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Varg In Jeep's Clothing

Discussion in 'Builds and Fabricators Forum' started by ITLKSEZ, Aug 20, 2015.

  1. Apr 19, 2022
    SFaulken

    SFaulken Active Member 2021 Sponsor 2020 Sponsor

    Marysville, WA
    Joined:
    May 24, 2011
    Messages:
    1,039
    Wheres the rest of the hub? Did I miss something?
     
  2. Apr 19, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    6,323
    :sneak: :watch:
     
  3. Apr 19, 2022
    Norcal69

    Norcal69 Out of the box thinker 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Northern California
    Joined:
    Sep 6, 2014
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    2,773
    Locking hub spare tire carrier pivot???
     
    Ol Fogie and ITLKSEZ like this.
  4. Apr 25, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    Yes!!

    And here’s the build.

    I picked up a front hub and axle shaft from an OBS F150 at the local yard. I wanted to cut most of the flange off and leave a tab to incorporate into the tubing for extra strength.

    [​IMG]

    Torch cutting this revealed that it wasn’t a standard high-carbon steel. The oxygen would cut it (albeit slowly), so it wasn’t typical cast iron, but the molten slag would hit the ground and explode like fireworks. A cutting disk was ok, but produced medium amounts of spark. Again, less than steel, more than cast iron. I welded some scrap pieces and came to the conclusion that it’s nodular iron. It will make welding to it a challenge, but I have a plan.
    Cleaned up and ready…

    [​IMG]

    Next up was the spindle. This needed the shoulder removed from the face…

    [​IMG]

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    And then I stared at it like this for about two days, trying to come up with a way to mount this that is strong and easily removable.

    [​IMG]

    I got stuck there, so I moved on to axle shaft prep. This needs to be centered in the spindle and locked in place. When the hub is unlocked, it can freewheel around the axle. When it is locked, the stress of the carrier will be against the attachment of the shaft to the spindle.

    [​IMG]

    I needed to completely reassemble the hub in order to place the shaft at the proper depth. The locking hub centered the outside, and I used screws to center the inside.

    I had to make a tight-fitting shield to protect the exposed bearings from weld spatter.

    [​IMG]

    This thing was too hot to touch for two hours.

    [​IMG]

    At this point, I figured out that I could use a riser out of 2x3” tubing with a 3/8” plate to allow enough room to access the bolt holes I built into the bumper for this 13 years ago.

    [​IMG]

    I ended up cutting another 1/2” out of the riser just so the whole assembly clears my tail light.

    [​IMG]

    [​IMG]

    More updates at some point….
     
    Last edited: Apr 25, 2022
    fhoehle, tomasinator, tymbom and 10 others like this.
  5. Apr 25, 2022
    Howard Eisenhauer

    Howard Eisenhauer Super Moderator Staff Member

    Tantallon, Nova...
    Joined:
    Nov 22, 2003
    Messages:
    7,520
    :(

    My guess was "Thermos"
     
    Lockman likes this.
  6. May 2, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    I notched the 2 x 2 x 1/4 tubing to accept the flange tab. I drilled a 7/8” hole in the top and plug welded it in place with the other side at the proper height.

    [​IMG]

    From there, I could tack on the gusset, get it onto the bench, fit the band around the top, and weld it up. The band will just get seam filler, not weld. If there is catastrophic failure in the mild steel/nodular iron connections, the band will act as a safety belt, holding it from complete failure.

    The iron/steel welds look cold, but it’s just how they end up. It’s a weird process.

    [​IMG]

    The cradle was next. I went with a bolt-style latch with cow mat.

    [​IMG]

    [​IMG]

    The end of the tubing was cut to length, notched, and I bent up this insert to weld in for an angled bolt surface.

    [​IMG]

    Welding it in…

    [​IMG]

    I tacked a little ring to the bolt inside the tubing before capping it off. This prevents the bolt from falling out.

    [​IMG]

    Added a handle…
    Zoom in on the left side. :D

    [​IMG]

    I’m super pleased with how it feels.

