Boardbysled's Budget Buggy Build

zukkev

Cornfuzzled yet again...
Joined
Feb 22, 2007
Messages
14,290
Location
Da Ham, Wa
You sleeved the rearmost upper tube connection, right? If not sleeved and roset welded, it will crack with not much contact form something...ask me how I know! There IS a reason why I now have 2 support braces coming from the side tube...:redneck:
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
You sleeved the rearmost upper tube connection, right? If not sleeved and roset welded, it will crack with not much contact form something...ask me how I know! There IS a reason why I now have 2 support braces coming from the side tube...:redneck:

Yup, all the tube connections are sleeved.:awesomework:
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
No change, been busy with the holidays and honey-do's. Should get started on it again here pretty quick. Should get another pile of parts before long as well.
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Haven't had much of a chance to work on this the last few months, busy with work and the holidays. But I have amassed a pile of parts:

For the Front:
2.5"x14" FOA reservoir coil overs
3 link kit w/7/8" heims from Barnes4wd
2.5"x8" Surplus Center Ram
22"Wx19"H crossflow aluminum radiator from Speedway
Set of Pacesetter headers (stock manifold is cracked to shit)

For the Rear:
22 gallon RCI fuel cell
2.5"x2" FOA air bumps

Still need to get a pile of steel to finish out the rear and start on the front.

20170224_194603_zpsgqxlfz8e.jpg~original


20170224_194610_zpsm6qvxppf.jpg~original


20170224_193704_zpsqomwkbk0.jpg~original
 

jprcrpr94

Active Member
Joined
Nov 22, 2007
Messages
2,451
Location
NE Tacoma
Haven't had much of a chance to work on this the last few months, busy with work and the holidays. But I have amassed a pile of parts:

For the Front:
2.5"x14" FOA reservoir coil overs
3 link kit w/7/8" heims from Barnes4wd
2.5"x8" Surplus Center Ram
22"Wx19"H crossflow aluminum radiator from Speedway
Set of Pacesetter headers (stock manifold is cracked to shit)

For the Rear:
22 gallon RCI fuel cell
2.5"x2" FOA air bumps

Still need to get a pile of steel to finish out the rear and start on the front.

20170224_194603_zpsgqxlfz8e.jpg~original


20170224_194610_zpsm6qvxppf.jpg~original


20170224_193704_zpsqomwkbk0.jpg~original

Also been busy with completely destroying the old rig on the busy. :fawkdancesmiley::haha:
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Worked on this a bit today for the first time in a few months...

got a 2.5"x8" Surplus Center Ram.

20170303_172027_zpslu2tr26a.jpg~original


Was able to take a closer look at some of the stuff in the parts pile. Kinda disappointed with the quality of the FOA shocks and bumpstops. But they aren't leaking oil yet and the price was cheap enough to put up with some cosmetic issues. Not sure on the dual rate slider with 2 short sides though...

20170304_163510_zpscavwuxio.jpg~original


20170304_163600_zpsf1wwlodp.jpg~original


Hard plastic pads on the bumps should hopefully mean they are at least somewhat quieter then the all aluminum style.

20170304_164036_zpsft2q9uop.jpg~original


Looks like they should fit good on the rear axle. Little worried about fitting 2.5" on the front, guess we will have to see when I get it all mock'd up.

20170304_171648_zpspfbsdwj7.jpg~original


Corners of the RCI cell are all beat up. Should be able to straighten them out though.

20170304_170347_zpsu83grel3.jpg~original


Threw the fuel cell in to see how well it fit. Fits almost like I had planned for it all along! Should be plenty of room behind it for tool/spare storage. It will sit an in and a half lower when it is all said and done. Plenty of link clearance.

20170304_171533_zpsjiwk3eqz.jpg~original


20170304_171558_zpsw5jcm7zn.jpg~original


20170304_171537_zpsixjpdlx9.jpg~original
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Started mock'n up where I am going to add some more tubes in the rear.

20170304_172633_zpse2jcqxz5.jpg~original


20170304_172645_zpsllmoxx47.jpg~original


20170304_172654_zpsle7yxghd.jpg~original


Worked on tearing the body forward of the firewall today. Plan is to chop the inner fenders/core support off at the firewall and tube it out forward of there and the motor mounts.

20170304_180850_zpshdyfsidi.jpg~original
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
The time came to steal the good parts off my original Pathy. It will be sad to take it to the scrap heap, but the time has come. It was my first vehicle and the one I really learned how to fix/fabricate on.

20170228_132034_zpsctbpcuo7.jpg~original


Got the t-case setup out of it along with the front axle, rear third member, and some other goodies.

20170402_164256_zpsxyxdy6ap.jpg~original


Little more work on the cage. Got the roofbars in.

20170416_190438_zpsuo3xjx6w.jpg~original


20170416_190420_zpscaibjqqo.jpg~original


Tied to cage into the door hinge mounts.

20170416_142316_zpsljz8eagk.jpg~original


Got some more goodies: Trail-gear orbital, mount, & column and 2"x2" FOA bumpstops.

