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TeraFlex Now at Rockridge 4WD! BEST DEALS around!Alloy usa heavy duty ball joint kitsENGO QUADLUX 6" to 54" LED AMBER AND WHITE MULTI

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Unread 10-01-2011, 05:01 PM   #646
mudhunter51
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1999 TJ Wrangler 
 
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Ok thanks for the information. I'll have to look into that more

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Unread 10-02-2011, 07:08 AM   #647
djflyy
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Yesterday the spindle arrived from Comp 4x4. Pretty quick shipping from Utah, it was here in 3 days via USPS which is pretty much unheard of. This thing is BEEF. Solid beef. Like, burger beef. I couldn't believe it, and was almost glad that I didn't order the "mega" version as I don't know if it would have fit in the bumper! I have no doubt of this things ability to hold the swing arm on, as long as I can get enough penetration with the welds into the bumper.

Here are a few quick pictures of the spindle for anyone considering buying it. $65 delivered, and it came with an extra shaft for the spindle to go into for a more secure mounting in the bumper. I took a photo of it next to a soda can just so you get an idea. Also did some engine work on the Audi

Bumper modification starts today.












One of these things is not like the other.........

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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-02-2011, 07:44 AM   #648
Kenbo-Slice
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I don't want to sound like an ***, but I also don't want you be be disappointed with the final product....

Make sure your material is clean, try to get a better ground on the material and if you have access to a larger welding machine, use it to burn in the spindle. That Hobart is not going to have enough oomph to appropriately get the job done. What material are you using, what are the wire speed and heat settings you're currently using? Also, I'm assuming the machine is set up with 0.030 flux core?
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Unread 10-02-2011, 09:09 AM   #649
djflyy
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Quote:
Originally Posted by Kenbo-Slice View Post
I don't want to sound like an ***, but I also don't want you be be disappointed with the final product....

Make sure your material is clean, try to get a better ground on the material and if you have access to a larger welding machine, use it to burn in the spindle. That Hobart is not going to have enough oomph to appropriately get the job done. What material are you using, what are the wire speed and heat settings you're currently using? Also, I'm assuming the machine is set up with 0.030 flux core?
No worries, I appreciate the input.

The 140 is the largest I have access to. I've been running it at 45 ipm and on the 4th power setting, going very slowly. It's .03 flux core. I'll be wire brushing/sanding the bumper before beginning. I was also planning on adding gussets in 2 or 3 positions to try and make it stronger. As far as getting a better ground, how would you suggest going about that? The clamp on clean metal is about as best as I could think of.

For what it's worth, I'm not rushing through this. I know that the spindle is going to be a little challenging for the welder since it isn't the 187 or any other 220v.

Thanks for any advice/suggestions.

Edit: AFAIK, using a 75/25 mix would decrease the amount of heat from the welder. From what I've read, flux burns hotter, correct? No benefits to be seen from switching to argon/c02 now?

Edit Edit: I might actually have access to a 220v at my dad's friend's house. That might make this all easier for the spindle welding.
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Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-03-2011, 12:23 AM   #650
CanadianCody
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Hey man, love everything you have done to your jeep. The black on red is awesome, just read your entire thread and now it's 2:30 in the morning. Keep it up man!
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Unread 10-03-2011, 09:38 PM   #651
djflyy
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Today I cut the hole (1 3/4" hole saw) and cut the spindle. One thing that I had heard from people was that there was going to not be enough surface to weld the spindle to the bumper for a strong hold, so I made a plate for the spindle to weld to that I will then weld to the bumper. I'm not sure if this will give me any gains vs. just welding the spindle, but it seemed in my head like the increase of surface area to weld to would help with strength. If I'm wrong, don't kill me. It's only my second true welding project.

So I cut the spindle down at a 45 degree angle, and made this plate of 3/16" steel welded. Did an high amperage burn in very slowly with deep penetration to secure the plates. Tomorrow I'll weld the A-frame to the spindle and secure the shaft into the bumper.

