TonyB66's Ownership -> Build Thread (2000 Limited)

[BrianSD_42]

Given that the key fob was in your house both times the alarm went off in the early am I would say it is near impossible that the key fob could be the cause. They usually only have a range of 10-15 feet.

So ruling that out you are left with alarm system itself or someone trying to break into your truck. But since the window sensors seem to be basically useless I'd guess no one was messing with your truck. Is it possible someone tried to slim jim the door open? That would cause the alarm to go off. Coming back a second time would take crazy balls though so I doubt that's what happened.
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[octanejunkie]

[MENTION=65101]BrianSD_42[/MENTION] especially if he keeps his keys in a faraday box

Coming back a second time would take crazy balls though so I doubt that's what happened.
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Sent from my Pixel XL using Tapatalk

 

[TonyB66]

Thanks for additional follow-up on the alarm. I really believe it was the door not closed all of the way. I parked on an incline, such that gravity would attempt to pull it open. Maybe the changing temps too were a factor, that eventually was enough for it to register as an opening, triggering the alarm. No problems since, so I'm sticking with that as the answer...

We have some rain coming Wed, so the first test for the seal job. It only leaked that one time recently, and that was during a downpour. Coupled with the steepness of the incline where parked, I believe the "gutter" system was overwhelmed making for some spill-over onto the center console area. Hopefully I don't have to worry any longer about where or how I park, like what end is up or down...

Yep, I was eye-balling the 2nd gen end links alright, and almost went that route. I had found a couple threads about those and a YouTube video too. These look to be more substantial and I like that I can shorten (or lengthen) them with different length sleeves. The bolts used by ES are grade 5. Grade 8 is about 25% stronger, as I recall. I might upgrade later to grade 8. The oversized shank Heim is rated at over 8,000 lbs. Pretty happy with this solution, especially for 40 bucks.

Hey, I do have a Faraday cage actually. Basically an old file cabinet. Keys were not in there though....

 

[TonyB66]

I had a few items show-up today, stuff that I had not talked about previously as I've been so busy with work and still Mr. Mom duties as my wife heals from surgery....

I had taken this measurement some time back...

These also arrived today (3/8" NPT).

I got this portion assembled with some thread sealant.

I have some homework support for a while, but I'll try to share more later, including other photos...

 

[octanejunkie]

I had a few items show-up today

I have some homework support for a while, but I'll try to share more later, including other photos...

Okay, I'll bite... what is that?

 

[TonyB66]

Okay, I'll bite... what is that?

Fuel storage. Should be a little shy of 4.5 gallons.

 

[octanejunkie]

Fuel storage. Should be a little shy of 4.5 gallons.

I guess the second/ford tank mod is out, then :hello:

Care to share your plans?

 

[TonyB66]

I guess the second/ford tank mod is out, then :hello:

Care to share your plans?

Just got back from school drop-offs... I'm so beat. I wake up much earlier to cook breakfast and lunch for the little ones, get them to school, deal with clothes (wash, dry, fold), and cleaning dishes, which seemingly never ends. Oh, and grocery shopping. My employer has been fantastically supportive! Even sent groceries to our home the first week after surgery. The biz trip next week, which I normally don't like, allows me a break though. My wife will attempt to drive, with me at her side, later today and into the weekend. Hopefully all will go well during my absence next week. I'll be doing homework support over FaceTime, which has worked well before. Ok, I digress...

The project is about creating storage, and not just for fuel. I wanted to have an extra 3-5 gallons. This gets me around 4.4 (pi x r squared x length). It will also afford additional storage space, like for: tools, recovery gear, and parts.

I went to South Bay Metals in Gilroy, CA several days back, and coupled with some angle from THD, I spent about 100 bucks.

An oversized 4' x 2' piece of 3/16".

Two 36" length of C-channel.

Two 36" lengths of 2" angle (one was cut closer to 37", and desirable).

Also a foot length of 1/4", 4" wide aluminum.

As seen in a photo above, that piece of wood was scrap backing from a cabinet project. It was useful as a template and helped me determine that this project was doable.

First, the two inner bolts, as you all know, go into welded nuts within the frame. The two other ones on the outside (most forward and rear) are on removable brackets that have welded nuts. This project will be utilizing those on each side, plus adding a third bolt. The rear bumper does not need to come off.

Took careful measurements to create the template.

I have a mtg at the top of the hour, but I'll try to share more later. That should give you a pretty good idea as to what I'm doing...

Oh, a slight bend in the sheet was corrected...

 

[TonyB66]

I've been thinking about this since I removed the spare tire carrier, actually before. There's some good space up there.

I cut the sheet down to 42" so that it extends about 1/4"outside the frame rails. Front/back was more involved. I decided upon 22 1/2", although I could have gone with 23". Any more, then the exhaust pipe becomes a factor. I chose 22 1/2" because that's where the floor cross member is above, the front edge of it (cardboard in photo). Happy I went with the cordless jigsaw. Worked very well.

