Front Range 4x4 Upcoming Trail Runs - Add a New Trail Run

Page 2 of 2 FirstFirst 12
Results 21 to 33 of 33

Thread: Making a Swag Offraod 50" finger brake our own

  1. #21
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

  2. #22
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Got the frame off the table with the forklift so it could be flipped over.





    Welded the web gussets into position:





    Then clamped the outer plates and the frame to the table again to weld everything solid:



    Then took the assembly off the table to get wire wheeled:





    Then outside to get blown out with compressed air:



    Then it came back inside and the casters were put on so it could be moved easily around the shop without the forklift:





    Should be ready to start mounting the brake and the hydraulics soon!

  3. #23
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Was debating adding some gusseting to the top crossbeam and finally decided to just do it. Cut some 4x4 square tubing:



    And welded them into position:





    Then mounted the top plates and eye bolts:






  4. #24
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Drilled a couple holes into the base of the finger brake assembly to be used for mounting:







    And mounted the base into the frame:





    And assembled the brake:



    Then got to work on the bottle jacks. They need to have the knobs added to them for ease of use. And to have the return springs and plates removed. The jacks as they come:



    The knobs:





    Pressed the roll pin out of the release valve:



    Then added the new knob and pressed the pin back into position:


  5. #25
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Installed the jacks:





    Then quickly plumbed them together using the HF 3 way coupler to test the system. They worked! But were not in sync. We have a solution for that, stay tuned:





    Knowing that the system will work was a relief. Reading up on what others do is great, but getting the same results isn't always likely. And since it works, the decision was made to plumb the air lines in a much cleaner fashion then using the bulky stock rubber air hoses and HF coupler. So it was plumbed using pex tubing and fittings, as well as uses the foot pedal that was mentioned earlier:








  6. #26
    Join Date
    Sep 2011
    Member
    #921
    Last Online
    4 Hours Ago
    Location
    Fort Collins
    4x4
    1990 Jeep Wrangler (YJ)
    Posts
    7,414
    User Name
    Jim
    Real Name
    Jim Williamson
    Thanks Given
    1,398
    Thanked 1,811 Times in 1,217 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    `looks great. I like the bare metal look. Did you do anything to keep it from rusting?

  7. #27
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Jim previously posted:
    "`looks great. I like the bare metal look. Did you do anything to keep it from rusting?"

    Thank you for the kind words. I haven't done anything special to keep it from rusting. Still deciding if it will get paint. Most of the equipment and tooling I have built stays bare, if anything they see a little oil.

  8. #28
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Time to get started on the mid plate. This piece will be crucial to making the press function correctly as well as making it easy to setup and operate. The mid plate will tie the bottom of the bottle jacks all together and keep them aligned. It will also act as a mount for the different press attachments, with the finger brake being the main attachment used. The assembly will be made up of a series of stacked plates in the center with sections of tubing on the outer edges. It will also feature a pair of removable guides that will straddle the vertical legs of the press frame, keeping the assembly aligned within the frame and parallel to the horizontal beams.

    Start by cutting and cleaning up the pieces needed for the main assembly:



    And since the brake press works, and are excited to try it out, the guides will be first to be made. Start with two pieces of 3/8" x 2" flat bar cut to the identical length:



    Then bend them using the new brake:



    Drilled some holes in the bottom of them:



    Prepped the bent pieces and a set of 1/2" thick plates to be welded together. Clamped them to the fab table and welded them solid including filling the drilled holes by plug welding them for extra strength. Then cleaned them up:














  9. #29
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    The main body will be made up of stacked plates with tubing run along the edges. Cut a couple plates, one 1/2" thick and the other 1/4" thick, then drilled a couple holes in the 1/4" thick piece to use for plug welds, and welded them together:







    Capped and sanded the ends of the tubing:



    Clamped the pieces together and to the table using another piece of 1/4" thick material to help keep things aligned. Then welded the assembly together:





    Then sanded the ends smooth and clamped the assembly back to the table in order to weld on the end pieces:







    Finished sanding the assembly smooth then drilled a hole in each end and drilled and tapped the guides to match:






  10. #30
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Placed the mid plate assembly into the press frame using some scrap tubing to keep it off the bottom beam:





    Nice tight, but not too tight, fit:





    Moved the assembly closer to the bottle jacks to begin layout of their mounting and the layout of the through holes needed for the different attachment mounts:



    Machined a few hold down clamps to keep the bottle jack in position:





    Positioned the clamps near the spring mounts since that area will see the most force:







    Then used transfer punches to mark the centers. Also laid out the locations of the through holes. Then removed the assembly and drilled the holes:


  11. #31
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Assembled everything back together:







    Tested it and the mid plate worked well all round. The jacks do not release fully and start to recede until each knob is turned. And the jacks now work together as one can not move without the others. Happy with the results. Now just need to make the mount for the brake, fab a handle for the frame to help ease of moving, assemble the gooseneck and hemming dies, and then come up with a storage solution for the die sets.

  12. #32
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Came to our attention that we forgot to show how we secured the top of the jacks to the top of the frame. The top mounts were drilled in the center and then countersunk.





    Then the top of the jack was drilled and tapped in the center:





    And the two were married:





    Made an intermediate mount for the brake. Started with a piece of 3/8" thick flat bar, then drilled and tapped a series of holes in it to match the mid plate. Also included a couple holes to attach to the brake.





    Then laid out the mounting holes on the top of the brake and drilled and tapped them:





    And then assembled everything together:




  13. #33
    Join Date
    Jun 2013
    Member
    #1249
    Last Online
    4 Days Ago
    Location
    Broomfield, CO
    4x4
    97 Dodge CTD, 85 Toy P/, 85 4R, 89 YJ, 97 TJ,51 F1
    Posts
    2,756
    User Name
    Brucker
    Real Name
    Aaron Brucker
    Thanks Given
    319
    Thanked 403 Times in 313 Posts

    Default Re: Making a Swag Offraod 50" finger brake our own



    Been slacking on the updates, though do have some. But to hold ya'll over, here is a short video of the brake press in action:


  14. The Following Member Says Thanks to Brucker For This Post:

    cnstaco (February 17th, 2020)

Page 2 of 2 FirstFirst 12

Similar Threads

  1. stickers and other swag
    By Jackie in forum Chat
    Replies: 1
    Last Post: August 28th, 2019, 01:42 PM
  2. Swag Tents
    By Paul in forum 4x4 Videos & Photos of Interest
    Replies: 1
    Last Post: May 10th, 2016, 10:13 AM
  3. CBI Offraod Opinions
    By Fordguy77 in forum General 4x4 Tech Topics
    Replies: 6
    Last Post: February 6th, 2013, 12:31 PM
  4. Five Finger Death Punch
    By mattzj98 in forum General Topics
    Replies: 4
    Last Post: August 2nd, 2011, 09:27 PM
  5. Ford 9" Disc Brake Conversion Links
    By Brody in forum Tech Links
    Replies: 0
    Last Post: October 9th, 2009, 07:56 AM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
BACK TO TOP