Body mockup: round 2

Today we test fit the front end so we could see how the cab sat with the modified mounts and also clearanced the front end for the tires.

Body drop: Cab mount relocation and modification

Lowered the cab mounts 5/8" to give the body a little more drop.

Frame painting

The frame modifications were not quite complete but I was getting antzy to clean it up and paint it. It had been 7 weeks since I took the truck apart and I wanted to feel like I was heading in a forward direction. I created a Dexter type lab with some plastic and fired up the paint gun.

Converting a long bed frame into a short bed frame

Removed the rear cab mounts, they will need to be relocated 12" back. Then marked the center of the frame to remove 12"

Cut!

Tacked.

Welded. Main frame now complete. I later added a fishplate on the inside of the frame.

Then cut 8" off the rear.

Cab test fit

We installed the cab tonight to see where the cab would sit when lowered on stock cab mounts. Pretty close to having the rocker on the ground but not quite there. So we'll lower the cab mounts to make up the difference.

Steering relocation

We needed to move the steering box forward 1" and up 2" to account for the crossmember modifications.

Boxed lower control arms

Boxed the lower control arms to accept the air bags and help lower the assembly.

Drilled out the bump stop.

Cut out.

Tacked in for a test fit.

Pancaking front crossmember.

Removed 2" from the center of the front crossmember.

Rear bag mount install

Knocked out the rear bag mounts over the weekend. Took about 3 days on and off.

To center the bag on the trailing arm required the top bag mount to both be trimmed and also to recess it into the frame rail with a backing / boxing plate.

I used a long threaded rod setup to help align everything.

Amount I had to trim from upper bag mount.

I later went back and added a piece between the top of the bag mount and edge of the frame rail.

Both sides done. You can see the burn in marks on the top of the frame rail in this picture that shows where the boxing plate is located.

This cross bar was later moved to the rear of the bag mount.

Bed disassembly

I wanted to get the bed off the lawn and out of the way so I disassembled it.

Notching the rear frame

Time to start on the rear notch. I ordered the kit from ThorBros and cut it to fit. 

  
I spaced the notch about 4 1/2" above the frame.

Had to notch the inside of the frame a little bit.

Welded the inside

Bam.

Added two cross bars