Archive for the ‘Upgrades’ Category

Dana 44 Diff Cover

by on Sunday, May 17th, 2015

While the carrier was on its way I decided that I would try to make a new Diff Cover for he Dana 44 axle. I had searched previously to find a DXF file with good enough dimensions to cut on the CNC Plasma. Since the cover was off and I had time I just created the file myself. I placed the stock cover on my weld table and used a scribe to outline the existing cover and the placement of the holes. Once I was comfortable with the markings, I proceeded to measure and draw it in CAD. The outline was fairly simple, but the holes tend to not be so easy. First off the tolerance of the stock cover was all over the place. So I first cut this into a thin sheet of steel to save on the cost of checking the dimension I took. After an initial trial, I discover that two hole were just far enough off that you could start all the others and just slightly off to start the bolt. On the thicker material I decided the easiest way to fix this was to open the hole size up to .375 from .34 and all the bolt fit with out an issue. (more…)

Jeep fuel Problems | Conclusion

by on Sunday, June 22nd, 2014

In my last post I started to figure out what the issue was with fuel leaking when the Jeep was running. What I found was the the return line was leaking right next to the sending unit. linesAfter taking out the tank twice in the last month for fuel related issues, I came to the conclusion that I should have replaced both fuel lines when I had it out the first time. Hind site is always 20/20. What I did do was create an access point in the back of the Jeep so I can easily get the sending unit without having to drop the tank every time. It did only take me a couple of hours, but it could have easily been fixed on the trail if I would have had the access panel. I will add pictures of the access panel to this post when I get it completed. I only cut the opening while the tank was out. I will add the hinge and the latch later this week.

CNC Plasma | Gantry Upgrade

by on Thursday, January 9th, 2014

This version of the gantry has undergone some changes since its inception. Mostly because I didn’t foresee everything needed to make these changes before i started and had to make some more changes. Others were changed for future plans, while still retaining functionality until the other changes are made. This image is the future version it will finish in. The main difference from what I am doing now is the addition of the second linear rail on the y axis (gantry carrying axis). The other is a lower profile of the gantry itself to allow a better connection between the welded pieces and a overall aesthetics of the gantry itself.

CNC Plasma Upgrades

by on Monday, September 16th, 2013

After using the table for quite some time, I have discovered a few issues. First off with my design for the guide rails using the v-groove wheels is flawed. The current design only uses these bearings on the top of the rail. With this type of setup it tends to not want to stay on the rails. Also when you cut thin material it tends to lift one side of the other when you change directions rapidly.

So I have been working on a new design. seen below.

The z axis will remain unchanged as will the table itself. The main changes are with the gantry itself. (more…)

CNC Plasma | Laser Crosshairs

by on Wednesday, August 1st, 2012

Been a while since I did a write up for this blog. I guess it is overdue.


A couple of weeks ago I was trying to line up a sheet on the Plasma table and struggling to locate a part within a piece of material very close to the same size as I was planning to cut. I told myself, “Self you need to make something to help with this little issue”. I only talk to myself on very rare occasions. Stop being so judgmental.


I decided to take a trip to the hardware store to see what I could use to make a device to locate my sheet. First thought was a device that went off of the edge of the table but seams too simple. So then I though about using a laser to help locate the sheet. Sounded like a nice little project. So I went in search of some sort of laser line generator. Off to the laser level isle. I found a cheap little level that had a laser line that could be rotated for around 15 bucks. Was hoping for something a little cheaper because I would need two of these.

I started off with just purchasing one (tight budgets suck) to make sure it would work as I expected.


Jeep update

by on Wednesday, May 25th, 2011

After a struggle with getting some electrical bugs worked out with my Jeep I think I finally have it ready for the year of wheeling. Thinking i had a short somewhere that was draining the battery I spent a lot of time tracing wires to not find any issues. Come to find out the battery had a major issue.

Then I had the task of replacing my spare that had a slight major hole in the sidewall. Only to find out that the price of tires have been jumping faster than the fuel prices. Sheesh will it ever end. I put the father-in-law up to the task of locating a suitable replacement at the Jefferson, Wis spring swap meet. He found me one with a little less than half tread for a mind boggling $5. Yes only $5! What a find.

Just waiting for June and the fathers day run at the cliffs.

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