66 Pro Street Build (Domeringer)

[aggie91]

Going to tune in for the rest of the process!

I really like the direction!

[markeb01]

That rear end setup looks killer!

[Gary V]

Hi All, Been pretty busy setting up shop, managed to make some progress. Here's some pics of the crossmember welded up and the 4 link frame tacked and squared to the jig... things should progress a little quicker now.

[Gary V]

Some frame progress pics...

[Jeff La]

Unreal fab skills

[Gary V]

Thank you Jeff... hope you all don't mind pics. Added some reinforcement from the frame to the crossmember, cut off and capped width. Rear end fab next .

[Gary V]

Has been a rough week... had a cold and then a stye in my eye... so didn't get a lot accomplished. Started making a jig for the 9" and should have it done by next weekend to go at it again. For those interested I will post a kind of step by step pictorial aimed at getting a braced 4 link rear fabricated properly. Some pics to start...

Looking through the drive shaft loop hole

[markeb01]

Wow! I'm tuned in!

[Gary V]

When I decided to fab up my own 9" rear end, I went looking around on the net for some good instruction. Was kind of disappointed that no one had taken the time to document a how to. There were plenty of home made jigs for doing one thing or another. But not a start to finish... so here we go.

To recap we're using a 3.25 Strange Center Section (part no. H1112) and 3.25 X 1/4 Wall DOM Tube. The rear will also get a back brace and that is the main reason for this jig... will explain as we go along

We're going to have to deflect or bend the rear end axle tubes down on this jig when the back brace is welded to the tubes and housing. When the brace gets welded to the back along the length, the weld will actually pull or deflect the tubes to the rear. What we're going to do is deflect the rear before the welding process so that when the weld cools it comes back to where it needs to be.... hopefully

The Rear End Jig

We need a good straight rear end fabrication with concentric tubes . To accomplish that 4 bushings were machined to a slip fit for the ID of the 3.25 DOM Tube and the OD of a 2" TG&P (turned ground and polished) length of shaft that runs up the center to keep everything in line. I should mention that the last parts that get welded to the rear are the housing ends... so a different bushed version of this internal alignment jig will also get used later.

Finished the welding of the tubes to the center housing. Once everything cooled the shaft would turn and was easily removed! Mission accomplished! A straight concentric rear end assembly! This rear end could be used as is without the back brace but we're going to be putting some big horsepower to this heavy truck... so well add the brace.

Ok enough for today I need tomorrow I will finish the bend jig and post some more pics and info.

[Modges'66]

Gary,
It is one thing to just strike an arc and lay nice welds.
It is quite different to forecast the outcome & effects on what you are welding
Nice job on both!!
Many kudos to your skills, I guess this is what experience proves!
This is how good fab-work is performed!

[Bomp]

Impressive build.

Late but Im in.

[markeb01]

Thanks for taking the time to photo document all this. I’m sure this will prove helpful to many. The whole project is well beyond my skill set, but I really admire and enjoy watching the creation of fabricating art work.

[Gary V]

Originally Posted by Modges'66

Gary,
It is one thing to just strike an arc and lay nice welds.
It is quite different to forecast the outcome & effects on what you are welding
Nice job on both!!
Many kudos to your skills, I guess this is what experience proves!
This is how good fab-work is performed!

Modges, This is the nicest thing anybody has ever said to me. Thank you very much!

[Gary V]

Originally Posted by Bomp

Impressive build.

Late but Im in.

Hi Bomp, Have been following your creativity and great work for a while... been a little shy about posting. Thank you!

[Gary V]

Originally Posted by markeb01

Thanks for taking the time to photo document all this. I’m sure this will prove helpful to many. The whole project is well beyond my skill set, but I really admire and enjoy watching the creation of fabricating art work.

Thank you markeb01! Been at it a long time. I really enjoy sharing the fab stuff and it keeps me motivated as well.

[Gary V]

Ok went at it today and got the rear end torture jig just about ready to go. Here's some pics... next week we add the back brace and get on to more fun stuff. I'm jigged out

[chevyrestoguy]

Very nice, Gary! I love fabrication work, and to see it being done by someone of your high standard is especially enjoyable. I'm really liking all of the jigs you have and how you're using them. I have to say that frame is going to be one strong mofo. I can't wait to see more!

[dwcardfan]

Very nice work Gary. That is going to be one sweet frame!

[Gary V]

Originally Posted by chevyrestoguy

Very nice, Gary! I love fabrication work, and to see it being done by someone of your high standard is especially enjoyable. I'm really liking all of the jigs you have and how you're using them. I have to say that frame is going to be one strong mofo. I can't wait to see more!

Thank you! More jigs and fixtures soon!

Originally Posted by dwcardfan

Very nice work Gary. That is going to be one sweet frame!

Thank you!

Break from the fab work... Machined some 4130 rod ends and 1 3/8" X .093" wall 4130 links. Rod ends are a press fit... will weld them up today and get that rear end ready for the frame this week and post updates Sunday evening.

Fixture to set the link lengths equal to the 18" C/L dimension

[chad64chevy]

loving the updates, cant want to see the rearend in with some wide tires

[Gary V]

Originally Posted by chad64chevy

loving the updates, cant want to see the rearend in with some wide tires

Hi Chad, Thanks and here's some updates!

Good day today! Had to fire up the plazma cutter and make up some new back braces. The ones I received were not correct... they were for a standard rear end housing and 3" axle tubes. The rear end housing will be shortened to the inside of the orange tape so thats where I ended the back brace. Here's some pics explaining how the jig was used to preload the axle tubes prior to welding the back brace on. The brace was fit after the tubes were loaded. Should have the rear end back under the frame and 4 links installed tomorrow... will post progress Sunday evening!

[Modges'66]

Yeah?
Still waiting for all of the shots of the picture-perfect welds...LOL!
Very skilled work!

[Gary V]

Originally Posted by Modges'66

Yeah?
Still waiting for all of the shots of the picture-perfect welds...LOL!
Very skilled work!

Hi Modge, Looking for a little weld porn eh LOL. We''ll get some close ups for you next week. I weld mild steel structural on the hot side... penetration with no undercut... so the welds are more girl next door looking.

Progress pics! Rear back under the frame, links installed and jig work stripped away. Next... mount the shocks, wishbone locator and ARB (anti roll bar)

[Bomp]

With a chassis/suspension set up like that I'll take the girl next door any day.
Somethin's getting hacked apart on my build now.
Note to self: cut off and start over.

[Gary V]

Originally Posted by Bomp

With a chassis/suspension set up like that I'll take the girl next door any day.
Somethin's getting hacked apart on my build now.
Note to self: cut off and start over.

Hey Bomp... any fabricator that says he never has to cut stuff off and start over is not telling the truth Keep up the great work!

Been working on machining the wishbone and anti roll bar details and ordering parts... so not a whole lot got attached to the chassis other than the coil overs. Should have everything else ready to get on there this coming weekend. For now here's a couple of pix with the coil overs mounted.