Joelzy's 96 5SPD(daily) & 5VZ block-up rebuild

[Joelzy]

Joelzy's 96 5SPD(daily) & 5VZ block-up rebuild

are you welding in long strings/beads? what we do with our mig on parts we think will warp is basically lay one bead at a time if we dont have any jig or fixture to keep from warping. has worked well for us in the past.

i tried to avoid long beads near the hinge, so i'd run a couple inches and then move to the far end of the piece for a few while, alas, still warped a tad but all good now though, live and learn

got the zerk fitting in
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going to notch the bumper mounts tonight and hopefully get it all bolted up

 

[Joelzy]

If you do that, you'll need to slot the holes for the lug nuts/bolts for different/changing tire sizes. Also, keep that tire inflated...

Good idea though, as it will triangulate the swingout a bit so the weight isn't cantilevered up so high.

-Charlie

:noidea:
think this will work, pivoting the slotted lugs? the idea being i can weld one lug in and know for certain it wont rattle loose while the others can travel according to tire size.
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in frame bolt access
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this is what happens when i run out of gas and still want to work but dont feel like spraying pam on every weld. fluxcore slaggyness.
notched bumper mounts reinforced
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got the bumper back on and started on the latch and catch
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[Joelzy]

Joelzy's 96 5SPD(daily) &amp; 5VZ block-up rebuild

Been working on the catch and latch, this was going well until the front bolt holding the catch on stripped on me.
The big wingbolt isnt something i’ll have on everyday but will use on roadtrips and offroading to minimize rattle.

Plug welded the front hole with the flux and drilled a new bolthole through the side, had a bolt that fit it very snuggly to avoid movement.

Put the 3d printer to use for a hitch cover and swingarm catch

Update:
Got the hole on the mount drilled for the latchpin

Snug as a bug

Also got the wingbolt hole drilled

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[Joelzy]

Joelzy's 96 5SPD(daily) &amp; 5VZ block-up rebuild

Welp, i tried and tried again to notch a cross tube to match the hoop and no dice with the double compound curves.
Hats off to anyone who does that without a notcher on a regular basis because even with measurements and several attempts i failed hard at it.
Can’t win em all, back to the square tube, easy peasy.

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[mesooohoppy]

Welp, i tried and tried again to notch a cross tube to match the hoop and no dice with the double compound curves.
Hats off to anyone who does that without a notcher on a regular basis because even with measurements and several attempts i failed hard at it.
Can’t win em all, back to the square tube, easy peasy.

there are notch calcs on the net that allow you to plug stuff in and you print the template, wrap around the tube, mark, and cut. it isnt full proof (and likely will not work with compound curves), but i figured id let you know in case you arent already aware.

i googled it and here is the first one that popped up. ive used a different one in the past with success. same concept.
Tube & Pipe Notching Calculator - Printable Templates - Metric

 

[Joelzy]

Joelzy's 96 5SPD(daily) &amp; 5VZ block-up rebuild

there are notch calcs on the net that allow you to plug stuff in and you print the template, wrap around the tube, mark, and cut. it isnt full proof (and likely will not work with compound curves), but i figured id let you know in case you arent already aware.

i googled it and here is the first one that popped up. ive used a different one in the past with success. same concept.
Tube & Pipe Notching Calculator - Printable Templates - Metric

Interesting! Thank you, a had someone mention using old TP rolls, its not perfect but could help as could this, i imagine i’d just need to do the template for both sides then undercut and do a little at a time.

Maybe the next project i’ll play with it more but for now, we’re trucking with square.
Got it all tacked up including the plate but didnt slot my holes yet.

That was mostly to see if my measurments held up with a tire and a factory offset and it did.

Still looking to make a base support for the bottom if i can without it being too goofy. With the tilt to match the window i lost my definite baseline but should be able to make a little kickout. If that doesnt work there isnt really any reason to slot the lugs.

Update:
Test fit the 33 with nonfactory offsets and the tire size ill have on there.

Still hate these wheels but the 16s ill be using longterm are similar offset and its the right overall diameter.

Also drilled the slots but forgot to take an after pic so here is before

Also whipped these guys up

Ill definitely be trimming the verticals as they are longer than the swingarm currently but i think they’ll do for extra support once welded in.
Took a couple shots at the angle but got it pretty close to bottomed out in the slotted holes on this 31 meaning i have plenty of room for the larger diameters.


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[Joelzy]

one last pic with it all off

slotted plate, the 2 lugs are on a little bar now to make that part easier

Thats all she wrote, pretty damn happy with the turnout aside from the wrinklecoat which never cooperates with me.
Ended up hating the plate down on the swingarm so i fabbed a little bracket for it with a light.
Eventually i’ll get new tires and a fullsize spare.

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[Chuckles89]

Nice build! I have some catching up to do... I like your homemade stuff. I seem to do most of my stuff like you do... cheap and functional! LOL

Funny thing my friend Joel has a 1996 5 speed, but it's cardinal red- Almost twins! haha

 

[Joelzy]

Nice build! I have some catching up to do... I like your homemade stuff. I seem to do most of my stuff like you do... cheap and functional! LOL

Funny thing my friend Joel has a 1996 5 speed, but it's cardinal red- Almost twins! haha

thanks! yeah that was the idea, save some money and build what i can myself. If i can't make it or i try and it blows, I'll buy it.
Love that kind of work although the wife is definitely glad this project is over :boom:

 

[infamousRNR]

[MENTION=221666]Joelzy[/MENTION]

just love what you've done with your build... this rear swing out with the stock bumper is something I would def consider if there was a kit out there...


