M135 S and M Build

[gentrysgarage]

Been fighting for 2 plus days now the angles and clearance...either notch the crossmember for front output clearance or raise transfer case and rework both front frame mounts to lower engine trans. Engine/trans and tcase are centered in the frame, tcase front input and transmission output centered and rear output is centered to rear end pinion center.

What do you guys think?

 

[gentrysgarage]

PS Trans and tcase out 3/4 inch (trans high) at this point

 

[m1010plowboy]

Been fighting for 2 plus days now the angles and clearance...either notch the crossmember for front output clearance or raise transfer case and rework both front frame mounts to lower engine trans. Engine/trans and tcase are centered in the frame, tcase front input and transmission output centered and rear output is centered to rear end pinion center.

What do you guys think?

Think? You mean critical thinking right? I think the A minor chord goes nice with F major and if we add 2 more chords, like G and C, we have a 4 chord song. It's simple, the path of least resistance and since I only have 480 minutes in a day for thinking, it's the quickest think I have. Here's some music while you ponder a plan, I'm not the mechanic.

 

[M37M35]

PS Trans and tcase out 3/4 inch (trans high) at this point

That would make the angle 7.43 degrees.
I'm not a driveline expert, nor did I stay at a Holiday Inn Express last night, but my semi-informed personal opinion is that you would be fine with that angle.

 

[gentrysgarage]

Thanks Plowboy..I needed that..I knew there were a bunch of songs with 4 chords...just didn't know they were the SAME chords LOL!

That would make the angle 7.43 degrees.
I'm not a driveline expert, nor did I stay at a Holiday Inn Express last night, but my semi-informed personal opinion is that you would be fine with that angle.

Thanks for the feedback and advice M37M35! My brain is getting fried right now, another 12 hours outside today AGAIN! LOL! I am almost done fighting the angle/geometry beast! It is a little too much for me. I will welcome any numbers than these below FOR SURE!

If my numbers are correct, that amount of misalignment will cause the U-joints to be running at an angle of 24.41 degrees. That might be too much. Even if they don't bind, they may wear out fast.

4 ratchet straps



2 ratchet straps



3 of my most FAV- VOR-RITE tools here one is REALLY good for releasing frustrations! LOL!


No straps!


Just the notes from today with the measurements from the mid morning! Note numbers in blue are numbers achieved.


At 9 pm tonight no straps or come-along! Still have to finish right side mount, but I have to get the 5 3/4" {edited THANKS M37/35} engine spacing again before I drill the frame. I am so BEAT right now, hopefully, tomorrow will be just as good!

 

[gentrysgarage]

Can't believe this!
Goes to show you can't trust every tool...sometimes the simplest tools are the best! I was leveling parallel with the Harbor Fright digital gauge and once they where at the right numbers it looked worst than I started! Eyeballed it and lowered engine trans and found it was the opposite of the math (using the HF level) and engine trans are actually 1/4 down from LEVEL! WOW! I will have to fab new front side mounts once the LOCKDOWN is done as the steel suppliers here (I think it all the steel suppliers being too lazy to just have people social distance...as they are open for orders and curbside...but no remnant sales!! I am cutting down the front crossmember now for new 3/8ths thick mounting bracket and Ford F750 isolator. I haven't even edited the video from a week ago and soon need to make another one ARRRGGGHHHHHH!!!!!! I even promised the little punks a new game to edit it for me they said nope...gonna have to change all their meals to gruel soon!

 

[M37M35]

Looking great!!! This is an awesome project and I'm glad that you're putting it up here for all of us to follow along!!

Thanks for the feedback and advice M37M35! My brain is getting fried right now, another 12 hours outside today AGAIN! LOL! I am almost done fighting the angle/geometry beast! It is a little too much for me. I will welcome any numbers than these below FOR SURE!

Glad to be able to offer a bit of help!

...but I have to get the 6 3/4" engine spacing again...

As it sits here 3/4" mis alignment in the horizontal plane and 2.5* off in the vertical with 5 3/4" seperation

Is the 6 3/4" the trans to transfer distance here, or is that a different mesurement?? Or a typo? Just thought I'd ask before you drilled the holes in the frame! LOL

 

[gentrysgarage]

Looking great!!! This is an awesome project and I'm glad that you're putting it up here for all of us to follow along!!

Thanks! Actually I consider it a way of
1) Helping others learn from my mistakes and help beginners to plan and to give them insight into how hard or easy a project is. How I go about project planning (or winging it when it DOESN'T go as planned! LOL!) Also for the seasoned professionals to see some of my outside the box (or crazy! LOL!) ideas I have! LOL!
2) Document what I have done so I don't forget!
3) Paying my time forward to all those who help and advice me.

Is the 6 3/4" the trans to transfer distance here, or is that a different mesurement?? Or a typo? Just thought I'd ask before you drilled the holes in the frame! LOL

LOL! Yep that's a typo I need to edit! the yoke/u-joint centerline is gonna be 5 3/4" Thanks!

