Zuk on 38's

[onac255]

Thanks for sharing and keep it coming!

 

[Tan Zuk]

Here is a look at the large Panhard bracket which is a perfect example of a 3D trapezoid.

It took a little longer to complete after collaborating with Jethrobodean on the best structural strength of the bracket location. He had pointed out with the bracket blending in at the end of the fishplate. This would cause extra stress on this area. The better option would be to keep it 1 to 1.5” away from the end of the fishplate.

The choice was the shorter route to correct the problem because the plates were made already. The new position just happened to be my original thought. The strong need to make it more visually pleasing with everything blending at one place just took over.

Jethrobodean also mentioned to add a fishplate to the backside of the bracket where it is being welded to the frame. This will be done as a precaution to eliminate the possibility of excess stress on this area. There was also mention to tie the top of the Panhard mount to the Ford Shock Tower for additional strength. All these were very good suggestions and will be performed as well.


Very Big Thanks to Jethrobodean for taking the time to point out something that I had contemplated on or over looked. It is always good to have an extra set of eyes looking at a complex design to accomplish the best out come.


Again it is better to be flexible ask for some input and make corrections on your design. This may require reworking or scrapping something that took a long time to make to address an issue.

You may be wondering why the tube bushing. It has been about 9 months or so since the original brackets were removed. Good thing I had remembered that the steel brake line had to have away to get to the brake line bracket. The tube seemed to be a good solution and give some more strength to the bracket.

 

[Tan Zuk]

 

[Carolinaboy]

Man I'm coming down to FL & have you build me a new bumpers front & rear

I'll bring the beer

 

[Tan Zuk]

 

[Tan Zuk]

Here is my old school cardboard 2D cad mock up of the 1.25 DOM radius support bracket.

The specs are:
1.25 DOM Dia. 1/4 wall with a 4.5” inner radius at 90*.
Bottom support bracket 3/8
Top support brackets ¼ (2)


There will still be a front bracket added. Working on the pieces now.

 

[Tan Zuk]

Front Side 2nd Bracket is made and welded in place. You can now see the extensive amount of surface area the brackets use for strengthening the Panhard Mount. There will still be the additional 3rd round bar bracket. With all three brackets in these positions will equally distribute the load on the frame.

There will also be an additional Tie in1.25 Heim joint bar mounted between the bumpstop mounts on both sides. This will transfer any additional loads to both sides of the frame for even more strength.

Some I’m sure had some doubt of this actually working out. Hope that these Brackets and Tie in’s have helped in changing your minds.

 

[Tan Zuk]

This is the steering link and panhard bars set at 3 ½ degrees. With all the mods made the steering is now close to stock geometry.

Waiting on the DS 1.25 DOM tube to be bent and that will finish this side up.

Made my old school cardboard 3D cad mock up for the PS bumpstop.

 

[Tan Zuk]

We are now on real time for the build so updates will be a bit slower now.

While working on boxing in the PS frame rail the rad support bracket was going to have to be removed. The DS bracket was also removed during the same process earlier. Before the removal of PS bracket the DS bracket needed to be made and reattached. This was to keep the 2 bracket oriented properly.

The process and a couple of tips for this bracket install.


Here is the DS radiator support bracket. This had to be remade because of the new location of the lock nuts for the FJ80 box. The box was also dropped an inch resulting
in chopping the frame down.

These 2 obstacles were a bit of an issue. This bracket needed to be made and installed before the PS inside rail was stripped of the radiator support bracket for the boxing in process.

The bracket was made of ¼” plate and 2 small pieces of ¼” plate were added to make a thicker pad for threading. To make up for the missing inch from the upper frame for mounting the bracket was made 1” longer and the top was given angle cuts to blend in to the frame. The bracket was also made 1” wider to go over the lock nuts.

 

[Tan Zuk]

Weather is finally getting better to get some work done. I have to work with the door up and the wind and rain was too strong to get much done.

Been busy stripping the bracket and under coating off the PS rail. Here is the progress and a bit of future direction on this side.

PS box plate with rosette weld holes.