Time for a Four Seater - Buggy Build

[Herzog]

Well, that front axle gave me hell today so I didn't ever get to the rear end. Maybe next weekend. But I did finally finish setting up the gears on the front end and threw a lube locker from Summit Machine and a heavy duty Teraflex diff cover on it. (Thanks TeraFlex! )



In between pulling bearing and scattering shims all over the place I did a lot of cleanup of various parts and painted quite a bit. Next session the buggy will start to be put all back together.

 

[cruiseroutfit]

 

[Bart]

NICE!!!

 

[rockreligious]

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This thing is a life saver. Borrowed from a friend, cuts through the sheet metal quickly and painlessly.
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what is this? is it just a skill saw with a metal blade, or is it a special saw?

I need one of these.

 

[Herzog]

what is this? is it just a skill saw with a metal blade, or is it a special saw?

I need one of these.

Metal cutting circular saw.

Same as this one: http://www.amazon.com/Milwaukee-6370-21-8-Inch-Cutting-Circular/dp/B0000WUQI4

And it kicks much ass. It is pretty much sparkless while cutting too.

 

[rockreligious]

Metal cutting circular saw.

Same as this one: http://www.amazon.com/Milwaukee-6370-21-8-Inch-Cutting-Circular/dp/B0000WUQI4

And it kicks much ass. It is pretty much sparkless while cutting too.

Im going to have to save up and buy one.

Rig is looking awesome, keep up the good work.

 

[Herzog]

Anybody have info on this flange? Is it a 1410 or 1350 Flange? Appears to be 4.25"... not sure if it actually uses all 8 holes for mounting or just 4. I wouldn't mind using this flange that came on the rear axle if I can find the matching end. Also, my atlas has flanges that are drilled to this same pattern, plus 1310 flange pattern and one other so that's a bonus for making this rear driveshaft the same on both ends.



Setup the rear axle. The OEM (D60u) carrier used thick shim spacers on the outside of the bearings similar to a d35, but the shims were not fragile castings. The OEM bearings were also shimmed on on the inside too. I was concerned about this but it appears that the only difference to allow the use of the outer shims was that the oem carrier was machined down slightly more where the bearings press on. See pic below:

OEM D60u (1999 Ford E350) carrier | Normal OEM D60 carrier


Spit shined & added a tera cover!

 

[Herzog]

With the axles setup, I decided I would plop the engine back in and start puting it back together.

 

[Herzog]

I then took the oportunity to clean and paint most of the parts while assembling. Probably took up most of my time. Glad that's over with.

This is the first time the rear shafts have been in the rear housing. Looks like my measurements all worked out.


Decided not to rebuild the king pins. They were in pretty good shape.


Here's how she sits now.

More misc pics below. Yeah the engine is still pretty dirty.

 

[chadschoon]

Looking very clean! Looks great.

 

[Amy]

That is a lot of hard ass work babe! Looks amazing!

 

[Greg]

Nice Shane!! It's coming together now, keep up the hard work!

 

[I Lean]

Awesome! Did you get it weighed? (curious to know what it tips the scales at)

 

[Herzog]

Awesome! Did you get it weighed? (curious to know what it tips the scales at)

Not yet. I figured I'd better get almost everything in it and then also account for fluids and full time gear.

 

[Bart]

Sweet, it's getting close.

 

[Kiel]

Looking sweet!

 

[xtremexj]

Looks great! Won't be long now.

 

[Herzog]

Just some more updates.

Added some bling to my non-bling build. Thanks Summit Machine!
Best drive flanges in town.

So now the front axle is complete. 5.38 gears, detroit locker, OEM inners for now, spicer joints, yukon 35 spline outers and finished it off with the drive flanges.

I also got most of the fuel lines ran. Still need a different fitting and a run of hose down to the pump and I also need to route the breather but the supply and return is ran all the way up to the fuel rail.



ECU & TCU mounted under dash, shifters in place... checking fit of center console cover.



And started building a tail shaft support for the atlas. Yes I'm cheap like that.

 

[GOAT]

nicely done sir

 

[Herzog]

Today I got the dashboard top in and also the front. I used some extra polycarbonate that I had laying around for the front. Next up is placing switches and gauges in it.



The tail-shaft mount all finished up. The bolt is overkill but that was the only sleeve size I had laying around.



If anybody is looking to make one, the tailshaft housing is 3.90". I had a friend keep an eye out for a piece of scrap tube close to that ID and he found one the next day. The actual ID on that tube was 3.99" but after slicing it a little extra wide, it clamped down perfectly all around. The piece pictured is about 3/8" wall and 1/2" thick. The bushing is from Summit Machine and the piece in between the two is just 3/8" plate.