    [​IMG]

    [​IMG]
     
  7. May 2, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
    Messages:
    2,049
    I have to stop reading other idea :p

    I have those part laying around and now i will have another project ahaha

    Nice work as usual :p
     
    ITLKSEZ and Twin2 like this.
  8. May 2, 2022
    Buildflycrash

    Buildflycrash The pride of Cucamonga 2022 Sponsor 2020 Sponsor

    Gulf Breeze FL...
    Joined:
    Jun 5, 2007
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    2,812
    Love the "Volvo" on the handle. (y)
     
    ITLKSEZ likes this.
  9. May 2, 2022
    Keys5a

    Keys5a Sponsor

    Florida Keys
    Joined:
    Jan 23, 2014
    Messages:
    3,546
    You mentioned that the hub is probably nodular iron. I experienced that metal when I was narrowing a Chevy 12 bolt rear for my ‘66 Chevelle. All I wanted was the nodular center casting, and needed to remove the axle tubes that are pressed, then plug welded in the housing. There is no harder metal to drill than those plug welds! Later I learned that the high amps used when plug welding mild steel onto nodular iron will produce a super-alloy. Something about some extra carbon molecules from the iron combining with the steel making an undrillable alloy. I ended up using carbide masonry bits, many of them!
    -Donny
     
    Ol Fogie, fhoehle, blalp! and 2 others like this.
  10. May 2, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    6,323
    I did some research and some test-welds prior to starting this, and it is definitely odd. I’m amazed at how flexible it is. It bends like steel until it breaks like cast iron.

    The welds themselves are brittle down the center when pried apart, but seem to bond to the base extremely well, despite the appearance of a cold bond. This is in direct contrast to cast iron.
     
    fhoehle, SFaulken and blalp! like this.
  11. May 3, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    A butt weld could make a simple and strong connection where two pieces of tubing come together, forever hidden behind a spare tire. Everything has to be a huge ordeal. :rolleyes::banghead:

    It’s times like this when I hear the little boy’s voice in my head, “Mommy, why can’t I just be like normal boys?”

    [​IMG]

    [​IMG]
     
  12. May 3, 2022
    Fireball

    Fireball Well-Known Member 2022 Sponsor 2021 Sponsor 2020 Sponsor

    Pullman, WA
    Joined:
    Feb 9, 2018
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    :rofl:
     
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  13. May 6, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    That bent axle shaft from a few posts back got repurposed. I cut the outer 8” off, cut holes through the tubing with a hole saw, and I welded it in place after breaking out the laser level to make sure the studs were symmetrical.

    [​IMG]

    I flipped it over and welded it in after grinding bevels. That weld got ground flat and blended smooth.

    [​IMG]

    Top got cut to length and capped. Some weld porn…

    [​IMG]

    My wife brought this stainless steel shelf home from work a few years ago. I’ve been hanging onto it specifically for this.

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    I grabbed some hinges with removable pins an attached it…

    [​IMG]

    [​IMG]

    Then built a framework around it…

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    To mount support cables…

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    For a table!

    It is virtually unnoticed when folded up.
    The corners of the frame will get utilized… update eventually.

    [​IMG]
     
    Ol Fogie, tymbom, Dandy and 18 others like this.
  14. May 8, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
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    I think the carrier is finished for now.
    I figured out how to mount the license plate; the lug nuts I bought for this came with locking nuts that I’ll never use, so I took two and welded some clips fast that I bent for the purpose. These just get spun on a few turns. They can’t back off when the plate is attached.

    [​IMG]

    [​IMG]

    I tackled the saw mount this morning. I used a door hinge from a car and frenched it into some 1/4” plate. I used a latch that has a loop for a padlock. Forgot to get more pics of that.

    [​IMG]

    I was planning on making a shovel mount for the other side, but I just couldn’t make it look right and not be in the way. I might still add it later, but for now, I'm calling it done. Now it gets all disassembled for paint.
     
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  15. May 8, 2022
    Admiral Cray

    Admiral Cray I want to do this again.. Staff Member

    Bainbridge...
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    Sep 21, 2009
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    204,286
    Use your thumb to cover the license plate number please... (y)
     
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  16. May 8, 2022
    colojeepguy

    colojeepguy Colorado Springs

    At the foot of...
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    Apr 4, 2010
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    5,817
    I hope you're not planning on hauling firewood in the Varg! :shock:
     
  17. May 8, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    That’s what trailers are for. ;)

    [​IMG]
     
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  18. May 8, 2022
    johneyboy03

    johneyboy03 The green beast

    Quebec, Canada
    Joined:
    Jan 15, 2011
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    2,049
    Great idea about the folding table. I was wondering what you were up to ahah
     
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  19. May 9, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    Here’s a closeup of he saw mount. It’s all painted gray now. I’m out of hardener, so it’ll probably take 3 weeks to dry

    [​IMG]

    [​IMG]
     
    tymbom, jeepstar, homersdog and 6 others like this.
  20. May 10, 2022
    ITLKSEZ

    ITLKSEZ Hope for the best, prepare for the worst

    Post Falls, ID
    Joined:
    Aug 13, 2015
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    6,323
    This look will take some getting used to.

    [​IMG]

    [​IMG]

    [​IMG]

    How it works:

     
    Muzikp, tymbom, dozerjim and 11 others like this.
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