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Norcal69's Common Sense Build.

Discussion in 'Builds and Fabricators Forum' started by Norcal69, Sep 11, 2014.

  1. Jan 20, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    That was my original plan, but PSC recommends an internal stop to prevent mud and debris from getting packed into the seal when fully compressed.
     
    timsresort, 47v6, Jw60 and 1 other person like this.
  2. Jan 20, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    I will watch this. When I have done the Redneck Rams, they asked me to determine this beforehand, and they install the spacer.
     
    Norcal69 likes this.
  3. Jan 25, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    More progress!
    Both ram ends with misalignment spacers.

    [​IMG]



    With everything assembled I tack welded the axle side ram mount in place and fired up the forklift for a lil' flex test.
    Left rear lifted to full stuff, wheels turned hard right.


    [​IMG]

    [​IMG]


    Right rear lifted to full stuff, wheels turned full left.


    [​IMG]


    [​IMG]


    With everything bind free I welded the axle side bracket in place.
    A heavy coat of paint inside and out.


    [​IMG]
     
    Last edited: Feb 1, 2023
  4. Jan 25, 2023
    Stakebed

    Stakebed Member

    Lake Co....
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    That's impressive articulation.
     
    vtxtasy likes this.
  5. Jan 30, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    Yesterday was productive in the in the shop.
    I was hoping to drill and tap the steering box with it mounted on the jeep..... Its a real PITA to get the steering box off..... After dithering around for a few minutes I decided to remove the box to drill and tap the fittings.
    Removed steering box brace, winch and sway bar arm in order to access the box bolts.

    [​IMG]


    Sorry, No pictures from the drilling and tapping process...... didn't want to get the phone greasy.
    You get the idea. The upper port is the pressure port, the return port is the lower. The draining power steering fluid rinsed out all of the metal shavings from the drilling and tapping.
    The lower port is shallow for a pipe thread... you have to start the tap and run it down until it bottoms out. After it bottoms out you have to cut several threads off of the tap and then re cut the threads until it bottoms out again.


    [​IMG]


    Here is the finished product.
    Steel 1/4 NPT/#6JIC fittings installed.
    The lower fitting needs a couple threads cut off of it so that it does not bottom out in the hole and prevent fluid flow.


    [​IMG]



    Next victim...... limiting the steering ram.
    I was able to take the PSC ram apart fairly easily with a wrench from a 7" angle grinder.


    [​IMG]


    I removed the piston from the ram and installed a spacer over the shaft. The spacer fits tight enough that is should not slide on the shaft.
    The spacer ended up being 1.5" long.


    [​IMG]


    Now I just need to source a new PS pressure hose and everything can go back together.
     
    73 cj5, timsresort, Fireball and 2 others like this.
  6. Jan 30, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    Since you will probably have 90* fittings on the hoses, and I know you already thought of this, one thing you can do is get the hose and fittings loose, so you can clock them the way you want them, then take them for crimping. Also if you can, try to go to a real hydraulic house, not the FLAPS, I had some crimps screwed up by the kid at a NAPA, popped right off the first time I stressed it.
     
    Norcal69 likes this.
  7. Feb 1, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    I have the field serviceable fittings from PSC.
    They take up a little more space, but all I need is a spare length of hose and I can attach new ends on the side of the trail.
     
  8. Feb 1, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    I got the PSC power steering pump installed last night. It was a good time to go ahead and replace the engine drive belts since they were already off.
    My original plan was to use the YJ pressure hose that was on the jeep with the old pump. After thinking it over I decided to switch the pressure hose to a hydraulic hose style.
    The pump to box pressure hose will use the weatherhead field serviceable fittings just like the rest of the system.
    One 26" piece of spare hose in the toolbox will allow me to replace any steering related hose on the trail.
    I'm just waiting on the metric o ring/jic adapter fittings for the pump and box.

    Who doesn't love new parts on a grimy engine!

    [​IMG]


    Steering box hose ends and cylinder hose ends installed for mock up.