I did have to cut the bumper up to get inside of it. so I'll be re-welding that as well. All in all, I think this should be a successful project.













The spindle will weld to the top plate in the following pic:

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Quote:
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Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-04-2011, 06:28 AM   #652
NBFarmboy
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That looks like it will work out great
Great idea and it looks just as good!!!

Stalking your thread from the comforts of my tractor .... seriously!!!!
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Unread 10-05-2011, 12:17 PM   #653
djflyy
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Got bored at work (Audio Engineering for the Substance Abuse and Mental Health Services Administration 2011 conference) and decided to draw this! Looks a tad JK-ish, though.


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Quote:
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Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-05-2011, 02:13 PM   #654
2003X
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lol
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Unread 10-06-2011, 06:52 AM   #655
djflyy
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http://jmak.tumblr.com/post/9377189056
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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-06-2011, 10:28 AM   #656
MagnumPI
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Today is indeed a very sad day, well yesterday and today...
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Unread 10-06-2011, 11:55 AM   #657
djflyy
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Quote:
Originally Posted by CanadianCody View Post
Hey man, love everything you have done to your jeep. The black on red is awesome, just read your entire thread and now it's 2:30 in the morning. Keep it up man!
Thanks! Glad you enjoyed it. I suppose I should mention there's "more to come!" although I'm just meandering along enjoying it!
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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-07-2011, 10:48 PM   #658
djflyy
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Well I had the day off from work today, so I slaved at my tire carrier in hopes of finishing and being able to paint it tomorrow (weather is supposed to be upwards of 75 degrees this weekend). I started working around 9 AM and finished around 7 PM. You'll notice the final photos are in the pitch black with the camera flash being the only source of light. Needless to say it was entirely worth it, as it's now COMPLETELY done! Just need to do a few more layers of paint and let it dry, then mount 'er up.

I started the morning with the spindle. I was nervous about not mounting it perfectly level, so I had 3 different air-bubble levels on it at once so that I could make sure it was straight from all angles. Once that was all set, I tack welded the bottom spindle plate to the bumper and re-checked all my levels (a little OCD, and I admit it). Then I fully burned the plate in. Lots of surface area covered by these welds, so I have a lot of faith that this thing isn't going anywhere. Post-welding the spindle plate, I mounted up the swing arm as a mock-up to see how it looked. Surprisingly, it was level and worked beautifully. I used 2 chlorine bottle covers from the hot tub to keep the height of the arm up, and drew out the cut in the A-frame arm that would be needed to meet the spindle end. 5 minutes with the angle grinder and everything was matched up. Same gig from there, tack weld then final burn in. I did add a gusset to the arm for some extra support as many people on here had suggested doing.

After that was mounting the latch clasp, welding that plate in, and then finishing the tire mount. I had some problems with the tire mount as the largest drill bit I've got at the house is a 1/2"..... the end of the lug studs are just under 5/8". SOOO... much to my annoyance, I took my small hand file and filed away at the 3/16" steel until everything fit. Then took a hammer and bashed the crap out of the lugs to seat them all the way, then welded them in. From there, welded the plate to the A-frame, and added a gusset as everyone in the Fab forum suggested.

Then it was time to paint! I hung it off a rope in the back yard and shot it with Rustoleum Hammered. First coat went well, then I realized I forgot to weld the latch on... oops. So I took it down after dinner and welded the latch, as well as re-welded the back of the bumper on so that I can mount it back on the Jeep.

Tomorrow it'll all get hit with a few more coats of the Rustoleum, then I'll bolt 'er up and work on some frame tie-ins to get the weight off of the crossmember. All in all, I'm pretty happy with this silly thing. Tons of pics... enjoy!!!


















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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-07-2011, 10:49 PM   #659
djflyy
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More photos........
















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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 10-08-2011, 05:18 AM   #660
SaxManClay
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Nice job!
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