ALBO1023
Member
- Location
- Midvale,Utah
1998 XJ Super Duty
- Thread starter ALBO1023
- Start date
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
Repaired
I repaired the outer rail by tig welding and hammer welding the damaged areas that were cut to remove it. The plug welds are drilled through so that it can be welded back on. The plan is to use dom were the bolts go thorugh .250 wall at least, then run a 1/4 thick square tube down the center extending the brace the factoy but in. In my opinion if they had extended it to the end of the rail in the first place it would have most likely not of been able to twist. It still would crush though. After the dom and square are in i will take short pieces of 1/4 plate and connect them. I weled the bottom plate to the outer rail also but didn't get a photo yet.
I repaired the outer rail by tig welding and hammer welding the damaged areas that were cut to remove it. The plug welds are drilled through so that it can be welded back on. The plan is to use dom were the bolts go thorugh .250 wall at least, then run a 1/4 thick square tube down the center extending the brace the factoy but in. In my opinion if they had extended it to the end of the rail in the first place it would have most likely not of been able to twist. It still would crush though. After the dom and square are in i will take short pieces of 1/4 plate and connect them. I weled the bottom plate to the outer rail also but didn't get a photo yet.
Attachments
- Location
- Smithfield Utah
Looks good 
Silly Willy
Well-Known Member
- Location
- American Fork Ut
Where did you get the rebuild kit for the I6?
TRNDRVR
IMA BUM
- Location
- North Ogden, UT
Please tell me you aren't using this track bar and steering set-up.
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
Steering
LOL of coarse not that was just to get the project moving under its own power. I welded 1" nuts to the tops of the knuckles and then had a piece cut from 3/4 " plate and welded it to the right knuckle. Made a custom high steer kinda. It works but could be better. I plan to actually buy spidertrax knuckles one day so I can correct the caster angle . I bought some brackets from BHR and welded them to axle for the track bar bracket on the axle side. then used DOM tubing and heim ends for the track bar and steering set-up.
Please tell me you aren't using this track bar and steering set-up.
LOL of coarse not that was just to get the project moving under its own power. I welded 1" nuts to the tops of the knuckles and then had a piece cut from 3/4 " plate and welded it to the right knuckle. Made a custom high steer kinda. It works but could be better. I plan to actually buy spidertrax knuckles one day so I can correct the caster angle . I bought some brackets from BHR and welded them to axle for the track bar bracket on the axle side. then used DOM tubing and heim ends for the track bar and steering set-up.
ALBO1023
Member
- Location
- Midvale,Utah
Progress...
So I got a little done last night. I bought some 2" x 1/8" flat bar and made the brace's. I am really trying hard not to over build this. I feel like some mods look over done. I want to try and make things look like the factory built it but did what they should of done in the first place. I am also adding hydraulic assist steering, so it really would of been just fine if I had added it sooner.
So I got a little done last night. I bought some 2" x 1/8" flat bar and made the brace's. I am really trying hard not to over build this. I feel like some mods look over done. I want to try and make things look like the factory built it but did what they should of done in the first place. I am also adding hydraulic assist steering, so it really would of been just fine if I had added it sooner.
Attachments
Last edited:
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
Got the new rail
So I got a chunk of rail from Bill @ Alltruck. Thanks Bill. I cut it apart from the inside out that way I can use the resistance compression spot welder to weld along all the edges. No grinding !!! No Spatter !!! I will still have a seam to weld up and will have to grind and finish it off. I am hoping to get it on the trailer this weekend and down to work to do the CSW.
So I got a chunk of rail from Bill @ Alltruck. Thanks Bill. I cut it apart from the inside out that way I can use the resistance compression spot welder to weld along all the edges. No grinding !!! No Spatter !!! I will still have a seam to weld up and will have to grind and finish it off. I am hoping to get it on the trailer this weekend and down to work to do the CSW.
Attachments
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
ALBO1023
Member
- Location
- Midvale,Utah
bradm
shameless posing...
- Location
- Bountiful UT
Wow, you've put a lot of time and effort into this fix. Lookin good. I sure wish I had your headers...
ALBO1023
Member
- Location
- Midvale,Utah
Thanks
Thanks.
Wow, you've put a lot of time and effort into this fix. Lookin good. I sure wish I had your headers...
Thanks.
redneckbronco
Active Member
- Location
- Provo
I wish i had the shop the time and the $$$$$$$
ALBO1023
Member
- Location
- Midvale,Utah
Not enough rooooooooooooom!!!
Well I thought I had it all figured out. Little do I know! So my plan was fixing the rail and adds hydro assist. Easy right, lol. So the rail looks great and the other mods I made while doing look like the will pay off big. So here is the problem and the solution, I think. The problem as title implies is that there isn't enough room. To be specific not enough room between the tie rod that connects the knuckles and the housing for the ram to fit in between, or on top, or under, or upside down, or backwards. I must have spent 2 hrs holding the ram in different positions trying to make it work. So my solution, make custom high steer knuckles our of 1" thick plate. YEAH BABY!!! I have done a ton of research on how to weld it together and am pretty confident it is going to be sweet. So far I’m into this mod (just the knuckles) like 25 bucks. I went down to Wasatch metal and picked up a 25lbs chunk of scrap 1" thick plate. I figure if this doesn't work all I did is waste my time and ruin my stock ford knuckles. If it doesn't work I gues I'll have to do what everyone else does and break down and buy some aftermarket knuckles.
Well I thought I had it all figured out. Little do I know! So my plan was fixing the rail and adds hydro assist. Easy right, lol. So the rail looks great and the other mods I made while doing look like the will pay off big. So here is the problem and the solution, I think. The problem as title implies is that there isn't enough room. To be specific not enough room between the tie rod that connects the knuckles and the housing for the ram to fit in between, or on top, or under, or upside down, or backwards. I must have spent 2 hrs holding the ram in different positions trying to make it work. So my solution, make custom high steer knuckles our of 1" thick plate. YEAH BABY!!! I have done a ton of research on how to weld it together and am pretty confident it is going to be sweet. So far I’m into this mod (just the knuckles) like 25 bucks. I went down to Wasatch metal and picked up a 25lbs chunk of scrap 1" thick plate. I figure if this doesn't work all I did is waste my time and ruin my stock ford knuckles. If it doesn't work I gues I'll have to do what everyone else does and break down and buy some aftermarket knuckles.
Attachments
ALBO1023
Member
- Location
- Midvale,Utah
Progress
I'm further along then these photos but this is all I have right now. I have the Drivers side cut and mocked up also. I hope to get some work done this weekend but now we are open Saturdays so Sunday is all I am really left with to work on it.
I'm further along then these photos but this is all I have right now. I have the Drivers side cut and mocked up also. I hope to get some work done this weekend but now we are open Saturdays so Sunday is all I am really left with to work on it.
