DAY 2
EXTREME BUILDUP 2000 Project 1
RickRock's 1976 Scout II
Day 2 marks the start of the actual work. Once the rig is brought into the work bay, we start tearing into it. First to go is all 4 tires and the front axle. Today we
will concentrate on getting the Reverse Shackle conversion completed.
First we cut out off the original front spring mounts. Scouts are known to have weak spring mounts here so we cut them without hesitation. Since we will be
building custom front shock mounts, the old mounts are also removed. After we finish cutting, we use a die-grinder to smooth everything out. (The spring is now
hanging from the rear mount only).
Once everything is removed and cleaned up, the next step is to start welding on new stronger spring mounts. Since nobody makes a reverse shackle kit for the
Scout II’s, we will modify an existing kit to fit the Scout springs. Placement is important here, so we will temporarily attach the spring to the new mount in
preparation for welding. Then we use a floor jack and lift it till the new mount meets the frame. This is where we will weld the mount. With a couple spot
welds the new mount is tacked in place (but easily removed if needed). We repeat this with the other side and then make sure the new mounts are at the
same locations on the frame.
Once that is taken care of, and the two mounts are equally located on the frame rails, we will use a 2”x1/4” piece of angle iron to tie the two front mounts
together. Not only does the angle iron get welded to the new mounts, but we also weld it to the front crossmember to give additional strength and rigidity.
Note: Because scout frames are prone to fatigue and can become weakened at these points, only weld short sections at a time.
Then go to the opposite side and make the same bead. This technique keeps the metal from becoming to hot (which can cause it to lose its temper). Then go from
one side to the other making thick, deep penetrating welds until the mounts and angle iron are completely welded into place. Don’t be afraid to allow extra time for
the welds to cool a bit before adding another bead.
After that, we prepare for the rear mounts. The placements of these mounts is critical to how much droop you want out of your suspension. The more forward tilt
in your shackle gives you more droop. Similarly, the more rearward tilt gives you more compression. To much in either direction and you could cause the springs
to bind.
We always give the shackle about 10 degrees of forward tilt to give more droop, anything more than that will compromise your compression movement
(so your axle won’t want to travel into the wheel as well). REMEMBER, this must be measured with weight on the spring, if you don’t have the vehicle resting
on the springs your measurements will be grossly incorrect.
(Notice that we measure the tilt with the wieght of the truck being supported by the spring. you can see about 10 degrees of forward tilt, this is what you want.)
Following the same welding technique as before, the new rear mounts are attached to the frame. With new shackles and the spring reattached, The Reverse
Shackle is now complete.
PLANS
| Day 1
| Day 2
| Day 3
| Day 4
| Day 5
| Day 6
| Day 7
| Day 8
| Day 9
| Day 10
|
