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

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

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

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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

715 booger weld(3).jpg
 
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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...

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Replaced with 3/16" cold roll plate

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Another gusset on the rear of the fender

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

Silicone bronze in all the small holes...

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

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All done. DA sanded flat

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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

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

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All 316 or 304 stainless

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O2 bungs

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Assembled (but not fully welded) drivers side

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

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

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Crossover...

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Welded flange

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

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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

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

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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

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

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

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Here we go...

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"A" pillars

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Few more bends...

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Tacked in place...

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

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

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

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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

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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
Click to expand...

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
 
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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 👍👍
Click to expand...

Thank you Sir. Yep, quality tools are the ONLY way to go in my opinion.
 
Mount for the PSC reservoir and filter...

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

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

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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

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

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

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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

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Also found a spot for the ARB compressor. If my measurements are correct, should clear the hood by about 1/4”

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Last of the main cage parts, upper crossbars....

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Ethan on the TIG, it's fun to watch and not actually have to do it :)

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Still needs seat mounts, hip guards, grab handles, dash bar, etc. but this is the "core" of the cage

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