. Nothing broken and nobody bleeding.
The mission was a success. Nothing broken and nobody bleeding.
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Michael B.
Well-known member
Dana 44 2.0 ready to go. The disassembly took significantly less time. I guess you can teach an old dog new tricks after all
My axel guy is ready to receive it next Monday.
My axel guy is ready to receive it next Monday.
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Michael B.
Well-known member
Last Sunday it was sunny and 77* as I loaded the axle for delivery on Monday. The picture says everything that needs to be said about Monday.
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Michael B.
Well-known member
While I’m waiting on the front axle, I decided to tackle the biggest sheet metal challenge on this project. I harvested the roof skin from a parts truck. Now I’m preparing the donor patch and getting ready to scalp the cab.
This little job wasn’t nearly as much fun as it would appear.
This little job wasn’t nearly as much fun as it would appear.
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Michael B.
Well-known member
The deed is done. I drew out my cut lines and started cutting.
I almost had a heart attack. As I made the first cut along the front, the roof literally started popping up as it was cut free. I couldn’t imagine why the roof skin would have so much tension in it. Then I remembered why I was cutting it off in the first place. When the sunroof patch was welded in they really did a terrible job of it.
I also broke in a new welding glove. After setting my left Mechanics Wear glove on fire with cutting slag.
I almost had a heart attack. As I made the first cut along the front, the roof literally started popping up as it was cut free. I couldn’t imagine why the roof skin would have so much tension in it. Then I remembered why I was cutting it off in the first place. When the sunroof patch was welded in they really did a terrible job of it.
I also broke in a new welding glove. After setting my left Mechanics Wear glove on fire with cutting slag.
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Michael B.
Well-known member
I removed the rest of the roof skin from the front edge of the cab. Then I wire brushed the inner structure of the cab and applied a rust reformer product. I also finished prepping the replacement skin. None of the inside roof skin will be visible with head liner installed. But I want a sealed coat of paint on it anyway.
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Michael B.
Well-known member
After weeks of staring and maneuvering the patch around, I started tacking it down. Apparently all 55/56 cabs are not identical. The patch was not a 100% match. Honestly a lot of the issues were probably me and my inexperience. Once I had it tacked on I had a “bulge” on both sides. They also were not “bulging” equally. My resolution was to make a strategic “relief” cut. I think this is going to work well enough.
Don’t hurt yourself laughing at my welds. I may be an awful welder, but I’m a terrific grinder
Don’t hurt yourself laughing at my welds. I may be an awful welder, but I’m a terrific grinder
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Michael B.
Well-known member
Finished welding, started grinding. Man I wish I was a better welder!
M.Brane
ALLIANCE MEMBER
Sheet metal is tough. Looks like you could have cleaned it up better before melting. You really can't have things too clean. I learned that welding gas tanks.
jollygreengiant
Well-known member
Hey those welds are better than mine, and on sheet metal too! I hate sheet metal, I either blow through it or don't get enough penetration.
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Michael B.
Well-known member
Thanks! I usually am better with sheet metal. I was a lot better with flux core. I haven’t quite figured this mig unit out yet. I certainly need more practice. I probably need to invest in a better helmet. I constantly struggle with seeing my welds.
M.Brane
ALLIANCE MEMBER
The right wire helps a lot. .023-inch or .025-inch ER70S-6