20170502_182742_zpso3o13jux.jpg~original


20170509_193809_zpsseidlwuh.jpg~original


Been slowly working on cutting all the un-needed junk off the front:

20170325_170922_zpscaiy4ka4.jpg~original


Finally got the front suspension cut out of it today.
20170514_183708_zpsrhyuxhwk.jpg~original


Next step is to get the front of the frame cut-off in front of the motor-mounts, get the new front frame-rails built, then mock up the front axle/suspension.
 

crash

-Oh no I picked a side-
Joined
Mar 25, 2001
Messages
39,839
Location
Da gold bar
Lookin good. My original plan for my rig was to do the same and remove the frame rails forward of the motor mounts.. Keep it up...
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Glad to see photobucket changed their linked images policy. I will update this with some fresh pictures! Haven't made as much progress as I wish but starting to move forward pretty good now.

Onto pictures!

Manual transmission TX-10 t-cases have this little lip on the input of the t-case. Auto TX-10 t-cases simply have this lip removed. So I cut the lip off my manual TX-10 range box and it bolted up perfectly to my auto trans.

20170730_153353_zpslqbesu08.jpg~original


20170730_172528_zps9hcw6bvl.jpg~original


Took the old rig to scrap, was a sad day, it was my first vehicle and I had owned it almost 10 years, 8 of those being SAS'd. It taught me a lot about wheeling and fabrication.

20170913_133039_zps57ubl4yr.jpg~original


Came home with a fresh load of tube

20170913_151311_zpss2kqo0cz.jpg~original


Finished out some tube work in the rear

20171001_163616_zpssmzcjbxh.jpg~original


IMG_20171112_171713_341_zpsfvj7pmgh.jpg~original


Built a mount for my 26 gallon fuel cell

20171007_182218_zpsxzs4jdpo.jpg~original
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
More parts arrived

20180218_173535_zpsdd4ndjne.jpg~original


Some sweet Ruff Stuff gussets

IMG_20171001_163920_222_zpsa3hwzwrg.jpg~original


And a heavily discounted Ruff Stuff aluminum rear facing lightbar

20171001_142903_zpse9d3c5ns.jpg~original


Started work on the front end. Chopped the frame just behind the motor mounts and started my tube frame.

20180304_150256_zpsf7lcfdcr.jpg~original


Started eyeballing the radiator placement

IMG_20180318_155341_530_zpsrrgep7d5.jpg~original


Custom motormounts built

20180318_201043_zpsq9gjhsht.jpg~original


Front radiator support hoop coming together

IMG_20180325_181846_710_zpsfh6agfs3.jpg~original


Hoodline bars in

IMG_20180407_180932_546_zpskiv90twz.jpg~original


And cross tubes/support tubes that I will build the front coil mounts off

IMG_20180421_195022_829_zpsbeq7hnxp.jpg~original
 
Last edited:

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Mock'd up the t-case setup. The D300 will allow for a flat belly, but the range box sits about 1.5" below the frame. We will see how it ends up.

20180415_160022_zpss1omflyp.jpg~original


Couldn't find a frame side panhard bar mount for tube I cared for, so I started building this one

IMG_20180422_202601_270_zpsyixsmvqp.jpg~original


Front axle all cleaned up and started the cut and turn. Shooting for 8-10* of caster.

20180428_192553_zpsxho4ewpy.jpg~original


Started on some custom high steer on the D44 knuckles.

IMG_20180512_182131_120_zpsie0hghwo.jpg~original


Got some sweet 2 1/8"x36" 7075-T651 aluminum round bar for $26 a piece off Amazon! Should make some sweet bling-bling links.

IMG_20180505_163059_882_zpsdi7ut1sp.jpg~original


Got the Speedway radiator mounted top and bottom along with the Derale 2 speed fan and shroud mounted

IMG_20180506_183653_416_zpsll7jsspr.jpg~original



And that pretty much catches us up. Next up is getting the steering ram mounted, front links setup, and then the front shocks and bumpstops mounted. Then need to work on getting the PSC steering pump and GM 1-wire alternator mounted.
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Had the Waggy D44 (with chromos, locker, and the right gearing) from the old rig, just going to reuse it. If I do anything else, I will likely go straight to a SD D60, but going to run this for the time being.

It may end up closer the 8* of caster range depending on what ride height and driveshaft angles look like. I was just really sick of the stock 1* of caster the waggy axle had. It will be full hydro, so steering effort shouldn't be an issue.
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Little more progress.

Got a PSC TC pump mount made.

20180604_173556_zpsvkg6rslc.jpg~original


Single wire GM 110 amp alternator mount made.

20180604_173631_zps7be1si9u.jpg~original


Dragged the axle back under the front to start mocking up the suspension.

20180609_210110_zpsgn2wzl9a.jpg~original


At full bump, axle pumpkin gets into the alternator mount.

20180609_210130_zps69k8116b.jpg~original
 

boardbysled

Tree Nerd.
Joined
Jun 10, 2009
Messages
4,467
Location
NW Oregon
Decided to sleeve the passenger side frame rail for the track-bar mount.

20180617_153935_zpsdwv4xibo.jpg~original


Track-bar mount built.

20180617_190745_zpse13sh54d.jpg~original


Got my China-Spec power steering cooler mounted.

20180617_190753_zpsjtbhsxmg.jpg~original


Oil pan hangs way too low. Looks like a 2wd pan will be a good replacement and give me some clearance.

20180617_174724_zpsskrbbgmw.jpg~original


And a current overall view

20180617_190818_zpswqktwq15.jpg~original
 
Last edited:
Top