Project Re-Gen: 1985 D350 Headed to SEMA '15!!

[Taquache]

Neat Idea for a truck to be rendered completely useless (except for show only). I'm sure it will look cool once it's finished, but I don't see a point in throwing a bunch of time and money into something that will get stuck on a speed bump.

I'm guessing by this statement you are completely unfamiliar with how air ride works?


Its an adjustable suspension system that allows the user to raise and lower the ride height of the vehicle when ever they please.

This truck will be capable of doing everything it was able to to in the stock form only better with more reliability and comfort. there will be zero loss of towing or usability.

The bed floor will be designed to accommodate a goose-neck hitch along with being able to haul motorcycles if needed. the truck will also comfortably carry Humberto's family across the country on road trips.

 

[ENafziger]

Looking forward to seeing more! Any recent updates?

 

[Taquache]

Ask and Ye shall receive!

 

[Taquache]

How about some updates!!

Humberto has been very busy working on this truck so there is a lot to post. It might take me a day or two to get everything up to current.

Where to start?

Let's begin with the end:

a few more things have been added to the rear of the truck including:

a raised fuel tank (1.5")

a custom bent panhard bar to clear the fuel tank

and a Helwig sway bar out of an Excursion with modified bushings to clear the 4 link setup

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The panhard bar has a double swivel on the ends which will allow for a full 11" of travel in the rear.

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[AEdelheit]

Looks good but why is the pan hard bar mounted so far forward? Seems like there will be a huge amount of leverage over that front mount making it fairly ineffective.

 

[Taquache]

Looks good but why is the pan hard bar mounted so far forward? Seems like there will be a huge amount of leverage over that front mount making it fairly ineffective.

Good question. I misspoke calling it a panhard bar.

From Humberto:

It's a diagonal link that is mounted to the frame at the front of the 4 link and mounted to the rear end brackets at the rear of the 4 link. It acts as a lateral brace and will stiff arm the rear end to the frame to keep it from moving from side to side. It's a much more effective setup than a panhard bar and has been used on several of the racecars he's built all the way up to 900 ft-lbs.

He wanted a setup that would keep rear end movement to a minimum as he has over 10" of bag travel. Using a panhard would allow the rear end to move 1/2 to 1 full inch. This design will keep lateral movement to no more than 1/8" through out the entire motion of travel, that is attributed to the length of that bar.

 

[AEdelheit]

Its interesting, but in terms of the axle moving though out the travel, and I fully understand these trucks with well over 10" travel, pretty certain that the geometry of how the pan hard bar, track bar, diagonal link or whatever you want to call it will be ultimitly determined by how it mounts perpendicular to the frame for lack of better wording. For example if it runs like a traditional pan hard bar at a 90 deg angle to the frame and is 39" long it will swing the axle lets say 2" over 10" of travel. Now take it how its mounted, the overall distance side to side (perpendicular to frame) is still 39" but mounts 60" forward all that really matters is that 39" side to side distance giving it the same 2" of axle shift over that 10" of travel but there is far more leverage on it now. I see the front mount is the same distance as the arms which looks cool and will minimize bind front to back but dont think that does anything for side to side shift.

Having a hard time expressing it in words, its an awesome build, not trying to be a dick or anything just trying to understand that setup more.

 

[AEdelheit]

I just talked to my buddy about this and he explained how since all the mounts are on the same plane it basically triangulates it which is what reduces the side to side movement, Very interesting!!

 

[Taquache]

Humberto is running the steering rack out of a 3rd gen dodge so mounts and all the linkages and mounting points had to be fabricated.
The cross member had to be opened up and slugs built to mount the rack.

Slugs were also built for the lower control arms.

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This was the original idea for the tie rods, This is a stock arm that would be modified to have the correct shape/angle to fit in the location it was needed. this idea would be scrapped as it was causing binding and not functioning correctly.

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This little arm was the result of a couple days of hair pulling trying to figure out the correct solution to tie rod angles. This keeps motion linear and without undue stress on the parts.

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[Taquache]

Moving to the front suspension.

Care was taken in parts selection and fabrication so that the arms would move freely with out binding providing a quality ride and correct geometry through out the entire range of motion.

Jigs were used to find the correct mounting location to attach the arms to the chassis.

