22 August 2012

How to not shear axle keys v.3

One of my biggest concerns about the rusty 40 project is this old banjo.
I've had friends who have broke axles and lost wheels,
and with the engine(s) this thing will have that doesn't seem too fun.
ford banjo rear end

I used the banjo style rear end cause I have too many of them,
and at the time the idea was to use what was lying around the shop.
removing spring

Another issue was converting this to a normal driveshaft.
An open shaft kit was needed and at $250,
there was better ways to spend that money.
rearend pieces

The split wishbone radius rod setup made it easy to dissassemble.
day care

If I had known all the kids wanted was a dirty tire hanging from a chain,
this would have been a permanent fixture.
It's like working at the  circus.

A template was made to hold the 1936 radius rods.

The green 40 will have the same rear end set up,
so 3 pair would be good to have so I can lose a set later on.

No I didn't cut these out with a grinder.
Hard to see here,
but I've found out the easiest way to torch a clean line,
is to scribe the shape with a cutting disc.
Much easier to follow the shape than chalk or sharpie.

A couple minutes later and the pieces were good to go.
ford 9 inch rear end

While the torch was out,
the old spring pads were lopped off this 68 mustang 9" rear end.
Much better way to spend that $$ than that driveshaft kit!
old and older ford rear ends

That wrapped it up for the first nights work.
The next day was all about setting up the 9 inch.

Jimi Hendrix - like a rolling stone
"that's his grandmother out there!"
test fit

The footballs need 2 half inch holes,
and I eyeballed the marks with a hammer and punch.
Unbelievably the bolts slid in perfectly,
hopefully I'll be lucky with the other 2 sets.

The pieces were cut to ring around the axle tubes.
angle template

Oh yeah an angle template was made to get an idea of the positioning.
The pieces were tacked together
test fit

The pieces were assembled for installation.
rough assembly

I had taken a bunch of different measurements.
Always write them on something that won't get thrown away.

The most important measurement is that the spring eyes were 49.5" outside to outside.
measurement marks

Some measurements were marked on the rear end to help center it.
jaxon perich

With the balljoints attached to the bracket,
the rear end was mocked up in the frame.
The kids were crucial at this point to keep me from going insane.
I'd slide around from side to side on the creeper comparing measurements.
It was ridiculous.
Once the rearend was centered and the spring points were perfect,
the pumpkin was rotated to match the tranny output shaft angle.
pinion angle

Again since the car is jacked up,
the actual angle isn't important as long as they match tranny and rear end.
perich brothers

Than everything was remeasured for the last time.
The kids were now going crazy.
welding time

The new pads were tacked,
and the whole unit removed and disassembled for welding.
I didn't want to warp the axle tube,
so short welds were buzzed over a long time for cooling.
rear end assembled

After some grinding and wirewheeling,
everything was painted black.
I really wanted to make a bracket for a future torque arm,
but didn't know the positioning yet.
nine inch rear end setup

What a relief when everything fit.
This was a big deal I'd been wanting to do this for at least a year.
Jakob Perich and the 40 coupe

The tire shop was lagging with the tire swap,
since inner tubes aren't normally carried anymore.
With some temporary rims installed,
the rear end was the perfect width.
ford posi third member

Later on I'll swap out the 3.0+ one legger pumpkin
for this 3.50 posi unit.
Double burnouts!
At least I won't get stuck as easily off roading.
1940 ford coupe chopped and channeled

The next day the tires still weren't ready.
Oh well,
Not like it's going anywhere.
perich brothers 1940 ford coupe

Much better with the running boards.

One thing off the list!


20 August 2012

pumpkin olympics

We have a winner!
and then there was one...

In a race against time,
one pumpkin remains.

Can you believe this one has lasted 10 months!?
This one may have itself 2 halloweens to celebrate.
the winner

Now the kids are fighting over who had the winning pumpkin.
Next year we'll mark them!

Rolling Stones - Midnight Rambler


18 August 2012

how to split wishbones, break a jack, make a tire swing...