With it cut to size (42 x 22 1/2 inches), the portions removed for those two inner bolt heads, four holes drilled-out, it was time for a test fit.

My floor jack did not go high enough. I have a tranny jack that I lent a friend a few years back, but that only goes up 18". I needed about 24"... I found a way using these clamps on both frame rails.

Very pleased with the first dry fit. I had to use the rat tail file on just one hole.

The average height from the top of the plate to the bottom of the floor, I'd say is about 7". The highest is near 9", with much like this photo, around 8 1/2".

Under that cross support, about 6 3/8", thus the choice for a 6" diameter tank.

 

[TonyB66]

With the plate secured, I took measurements for the front and rear angles. Decided to go with 35 1/2".

These will serve the obvious purpose, and also make for additional rigidity. I had saved these cardboard angles I got in some packaging and I put one to good use...

Fits well.

So, time to cut the real one to 35 1/2".

The front angle required no cutting. As noted earlier, the piece I purchased at THD was actually cut to almost 37". With no rear bumper that far forward on the frame rails, there is more separation up there...

And, speaking of the rear bumper, since the plate goes further forward there is gap where it ends. The aforementioned 3rd bolt will go in this location, on each side. There looks to be about 4" of frame before it curves upward, thus by choice to go with 4" wide aluminum.

I decided upon 2 1/2" for under the frame rails.

As far as marking the hole in the aluminum, with an opening in the frame rail, I was able to easily get my finger in there and down into the hole. I used some black paint.

Seems to have worked pretty well.

Some more to follow...

 

[TonyB66]

Which brings me to yesterday... With the tank arrived, the moment of truth.

First, a bracket in place, is a good sign.

I needed to remove the driver side rear tire and just by loosening the bolts a little, it slid right in.

Another hole to make and mark first... I used the same black paint, but this time with a small brush, like used when painting models. I did my best to paint around about half of it...

Not too bad...

I made the hole 1", so I have some wiggle room...

Starting to come together...

Oh, those 3rd holes into the steel. I used the same process (finger with paint).

The mark it left not all that great, but I drilled-out both holes and I'll be prepared to use the file if need be. Also, as with the Savage hardware, I used grade 8 fine thread 1/2" bolts. These are a little longer, allowing me to lower that end down further.

Anyone care to guess what's next, hopefully later today after I pick-up the kids from school?

 

[T4topher]

Looks good Tony! Might have to ‘borrow’ a couple ideas when I end up mounting my 20lb co2 tank in the same spot.

 

[TonyB66]

Looks good Tony! Might have to ‘borrow’ a couple ideas when I end up mounting my 20lb co2 tank in the same spot.

Thanks. Sure, of course. Wish we were more near each other. I need some welding to finish-up, that C-channel and angles... I'd treat you to pizza and beer, at a minimum. The local weldor is not available for such a job until Monday. I can see him that morning before I leave on biz travel...

 

[T4topher]

Thanks. Sure, of course. Wish we were more near each other. I need some welding to finish-up, that C-channel and angles... I'd treat you to pizza and beer, at a minimum. The local weldor is not available for such a job until Monday. I can see him that morning before I leave on biz travel...

Common down to SF brother and I got you no problem!

 

[TonyB66]

Common down to SF brother and I got you no problem!

That is so tempting. Like I'm really thinking about it, if you are serious. I know you and your wife are expecting, so no problem. I'd understand for sure. My wife's mom is here now from Taiwan, so leaving her for while would not be a problem...

Let me know, and if you don't mind a visitor and performing the work, I'd strongly consider it. I can order a pizza at a nearby place. I'm very empathetic to your wife being pregnant, and now not being a good time.

 

[T4topher]

That is so tempting. Like I'm really thinking about it, if you are serious. I know you and your wife are expecting, so no problem. I'd understand for sure. My wife's mom is here now from Taiwan, so leaving her for while would not be a problem...

Let me know, and if you don't mind a visitor and performing the work, I'd strongly consider it. I can order a pizza at a nearby place. I'm very empathetic to your wife being pregnant, and now not being a good time.

Yea man I think I’m going to hollister on Saturday but other than that I should be pretty free on the weekends. Let me know.

Edit: never mind hollister fell through, let me know!

 

[TonyB66]

Yea man I think I’m going to hollister on Saturday but other than that I should be pretty free on the weekends. Let me know.

Dang, you'll be driving right past me on 101 south (10 minutes from freeway). Too bad as the equipment is a pain to move of course.

I'll post a photo or two of the work involved and if that's something you feel comfortable with, sounds like Sunday would be better... Thanks again.

 

[octanejunkie]

Neat-o
I like where you are going with this...

How do you plan to fill that tiny tank?

 

[TonyB66]

Neat-o
I like where you are going with this...

