"Tank" my 91 Crew Cab Dually

chillman88

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Went out and finished removing the hangers today, that was the part I was dreading honestly so I'm glad it's done now. Wasn't too bad really. I'll probably dress the area with a flap disc on a grinder before fitting the new hangers. If my cold galv spray isn't clogged up I'll put some of that on before bolting in the new hangers.

How well did it penetrate at the overlap areas where individual cross members intersect with main outer frame rails? Traditionally those are not problem areas for rusting, just curious how well the hot dip process worked.

Well I can't tell you about the crossmembers, but I did have to remove the rearmost front spring leaf hangers....

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Didn't penetrate great, but better than nothing. I think if they had left it in the acid dip a little bit longer it may have looked better as it would have eaten away more of the rust.
 

chillman88

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I couldn't really get inside the body mount bracket with the grinder. I tried a 2" scotchbrite pad on a roloc arbor and the zinc is a lot harder than the scotchbrite LOL I got what I could.

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Cleaned up the rest of the spots pretty good.

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Turned out pretty decent. Sprayed several coats of cold galv on.

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I'm happy with it. Now I have to figure out how to jack up what's left of the parts truck in the yard without killing myself to pull the rest of the brackets off.
 

chillman88

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My other post is "pending moderator approval" so I don't know what order stuff will show up in.....

Brackets are off the donor. On the scale of sketchy things I've done this is pretty low on the list LOL

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Went better than I expected. The only thing holding the axle in now is the steering box which is already loose on the frame.
 

IDIBRONCO

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On the scale of sketchy things I've done this is pretty low on the list

Thought I was the only one doing sketchy things, your jack-all top mine.:rotflmao
I have no idea what you guys are talking about. OSHA? Oh I remember her. I dated her sister for a short time back in '93. :joker:
 

snicklas

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I've been thinking about trying out a 6.0 air cleaner when I get the turbo on. It's a smaller engine but I believe they flow pretty well from what I've heard and I know they're good filters.
The 6.0 Filter do flow well.. I think I’ve read in on a 6.0 they are good for over 500 horse before they are a restriction. The element last a really long time…. And filters very well. One think most don’t realize is the drivers side battery tray also has the mount for the filter on it. On a 6.0 the filter mounts between the engine and battery, just behind the core support….. I do have pictures somewhere do a 6.0 filter setup…
 

chillman88

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Rear brackets are installed!

Mocked up with some 3/8 hardware so everything was tight to the frame before drilling anything.

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Got a 1/2" "aligning reamer" from Amazon for $30

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Drilled a hole, put a dummy 1/2" bolt in to hold position, lather rinse repeat until they're all drilled. Put some ARP grease on the flange of the bolt and nut and torqued everything to 85lb/ft.

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I don't like how the front holes are so close together. Had to put one bolt in "backwards" but everything is in and ready to go! Now I can get to aligning everything for the front next time!

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All hardware is 1/2 Grade 8 Flanged. The nuts are thread deforming "prevailing torque" locknuts.
 
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chillman88

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Well I'm kinda frustrated today scratching my head.....

I figured I'd build some bars with the correct spacing for the spring mounts so I can just slap everything together and run. Sounds good right? Ehh.....

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Sky said the holes should be 55.5 inches apart. They also said the spring "installed length is 56 inches so the 55.5 gives you some shackle angle". Well my springs are measuring right close to 55" unloaded. A search for x code springs shows the length to be 55.62 from hole to hole, at least that's what I'm reading it as.

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I can't rotate the front hanger enough to get the full 55.5 inches of distance, but I don't think I want to after all these measurements. I would think the distance between the eyes of the springs should be the MINIMUM distance between the mounting points so the shackle cannot fold backwards at all. I'm right about 55 inches apart right now and I think I'm going to leave it there instead of fighting it.

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The issue I'm having meeting the 55.5 dimension is the drivers side frame horn is bent down just a little bit more than the passenger side so the RSK bracket is bottoming out there. I could beat it into submission but given the measurements I've been getting I think that would be too far apart.

I'm kinda scratching my head but I also think I've made up my mind on how to proceed. Just kinda venting my frustrations right now.
 

chillman88

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Drilled the holes this morning. Went to weld the spacers on and realized there is a slight amount of angle to the place they sit so just welding them "square" would have put them out of alignment with the opposite side. Thankfully I've got enough "junk" around here to be able to bolt the brackets together which would line everything up nicely and should keep everything straight.

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I won't be showing off my welds on this one! Let's just say they'll do what they need to do LOL

I'm going to test fit everything after it has had time to cool down and then I'll see if the sandblaster at work can hit them for me quick tomorrow.
 

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