Since the body is off the frame,
now is the perfect time to traditionally set up the rearend of the 40.
unsplit wishbone rear suspension

Early on I had tried to replicate an unsplit wishbone setup,
similar to using the front radius rod ball on the rear wishbones.
This setup works as it's on my pickup,
the problem is it is difficult to tune or align.
Now that there is a full floor on the body,
I've realized it is also easier to change right now.

rear unsplit wishbone balljoint suspension

Definitely a bummer to cut out all this old work out,
but that's what happens.
split wishbone kit

Speedway makes it too easy by selling a balljoint and weld bung kit.
Make sure you buy the little brackets with the 7 degree tapered hole,
this is really important unless you have the correct reamer.
All this is under $50.

There is a huge amount of measuring, positioning, remeasuring, jacking, thinking, cutting...
to get to the step where the threaded bungs can be welded in.
Once welded up,
I like to squirt some oil down the radius rods.
There are a couple small holes that hold the brake line brackets,
and it is amazing how rusty some of these are inside.
split wishbone mock up

Now it is time to make the template for the bracket mount.
To me it is easier and cheaper to build one from scratch using those tapered hole tabs
and some scrap steel.
full circle scrap

This chunk of scrap was used to press the top cowl piece.
Weird how that works.
input shaft angle

The most important part of setting up the rearend,
is matching the pinion angle to the transmission/engine.
pinion angle

Since the frame is jacked up at a random position,
the angle isn't important,
only that they are equal.

The only issue at this point is the correct angle of the rear end,
not the alignment.
Good time to have a stash of clamps and wood blocks.
aligning wishbones

The plate is mounted,
so now the tie rod brackets can be attached.
All that measuring that was done before the first cut now needs to be remeasured to perfection,
or else the car will crab down the road sideways.

Make sure to leave 5 or 6  threads out of the jam nut for tuning purposes.
Also make sure you take off the rubber tie rod covers when tacking,
and take the tie rods out when welding!
welded up

Let's let it cool off.
Perfect time for a break.

sausage - riddles are abound tonight

hot rod frame

With the suspension all assembled,
we did an extended frame bounce to make sure it wasn't bound up anywhere.
No problem.
Even forgot to take a picture of the finished assembly!
in position

With no time to waste,
the kids and I rolled the frame back underneath the levitating body.
broken jack

Perfect time to break the jack!
1940 ford coupe chopped and channeled

There was a concern that the body mount holes wouldn't  line up.
Nope this thing is stiff as a,
well let's just say everything fit perfect.
working or sleeping?

And here's a sneak peak of the rarely seen passenger side.
always been stuffed over by the wall.
It was a long day,
by this photo it was after 9pm.
Is that Jake sleeping or working?
jakob on tire swing

Nothing a tire swing can't fix.
perich brothers

Fortunately no injuries!
1940 coupe chopped rear shot

I'll call that a good day!


groundhog's day

I'm having a brief Alzheimer's moment,
cause I'm not sure if I posted these pictures already.
Groundhog Day it is.
sepp's garage

My old buddy Sepp from Austria sent these updated pictures of his creation.
I do remember posting some mock up photos not too long ago,
and I'm impressed at the speed at which he's assembled these parts.
ultimate bobber truck

Yeah that is some kind of airplane engine in there.
This thing was built with the sole purpose of shredding wire wheels!
sepp's garage

Sepp has a huge inventory of hot rod parts-
"Haus of Hot Rod"
Sepps Garage
probably the most in Eastern Europe.
It must be fun to pick and choose E&J lights, a quickchange, bomber seats,
some buick drums... and just build a car.

Definitely has an airplane theme.
sepp's garage

I know about drillium,
and bet half the build time was spent drilling all the holes.
Axle, backing plates, frame, radius rods..
front end

Looks like he's got the gauges covered to monitor the engine!
sepp's garage

The accelerator linkage will be real fun to figure out.
Probably a little loud too!

Knowing Sepp he's got this thing running by now.
I'd love to tear up that grass field!
Watch out ground hogs.
Definitely a holey chit moment.

mad scientist Sepp

I'm having a brief Alzheimer's moment,
cause I'm not sure if I posted these pictures already.
Groundhog Day it is.