How do you plan to fill that tiny tank?

Thanks Mike. I view the tank as a Jerry can basically. Depending upon the situation, it should add between 50 to 70 more miles of range... As far as how I plan to fill, well the photos I'm about to share will show that.

I wonder what that black line is in the bottom of the photo? Doesn't look factory with electrical tape securing it...

Ok, access to fill the tank and the storage area...

Four holes just big enough for the blade. I ultimately used the jigsaw again...

The opening is not quite 12" x 12". I filed all four sides so there are no sharp edges or points.

I reinstalled the plate and was pleasantly surprised that the 3rd bolt on the driver side went in beautifully. On the passenger side, the exhaust pipe has enough play to get the bolt in place, but the hole I made does not line-up. Drat. I can't use the rat tail file when it's installed because of the exhaust pipe, so I'll need to remove the plate, file, then re-install. A bit of a pain. Something for tomorrow or Saturday...

Time for the tank. As yesterday, I simply loosened the bolts a little and the tank squeezed into place.

The vented cap comes-off easily below the floor, so no need to trim a semicircle into the flooring to get it out.

I have maybe 3/16" space to slide the tank more forward, but the hole I made for the outlet is preventing such. So, that's on the list for tomorrow also. Minor, but having even a little bit more open space to get bags in and out could make a difference. I will then mark the holes for the mounting brackets. They looks to be about 3 1/2" center-to-center.

Then she'll be set for welding. Here are the four pieces that I want to have welded. This is the bottom.

[MENTION=271883]T4topher[/MENTION], is that something you'd feel comfortable doing? If not, no worries, I can use a local weldor on Monday before I fly to LA.

This came today and this is what I might ultimately use to transfer gas into the main tank, through its fill neck. I have another non-electrical solution coming in the next two days though (Fri and Sat deliveries).

A note from my oldest on the yard white brought a smile to my face.

I will start experimenting to see what size tool bags (fabric) I can get in/out of that opening. I think 8" wide max, up to 8" tall will work, with some decent length. I will try to fit various boxes and bags that i have to get an idea. I'm already compiling a list of onboard tools.

Yes, I will have a sealed cover for the opening, and while not yet determined, I have a couple ideas that I'm pondering... Since the storage area below the floor is quite open, I'm not overly concerned about fumes.

 

[T4topher]

Thanks Mike. I view the tank as a Jerry can basically. Depending upon the situation, it should add between 50 to 70 more miles of range... As far as how I plan to fill, well the photos I'm about to share will show that.

I wonder what that black line is in the bottom of the photo? Doesn't look factory with electrical tape securing it...

Ok, access to fill the tank and the storage area...

Four holes just big enough for the blade. I ultimately used the jigsaw again...

The opening is not quite 12" x 12". I filed all four sides so there are no sharp edges or points.

I reinstalled the plate and was pleasantly surprised that the 3rd bolt on the driver side went in beautifully. On the passenger side, the exhaust pipe has enough play to get the bolt in place, but the hole I made does not line-up. Drat. I can't use the rat tail file when it's installed because of the exhaust pipe, so I'll need to remove the plate, file, then re-install. A bit of a pain. Something for tomorrow or Saturday...

Time for the tank. As yesterday, I simply loosened the bolts a little and the tank squeezed into place.

The vented cap comes-off easily below the floor, so no need to trim a semicircle into the flooring to get it out.

I have maybe 3/16" space to slide the tank more forward, but the hole I made for the outlet is preventing such. So, that's on the list for tomorrow also. Minor, but having even a little bit more open space to get bags in and out could make a difference. I will then mark the holes for the mounting brackets. They looks to be about 3 1/2" center-to-center.

Then she'll be set for welding. Here are the four pieces that I want to have welded. This is the bottom.

[MENTION=271883]T4topher[/MENTION], is that something you'd feel comfortable doing? If not, no worries, I can use a local weldor on Monday before I fly to LA.

This came today and this is what I might ultimately use to transfer gas into the main tank, through its fill neck. I have another non-electrical solution coming in the next two days though (Fri and Sat deliveries).

A note from my oldest on the yard white brought a smile to my face.

I will start experimenting to see what size tool bags (fabric) I can get in/out of that opening. I think 8" wide max, up to 8" tall will work, with some decent length. I will try to fit various boxes and bags that i have to get an idea. I'm already compiling a list of onboard tools.

Yes, I will have a sealed cover for the opening, and while not yet determined, I have a couple ideas that I'm pondering... Since the storage area below the floor is quite open, I'm not overly concerned about fumes.

I think one of your images wasn’t showing up, I feel comfortable welding it if you feel comfortable having me weld it! Haha.. by no means am I an experienced welder, more of a hobbyist. I can snap a picture of my pan hard kit that I welded if you want to see what my welds look like. I think it will hold just fine, I just don’t want you to expect perfect dimes..