The "Donkey" build/rebuild


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Here's a question, should I paint the exoskeleton black like the truck or yellow like the decals?

I'm thinking yellow might be too tacky or garish, but two people so far have asked me that exact question. I was thinking black but now I'm curious as to what others think.

Yellow or black?
 


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Bgunner

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Split the hair, paint it both. Corners yellow for high visibility while driving close to objects and the rest black?
 

projectRanger93

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Really depends. If you want the exoskeleton to stand out, then yellow. If you don't, then black. Too much yellow though will look a bit tacky IMO, so a conservative application is recommended.
 

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I think you're right on the tacky...

Black with yellow corners is interesting too, never would of thought of that.

Maybe I'll go all black and paint some corners to see. If I don't like it I can repaint it black.
 

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Let it sit a day and got the slider on the drivers side. Didn't like how the bar going up the A pillar looked so I think I'm going to cut the bar off at the top of the fender then go across the hood and tie the bottom all together. Then I'll do the A pillar bars exactly where I want them which is right over the A pillar and closer to the body. If I don't do it now I don't think I'll be happy with it later on.

Oh, and thanks for replying guys, sometimes I wonder if anybody is even reading this or if they are, think it's crap and don't want to respond. Lol!
 

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Got a bit more done, here's the pass side with the tube cut off 3" from the top of the fender;

36871



And here's the drivers side with the slider on and the tube stopping 3" from the top of the fender.

36872


Just have to cut the fender off below the horizontal tubing over the tires now. Oh, and while it looks close, there is about 4-5" of clearance. If the tire does articulate that much at least all it can do it hit a smooth tube. It never hit the cut out fender though so I don't think there will be a problem.
A bar across the top to tie the uprights together and then start laying out the A pillar bars.

I have 3/16" sheet steel to work with too so that will be the skid plate underneath. I need to see some pictures on how the front skid plate goes.

....never ending....
 

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Lots of people watch without replying. Normally I just hit the like button to indicate I'm interested and watching. If I have constructive input then I say something.
 

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Huh...maybe it's just me who feels the need to constantly comment on what everybody's doing and how they should do it differently....lol!

Thanks
 

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A bit more progress.....

37098


37099


and of course seeing that, I think...it needs a bar in the front to complete the wheel well....here's a piece just clamped on for a reference. I'll bend a piece of tube to make it fit better of course.

37100
 

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After that's done, I'll trim the fender to stop at the bar. (I'm thinking of welding the fender to the bar actually)
I also have some rubber mat, so of course I'm thinking...hey, why not make rubber fender flairs since the 35's stick out 2-3" from the truck?


I have to stop thinking of new crap and just get what I have to do, done. I have the uprights ready to start bending but....ooh, here's an idea, what about.....


Something else I've left to see "what strikes me" is the front end. It's just horizontal and vertical bars right now. Waiting for inspiration on how I should finish it. I have some 1" x 1/4" flat stock, I could make vertical bars like a '47 powerwagon or something like that. Still thinking.
 

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Are you going to be able to change your wiper blades with the lower windshield bar where it is?
 

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I can change the blades but the arms would be interesting. lol. I can lift the blades about 5".

Got off at noon today because of the snow storm, roads are bad, lots of accident, so....I stayed at work and worked on the donkey!

I triangulated the front bars;

37131

37133


But, can't leave nothing alone so I trimmed the inner fenders back and then welded the fenders to the bars.

37134


Yes, that was before grinding and before I got a grip on welding small tin to a pipe...Drivers side is WAY better...I don't have a picture so you'll have to trust me on that, but ummm, yeah, it's great.. :)

Here's a shot of how tight the drivers door fits and my rear side window made out of an aluminum sign and painted black. (or as I call it, Extreme tint!)

37135


It's air tight...ish, but the body metal behind the door is pulled back and leaves a big gap on the outside.

Anyway, now to put the front tires back on and set it on the ground and start doing the halo bar then uprights.
Then when that's done, I'll probably go over it with either tube or flat stock to make gussets in the corners. Then cut the box sides off at home and bring the m in to weld on.

Sigh, it never ends. I was supposed to be snow wheeling with it but I can't stop "adding"...maybe I need a front winch too...ahhhh!
 

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All right, got some more done...man this is a never ending project!! I wanted to be out snow-wheeling by this time! Even the wife is bitching about "wish WE could go 4 wheeling like them..."

Anyway, I got the halo done and welded the back four uprights on. (note the back bars have 90 degree bends and slide into the slider bars) Then, I pulled the back bars back out of the sliders and tilted everything up so I could weld the inside of the tube connections.
37980


Damn phone is dirty again...

Then I dropped it back into place with the help of the sledge hammer. This was required because the middle uprights are actually in the drip rail. Not sure if anyone can see it but I cut away a piece of the drip rail to get the uprights in tighter to the side of the cab.

37981


and the other side...

37982


Then I welded it all up and now need to make the front A pillar bars and I'm also putting bars between the back two uprights level with the horizontal bar in the front. Also have to run a bar across the back of the cab and one on each side down to the back of the frame. LOTS more to do, sheesh.

Good news though, ordered a new milling machine and it just came in!! WooHoo! Not hooked up yet (or mounted to the floor for that matter) but can't wait! Picture in another post.
 
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Ok, see if this works...

37983


NEW TOY!!
Going to have to wait until after the end of the fiscal year before I can get the lathe I ordered...they might surprise me but I don't think so.

Anyway, either tonight or again tomorrow at dinner time I'll get a bit more done. I rolled it 26 Dec, STILL working on it...Grrr...
 

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Looks awesome man! Love the dedication with rebuilding after your.. Brief encounter with the side of the road
 


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