- Sean

 

[Joelzy]

[MENTION=221666]Joelzy[/MENTION]

just love what you've done with your build... this rear swing out with the stock bumper is something I would def consider if there was a kit out there...


- Sean

Thank you sir, If it was easy to make a kit i'd consider it but for now, if anyone needs details i'll provide everything i can to help. More than willing to help someone build some stuff :becky:

supdate: had a few minutes and started cleaning up the wheels
popped out the rivets and lightly wirewheeled all the crud off one so far.

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[Joelzy]

Got one completely cleaned up and damn what a difference it made. After seeing this i think i might just clear coat them

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[JZiggy]

Do it! Clean aluminum looks best on wheels in my opinion.

 

[JZiggy]

Got the platform about done minus drawers

Hey Joel, do you have a picture of how that little swing-down support engages with respect to the folded down seats? I'm planning out my own platform and want to use a simple design like this but want to figure out how to get that front section just right. Thanks!

 

[Joelzy]

Hey Joel, do you have a picture of how that little swing-down support engages with respect to the folded down seats? I'm planning out my own platform and want to use a simple design like this but want to figure out how to get that front section just right. Thanks!

hmmm i dont and i took the layflat flap out knowing we wouldnt be camping this season.
I kind of winged it in that i laid the big flap down level and measured to get an idea of how tall the support needed to be. Then realized the seat backs would give a little with the extra weight so i added an inch or so for that. I was hoping that gravity would drop it down automatically but with the carpet and all it needed assistance to drop into place. Also, in the very end, it wasnt quite level and i ended up trimming one side more to get a truly flat surface.

 

[fourfive]

Clear coat on the cleaned up aluminum wheels will be a good look. A 2k clear would be a good option to give it a tougher finish and better chemical resistance. I like the cheaper cost and longer shelf life of 1k aerosols but sucks how quickly it fades/dissolves when it comes in contact with solvents.

 

[Joelzy]

Clear coat on the cleaned up aluminum wheels will be a good look. A 2k clear would be a good option to give it a tougher finish and better chemical resistance. I like the cheaper cost and longer shelf life of 1k aerosols but sucks how quickly it fades/dissolves when it comes in contact with solvents.

:cheers: thanks, i figured regular ole rattlecan clear wouldnt hold up. Poked around and Eastwood has 2k aerosol, thoughts?

Eastwood 2K Aerospray Clear Coat Matte & High-Gloss

 

[fourfive]

:cheers: thanks, i figured regular ole rattlecan clear wouldnt hold up. Poked around and Eastwood has 2k aerosol, thoughts?

Eastwood 2K Aerospray Clear Coat Matte & High-Gloss

Eastwood & spraymax have good quality 2k aerosols. Both would hold up really well to solvents, brake cleaner etc. I've noticed a pretty significant difference in durability between catalyzed (2k) & uncatalyzed paint especially with solvents. Main downside is once activated, the 2k paint has a shelf life of a few hours before it completely hardens up & becomes unsprayable.

Amazon.com: USC Spray Max 2k High Gloss Clearcoat Aerosol (2 PACK): Automotive

 

[Joelzy]

Eastwood & spraymax have good quality 2k aerosols. Both would hold up really well to solvents, brake cleaner etc. I've noticed a pretty significant difference in durability between catalyzed (2k) & uncatalyzed paint especially with solvents. Main downside is once activated, the 2k paint has a shelf life of a few hours before it completely hardens up & becomes unsprayable.

Amazon.com: USC Spray Max 2k High Gloss Clearcoat Aerosol (2 PACK): Automotive

Noice! sold me, thanks man. Reviews are pretty damn good and I'd love to spend 40 bucks on a couple one-time use cans vs finding a powdercoater just for clear and spending a couple hundred.

Related note, these came in early so i have some work to catch up on.
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as seen in the other thread, wasn't planning on getting tires now but they were almost 100 bucks off on simpletire at a slightly larger size so i had to pull the trigger.
hoping to get the wheels cleaned up this weekend and tires mounted next week.

update: got the wheels all done and cleared, ready for mounting

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Used the Spraymax 2K high gloss(thanks [MENTION=116877]fourfive[/MENTION]) and it went on so well, hopefully it holds up just as well, good stuff so far for sure.
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[Joelzy]

got the tires on and balanced
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Just a test fit, need to swap my extended studs in as well as wait for new bolts to replace the rivets and centercaps to come in. This was mostly to check clearances on UCA and brakes with the 1/4" spacer. i have plenty of room with the UCA for no spacer but the wheels touch the tundra brakes without a spacer :der:
so i'll have extra UCA clearance, just enough between wheel and brake and with the slightly taller tire, a chance that i'll need to cut more pinch weld. :thumb:

also got the cupholder i made with my new 3d printer in and it works muuuuch better than factory. Also holds a larger bottle so thats nice
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