Mk6 transit crew cab tray back

[spudmab]

Well yesterday I got my nephew to help me put the new mk8 quad seats into the back of the truck.

Good news is they physically fit. Bad news is the mounts are no where near. It looks like its a case of making up some new brackets. More as i get there.

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[spudmab]

Well we have finally got back on the truck after the holidays and a case of covid. First job was to remove the rotten cross member so it can be replaced. The chassis is in excellent condition considering the rust in the cross member.

Also received my rear axle stub ends back from being machined. More on these soon.

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[BROWNYS V6]

yep, best place for that crossmember is the bin, axle ends look interesting ?

[spudmab]

yep, best place for that crossmember is the bin, axle ends look interesting ?

All we come clear over the next few weeks, well if everything goes to plan. Ha ha

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[spudmab]

Well this evening we got the cross member tacked in place. We also tacked the lower parts of the cross member in place. It looks so wrong due to the run of the propshaft but the lower parts are both the same length.

We also have figured out when the next cross member will be going so we can mount a anti-roll bar. Also worked out the lower 4 bar bracket lower cross brace.

Hope your OCD dont bug you to much.

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[spudmab]

Well more progress this evening, the next cross member is now tacked in place as well as the lower support rails.

The lower rails sit at different heights compared to the front lower support rails as they follow the chassis rails.

Still makes my brain hurt looking at it due to the propshaft run.

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[spudmab]

Well this evening we cut the last cross member out removed all the spot welds and cut a new piece of metal to slot into place.

We also cut the tack welds from the rear lower cross member braces so we could modify them for the anti-roll bar mounts. They where then tack welded back into place.

We also made some flanges for the removable front lower 4 link bracket cross brace.

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[spudmab]

Well this evening we turned done some M10 nuts and welded them on to 2 plates.

We welded the rear lower cross member braces then we marked and drill 2 holes for the nuts to fit it to.

We welded the plates into place, the we cut the cross bar witch will form the rear anti-roll bar.

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[spudmab]

Bit of a random update. Its now 2.30am on Friday, those who follow the build will normally see an update on a Tuesday evening and a Thursday evening. Well it was all going well until...

I had to end the evening short and be taken to hospital. I had a nose bleed out of the blue. Started at 18.50 ish and was still bleeding till 00.10 this morning. The hospital hasn't really said what caused it but its sorted.

Anyway the first few photos are part of my rear light setup, cant buy what i wanted so the only option was to make it. Bit of Google and i found exactly whay i wanted but its was a kit of bits. Well if you follow the YouTube link you will see what i have managed to make. Still needs tidying up ect but that cant happen until the rest of the rear light setup is done.

On another note we worked out the anti-roll bar arms to where the will allow the truck to sit fully aired out.

https://youtu.be/yOsP6FIqSss


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[spudmab]

So no updates from Tuesday and none from this evening as we have had the week off.

But i have been doing little jobs ready for next week. Turned down a lump of nylon to be used as spacers between the anti-roll bar bars and the mounts.

Also drilled the anti-roll bar arms. They will be set in place and be welded then connected with rose joints down to the axle.

Massive recommendation for McGill Motorsport i called them yesterday for some rose joints, threaded plugs, spacers and some nuts. My order arrived today. I have ordered 3 times from them now and i cant fault them.

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[spudmab]

Well this evenings progress, the link arms have been set and welded and the drop links have been made.

4× 1/2 unf rose joint with threaded plugs that have been welded both around the joints and rosette welded. Just leaving the axle brackets to make.

Also my shock travel limiting straps arrived and the quality is extremely good. They are to stop the airbags having any chance of over extending and being damaged. Many thanks to Damar webbing solutions there service was spot on.

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[spudmab]

Well this evening we cut the anti-roll bar axle mounts from 5mm steel plate. We sanded and drilled holes.

We set up the brackets and tacked them on to the axle. They will be welded when the axle comes back of. The second drop link has been made.

Just the lower spacers to machine down and thats another job ticked of.

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[spudmab]

So updates from Tuesday and Thursday, the front cross member is now cut and tacked in place. We have cut a hole in each end and also in the middle to allow air lines ect to be routed.

We also have the lower 4 link bracket cross brace outers tacked in place and the removable middle parts welded.

The last part we got on to was cutting the mounts of the second air tank as we needed them turned through 90° so the tank fits how we need it.

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[spudmab]

Sorry everyone for no updates last week. Had a few issues with motivation and my brother-in-law tested positive for covid.

Back at it today, we drilled the chassis and welded in threaded bosses for the second air tank. We cut the brackets of the air tank and rotated it to where we want it sat. Weld the brackets back on so thats another job ticked of the list.

Also i have now got the main feed air lines made. Just need to get some fittings to connect everything up.

We also made a start on making the rear lights. We have decided that we aren't going to share the rear lights until the truck is done.

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[spudmab]

Well this week we have made some good progress. The air distribution manifold is sat in place and air lines are run.

We have also made a start on the rear bumper, drilled the end of the chassis to allow the bumper brackets to bolt on.

Still need some more airline fittings but most of it is in place. Main feed line from the compressor to moisture traps then through a 1 way valve into the air tank. This is the same set up for both sides. Then the 2 tanks are connected via the manifold.

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