68' M715 AKA "Smokey", 8.1 engine on links, coils and 40's

Rock40 · Feb 7, 2021

I've complained about the welds on this 715 before. Now I'm going to show you some horrible proof.....

Dear goodness. This one didn't receive ENOUGH booger weld, probably why it broke.

This was probably a jerry can mount gone totally sideways... please appreciate the far from round torched out hole. Nobody ever bothered to even clean up the slag. Right on the side of the bed too

Rock40 · Feb 7, 2021

Fender gusset. Of the 4, this was the only one that didn't look like it had bounced off a tree or two. Sheet metal isn't going to cut it, needs to get beefed up...

Replaced with 3/16" cold roll plate

Another gusset on the rear of the fender

Rock40 · Feb 7, 2021

And the dastardly Jerry can mount. Time to correct some of the nonsense.

Silicone bronze in all the small holes...

Super sweet custom jagged piece that perfectly matches the torched out nonsense

All done. DA sanded flat

Rock40 · Feb 7, 2021

Slowly plugging away on the exhaust. It's HARD to shoehorn a full 3" system into something like this AND keep it clean and fully above the frame rails

Both crossover tabs welded in. Yes they are hard mounted. There will be flex joints on either end. I had no choice :rolleyes2:

All 316 or 304 stainless

O2 bungs

Assembled (but not fully welded) drivers side

Rock40 · Feb 7, 2021

Fully welded passenger downpipe and crossover. Using stainless clamps, fairly slick and easy disassembly

This is the coped crossover bit. The passenger side will single up into the driver side

Rock40 · Feb 7, 2021

Crossover...

Welded flange

It’s all welded and in place, good grief. 2 days of solid TIG

Stupid WA weather, it’s just pouring here relentlessly. Dogs have to be outside the shop while I’m doing all the TIG work. See the excitement

Rock40 · Feb 7, 2021

Time to massage the fenders a bit to clear the coilovers...

The idea is to create the necessary clearances but keep it tight so it doesn’t appear completely hacked and mangled.

Passenger side is DUN

Rock40 · Feb 7, 2021

Well I guess it needs a cage...:sigh: Time to get a bit bendy. Here it is drawn out on CAD

1.75" and 1.5" DOM tube. Both .120" wall

Here we go...

"A" pillars

Few more bends...

Tacked in place...

Rock40 · Feb 7, 2021

Main parts are in place, almost all 1.75” at this point

Fairly low profile but with the window up it’s not in the way of the view

Top view. The cross bars are yet to be completed here

Played around with a few of the tubing copes, pulled the top of the cage inward just a bit as it was hitting the upper frame on the driver/passenger door frame

CalSgt · Feb 7, 2021

Rock40 said:
1.75" and 1.5" DOM tube. Both .120" wall

View attachment 359169

Dang... That looks like about $500+ worth of tubing, the last stick of 1.75" x 0.120 wall DOM I bought was $107 at the fab shop's cost... Still haven't gotten my bill yet

Those bends and coping look very nice, wish I had skills like that

Rock40 · Feb 7, 2021

CalSgt said:
Dang... That looks like about $500+ worth of tubing, the last stick of 1.75" x 0.120 wall DOM I bought was $107 at the fab shop's cost... Still haven't gotten my bill yet

Those bends and coping look very nice, wish I had skills like that

You’re correct, the DOM adds up real fast but it’s the right way to do it.

I’m cheating a bit with the tube coping, this guy nails the copes/angles every time

Sent from my iPhone using WAYALIFE mobile app

Rock40 · Feb 7, 2021

Rock40 said:
You’re correct, the DOM adds up real fast but it’s the right way to do it.

I’m cheating a bit with the tube coping, this guy nails the copes/angles every time

Sent from my iPhone using WAYALIFE mobile app

Sent from my iPhone using WAYALIFE mobile app

Bierpower · Feb 7, 2021

Rock40 said:
You’re correct, the DOM adds up real fast but it’s the right way to do it.

I’m cheating a bit with the tube coping, this guy nails the copes/angles every time

Sent from my iPhone using WAYALIFE mobile app

What do you use for a bender. The corners look like they held round pretty well.

Sent from my Pixel 2 XL using WAYALIFE mobile app

jdofmemi · Feb 7, 2021

Rock40 said:
View attachment 359210

Sent from my iPhone using WAYALIFE mobile app

That's almost like cheating

The right tools sure make work a lot easier, and lead to a better outcome.

Great work, and many thanks for sharing. This is an inspiration

Rock40 · Feb 8, 2021

Bierpower said:
What do you use for a bender. The corners look like they held round pretty well.

Sent from my Pixel 2 XL using WAYALIFE mobile app

JD Squared mandrel bender. Yeah it doesn’t (and shouldn’t) crush any of the radius on the bend. Air over hydraulic

Sent from my iPhone using WAYALIFE mobile app

Rock40 · Feb 8, 2021

jdofmemi said:
That's almost like cheating

The right tools sure make work a lot easier, and lead to a better outcome.

Great work, and many thanks for sharing. This is an inspiration

Thank you Sir. Yep, quality tools are the ONLY way to go in my opinion.

Rock40 · Feb 8, 2021

Mount for the PSC reservoir and filter...

Tucks in pretty well, right above where the pump will be

Rock40 · Feb 8, 2021

Slowly trying to piece together where all the accessories are going to mount up in a way that makes sense....

Engine bay fuse panel. Using welded in threaded inserts for absolutely everything as I don’t want to play with back-up wrenches during assembly/disassembly

IPR Research coolant filter. Uses a machined reusable element and the filter can be fully bypassed also via mounted valving

Rock40 · Feb 8, 2021

More inserts and mounts, now on the front radiator core support...

Canton radiator overflow tank along with a Grote back-up alarm. The alarm will be used for an audible overheat warning, triggered via engine coolant switch. Loud and annoying when it activates but you also CAN’T miss it if you're bombing down a trail and not watching gauges