 

[gentrysgarage]

5.12.20 Picture dumpmp:

 

[gentrysgarage]

You want to know what true beauty looks like? I'll show you!



wait for it





wait





just a little more





BOOM!!!!!



There is at the most a 32nd of daylight at the front of the yoke for the transfer case!

What a bear to clean sand and prime and either they did radiator repair with the radiator in place or that poor motor got HOT there was a ton of lead in the trough! Maybe why the 302 is .020 over!

 

[M37M35]

You want to know what true beauty looks like? I'll show you!

 

[frank8003]

AND ...............He has and uses a real anvil!

 

[gentrysgarage]

Thanks Guys! Yep pretty old school here! LOL!
So Thursday I put the intercooler and radiator back in to check clearances one last time before cutting the crossmember, just to be quadruple sure. As expected there is more room than I needed (well under an 1 1/2 more than before I decided to also use the front side mounts that is).




Anybody know someone that works at Freightliner or a medium duty truck parts house..I think the guy said it was a Freightliner FL50 but I do know it was one of the small UPS day cab tractors CNG converted Cummins motor). I can find the big Freightliner stuff on eBay but these are smaller but same design.


One lesson learned no more using the cutoff wheel after dark...had to straighten a few lines the next day!
Got this done will paint this early and assemble the front mount.

5 frickin' clamps!
Then onto the side rear mounts...not liking what I think I will do though!

 

[gentrysgarage]

Picture dump 5.16.20



Now onto the rear side mounts..yeah!

 

[gentrysgarage]

Today's Dump with comments:


Time to use the modded template again (now with new and improved horizontal veiw..next picture)


Thinking a little art deco here, masononite board is the frame mount template.

Well I killed another Milwaukee tool...their quality has gone downhill since being made in China now. So sad I used to swear by Milwaukee sawsalls...not any more! I have killed 2 sawsalls and the Porta-band in the last 2 years and one sawsall didn't finish it's first cut before it let the smoke out! Anybody have a suggestion for another brand with a better track record?

Also filmed Part One of the Building motor mounts today...probably release a double feature when I go to edit. This week is my on week so progress will slow down till Friday. I think I concentrate this coming week on trying to get the YouTube video out.

 

[gentrysgarage]

New old video is out! Please like and subscribe!

 

[gentrysgarage]

Double feature TODAY! Part 2 of engine mount fabrication!!!!!!

 

[m1010plowboy]

""""""another Milwaukee tool """"""

Milwaukee tool co will be happy once you're done. I'd write them a letter with a link to your thread and get them to sponsor tools to you with advertising on your youtube channel. John Deere gives the millennial farmer tractors and toys so it wouldn't hurt Milwaukee to stand behind their tools.

Great progress with all the parts cut up, primed and ready to go......I can hear it now.

 

[gentrysgarage]

""""""another Milwaukee tool """"""

Milwaukee tool co will be happy once you're done. I'd write them a letter with a link to your thread and get them to sponsor tools to you with advertising on your youtube channel. John Deere gives the millennial farmer tractors and toys so it wouldn't hurt Milwaukee to stand behind their tools.

Great progress with all the parts cut up, primed and ready to go......I can hear it now.

Thanks for the suggestion a sponsor would be REAL nice, but I can't in clear conscience support a manufacturer that has been proven to me to not be reliable. I did find there was a free extended warranty available for the this particular bandsaw as there were design problems but said extended warranty has expired! Oh weeelll.

Caught some sunlight yesterday spent some quality time with the kid and mag drill!



Gonna need some triming!

Well can't get away without having to drill the flange ..I will drill a 3/8 and 7/16 hole in the flange

 

[gentrysgarage]

Picture Dump 5.27.20



Rear Mount is sorted out after 3 redesign and second set of lowers done when it didint work out drilling the center of the stock M35 upper mounts. This is as far I go as it will need a shim to level with the transfercase...but I haven't sourced polyurethane isolators yet for the transfercase yet.

Worked Soldier B and C yesterday and today! They got alot done...


Will film a video before cab is lowered it will be Motor Mounts 2.5 as when I did the coming attractions I said motor mount finale...forgeting I have to wait till the friggin' steel supply is open for rem sales! Arrgh.

OK I have went through all the trouble of using the M35A3 jackshaft and my eyes might be wandering....anybody have the measurement of the M35A2 jackshaft center of ujoint to center of ujoint? Reason being I am making alterations to the firewall and floorlan and with the transfercase set at the M35A3 5 3/4 inches the face of the transfer case is only 3 1/2 inches into the cab....so if the M35A2 is 9 1/2 inches or more it makes my life easier! Anybody have this measurement...I will post a standalone thread on this in the Deuce subforum also.

On a final note of this post I have been working every other week 32 hours during this PanicDemic and have been called back for every week (but still 32 hr week) so progress will slow down a bit .