    [​IMG]
     
    dozerjim, Ol Fogie, Lilbuff63 and 7 others like this.
  9. Feb 2, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Northern California
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    New twist in the project!
    I had a bit of a falling out with PSC today over their special hose and fittings. I went to 3 hydraulic shops in town looking for hose that would work with their fittings.
    None of the shops inventoried suitable hose so I stopped by my local Applied Industrial office; No luck getting hose within the next week.
    So we will chalk the PSC hose kit up to a waste of $$$... I guess I can make up a spare universal hose and keep it in the tool box..... darn expensive spare.... o_O

    My local hydraulic shop made me up a power steering hose to my spec, and 6' of hose with 2 ends. I just need to cut the hose to length and they will install straight fittings to come off the steering box with.


    [​IMG]
     
  10. Feb 2, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

    South Lake Tahoe CA
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    I think you are better off to use non-reusable fittings, I have had failures on my wood splitter with those. Even if you have to pay to have a trail spare made. Also to remember, keep those caps that come on the cylinder, and in the event of a failure, you can cap the box, and run without the ram.
     
  11. Feb 2, 2023
    Stakebed

    Stakebed Member

    Lake Co....
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    Nice to have a good hydraulic hose shop available.
     
    Ol Fogie likes this.
  12. Feb 3, 2023
    txtoller

    txtoller Member 2023 Sponsor 2022 Sponsor

    Weatherford, TX
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    This is getting to be common with PCS, Tom has become a real prick and their quality has fallen off sharply.
     
  13. Feb 5, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Rough idea of how the hoses will route.

    [​IMG]
     
    txtoller, jzeber, timsresort and 5 others like this.
  14. Feb 6, 2023
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
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    You could have re-usable hose and fiting from that hydrolic shop. That way you need only a 2-3 feet spare hose with two spare fiting.
     
    Ol Fogie likes this.
  15. Feb 7, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    Buttoned up the pump to box connections last night, topped it off with a fresh belt.

    [​IMG]


    [​IMG]


    Tonight I hope to get the cooler mounted so I will be able to flex test the hose situation.
    I picked up a hydraulic line mount that should tame the lines somewhat. Of course a flex test will be necessary to determine the proper location for it.


    [​IMG]
     
    Last edited: Feb 9, 2023
  16. Feb 7, 2023
    supertrooper

    supertrooper Member

    moreno valley, ca
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    That is a slick setup. I think you made the right choice by not mounting the ram to the diff cover, i cant see the bolts not coming loose and causing a leak when mounted to the cover
     
    johneyboy03 and timsresort like this.
  17. Feb 7, 2023
    timsresort

    timsresort Active Member 2023 Sponsor 2022 Sponsor

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    X2
     
  18. Feb 9, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    The last part of this project is the cooler install.
    I did not flex test before finalizing the cooler location. I am 99.9% sure that it will be just fine...... Of course I will flex test it once the system is operational.
    1/4" thick cooler brackets cut from some old mill machinery.

    [​IMG]


    The cooler brackets welded in place. Once the flex test confirms my confidence in the clearance, I will add a triangulated brace to the cooler tabs to prevent vibration cracking down the road.
    45 degree fittings on the cooler inlet/outlet to prevent return hose kinking.


    [​IMG]


    This is what the finished product should look like. I still need to plumb the return lines, fill/bleed the system, locate the hydraulic hose mount on the grill and get some locking jamb nuts for the cylinder end bolts.


    [​IMG]
     
  19. Feb 9, 2023
    jeep peep69

    jeep peep69 Member

    redding ca.
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    Put some old fire hose or spiral wrap on the hoses to prevent chaffing .
     
    Norcal69 and vtxtasy like this.
  20. Feb 10, 2023
    Norcal69

    Norcal69 Out of the box thinker 2024 Sponsor 2023 Sponsor 2022 Sponsor

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    That’s the plan. Spiral chaff guard.
     
    timsresort likes this.
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