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Here you can see the lower arm mounts that have been set into the crossmember and the raised upper mount brackets welded to the frame rails.

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Close up of the welds:

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Full droop to full lift sees only a 1.5 degree change in camber.

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After custom bag mounts were fabricated along with custom shock cups the pieces of the puzzle were put together.

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(shock mockup)
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The front swaybar is from a Duramax.

Throughout the entire range of motion this setup has no binding and no bottoming out, a lot of that is thanks to Jeebus Joints from Michigan Metal Works in the control arms and high misalignment spherical rod ends elsewhere.

The truck is also running a stock spindle.

(note: the long bolts on the tie rod ends of the steering are for mockup purposes only, this was due to a previous design)
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I like this view personally:
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[Taquache]

On to the engine mockup and placement:

The air ride system will be running a engine mounted compressor for very reliable on board air with out the disruptive noise of electric compressors.

Humberto found a way to mount it inline with the powersteering pump and has eliminated the vacuum pump completely.

Now this might present a few questions to you such as how will the brakes and HVAC function?

This truck will be running a new design of air/hydraulic brakes (more on that when it comes in) and aftermarket HVAC which is all electric.

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Humberto also raised the engine 1" so that the oil pan will be above the cross member and for steering rack clearance. While this truck is not being built to "lay frame" this addition clearance helps everything fit better.

The transmission tunnel will be rebuilt to accommodate the raised height and the NV4500.

The engine lift was achieved with modified motor mounts.

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Here you can see the original mounting holes and the new holes (which have bolts in them)

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[Taquache]

Here are a few pictures to demonstrate full lock to lock turning with out binding.

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And to show clearance while riding low. This truck will have an excellent turning radius at a low ride height because everything was designed and built correctly.

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The truck is built to accept a 32" tall tire but will be running a 31.5" tall tire.

 

[Taquache]

Humberto also did a quick mockup of the front end:

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And completely stripped out the interior.

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Here is the dash removed to be disassembled for updates:

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He was very proud to mention that he successfully pulled out all of the glass, including the windshield, without breaking a single piece!:-laf

 

[Taquache]

While the body parts are out being media blasted and prepped for paint and Humberto is finishing up a few other side projects you can get excited over this:

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There is a friendly little "build off" happening out in Lubbock, Texas between Humberto and Vulcan Specialties and former Gas Monkey Dustin Deleon who is now a part of Rev Limit Customs. Both trucks are square body crew cabs that will be diesel powered and revealed at SEMA 2015!!

Check out the August 2015 issue for Street Trucks for a nice little preview!

Of course, stay tuned here for in depth updates of Project Re-Gen!

 

[Taquache]

Humberto has the frame completely stripped down and is beginning to box and add crossmembers where they are needed.

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Progress, Progress, Progress

 

[RWherley]

I believe that the air compressor ps pump combo is an off the self cummins part for use in medium duty trucks and school buses that would have run air brakes

 

[JHumphries]

...The air ride system will be running a engine mounted compressor for very reliable on board air with out the disruptive noise of electric compressors.

Instead, you have the pleasantly disruptive sound of a Cummins diesel! Oo.

How big of a supply tank are you running? i.e. how much can you move the truck with the engine off?

 

[Taquache]

I believe that the air compressor ps pump combo is an off the self cummins part for use in medium duty trucks and school buses that would have run air brakes

Humberto sourced the parts for his compressor out of heavy truck catalogs but you are probably correct that it can be found on medium duty trucks and School busses equipped with factory Cummins motors.

Instead, you have the pleasantly disruptive sound of a Cummins diesel! Oo.

How big of a supply tank are you running? i.e. how much can you move the truck with the engine off?

This truck will be running two 7 gallon aluminum tanks for on board storage.

 

[Taquache]

The body parts and cab have been stripped down and media blasted to prepare for a little bit of metal work and then in to paint.

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The bed floor was cut out as it will be raised a few inches to accommodate the new frame rails in the rear.

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[AEdelheit]

Making fast progress. So how is the will the adapter plate from the steering rack to TRE going to be reinforced? Surly such a great fabricator wouldn't have a piece of sheet metal connecting the two putting such odd forces on that critical of a component.