TrashE

[Dan]

New AA 29 spline input installed in the np205. New seals all around and new F/R yokes.
AA spacer and 1350 CV yoke up front.

1410 non CV yoke on the rear.

Both assembled and ready to test fit. That aluminum spacer is a really good fit on both the 205 and the transmission tail housing.

 

[Dan]

I made some progress on the fuel system. Started by taking the fuel tank module out and measuring the tank depth.

Then I cut off the threaded mounting part to adapt to the new ford tank.

 

[Dan]

Then the ford tank went from this:

To this:

 

[Dan]

Then about a hundred 1/4x20 button head screws and the tank was ready for the dodge fuel tank module. Now I can hook up my fuel lines and everything should be good to go. The new tank ended up 1/2" deeper than the factory dodge tank but there is plenty of adjustment on the fuel module to make up for this.

I kept top threaded (flange?) part warm while I was installing it so that it formed into the tank better.

 

[Bebop]

Kind of embarrassed to be building this thing in the dirt and wasn't going to do a thread but oh well.

I wouldn't be embarrassed dude, you're doing awesome !
Fab skills on point, I like where it's going.

 

[Dan]

I wouldn't be embarrassed dude, you're doing awesome !
Fab skills on point, I like where it's going.

Thanks!

 

[Dan]

Started the fuel tank mount. Big tubes are 2"x.120" and the "X" is 1"x.120" tube.

The two square bars are temporary.

 

[Dan]

Added another tube (1.75"x.120") and some gussets.

Test fit the tank and started on the straps.

 

[Dan]

Finished up the straps.

Rear mount has a through bolt so I added a sleeve to prevent the tube from crushing and keep the inside sealed.

 

[Dan]

Test fit a little more then burned in the tubes.

 

[Dan]

Almost forgot about the leaf spring eye bolts.

Added an access window & sleeved it with 2" tube.

 

[TrailTamer]

nice build! I def will be following.

slight derail. Look like you could’ve just cut down the 2wd shaft? They appear to be same size and spline by eyeballing in the picture

 

[Dan]

nice build! I def will be following.

slight derail. Look like you could’ve just cut down the 2wd shaft? They appear to be same size and spline by eyeballing in the picture

No worries on the derail, that's a good question. The 2wd shaft is 31 spline & the 4wd is 29 spline. But if it has the same pressure angle as a 31 spline ford (np205) input then it could most likely be done.

And thanks!

 

[Projectjunkie]

Would you mind putting up some prices on your 2wd to 205 parts? I've got similar thoughts on my head

 

[Dan]

Would you mind putting up some prices on your 2wd to 205 parts? I've got similar thoughts on my head

​​​​​4wd mainshaft: $230
New 5th gear: $50
New tail housing; $290
Output seal: $13
T-case adapter kit(AA-50-9550): $450

​​​​​That is buying mostly from torque king and doesn't include synchros, bearings, shims, oil, & misc. small parts you might need in yours. Add another $300 to the above for misc parts in my case.

If you are on a budget and aren't too concerned about quality you can get a 4wd rebuild kit for under $400 and that will come with a new mainshaft, 5th gear, synchros, and some bearings. Another $100 for a tail housing then just buy the AA-50-9550 kit.

 

[Dan]

Last few pieces of the fuel tank mount/x- member coming together.

 

[Dan]

Needed some practice with the Tig torch... Definitely need more.

But that's one more thing down.

 

[Dan]

Starts and stops could use a little work, but other than that welds don’t look too bad. Maybe a tad bit too hot. Luckily, with that many feet of weld to lay down you should be stacking dimes in no time

I want to Tig more but the time commitment is a killer. Restarts definitely do need some work.

 

[Dan]

The transmission and transfer case are installed behind the engine and the truck is a little closer to being 4wd. They are installed but not mounted to anything yet, just resting on a jack stand.

Here is the start of the trans cross member. With the trans. in the appropriate position I started piecing some metal together under the truck. After the first few pieces came together I added a temporary brace (square tube tacked to the front) to keep the parts straight and prevent them from shifting when I removed it. Now I can finish up the remaining fab work on the bench.

I made a jig thingy with some 1/2" drops and some scrap rectangular tubing.

After I fit and tacked the front pieces I removed the temporary square tube.

 

[Dan]

Working on the bottom plates.

Little closer to getting this mount wrapped up. It will use the factory trans bushing in the middle.

 

[Dan]

Needed some oval holes so I cut up some 1.75" tube.

Then added some spacers to make them oval.

Then welded them together. These are access slots for the trans bushing. These are 1/8" everything else is 1/4".

I tried to oval some 2" tubing in the press but it kept leaving a kink instead of a smooth radius, which is why I did it this way.

 

[Dan]

Something like this...

... where I left off earlier today. Should be able to get most or all of it welded up tonight.

Not quite patient (or talented) enough to make it with one piece.

 

[Dan]

Welded it up in the fixture.

 

[Dan]

Painted.

 

[Dan]

Installed.

So that's cool.

 

[Dan]

Cut a pretty big hole in the bed floor. The 1" angle iron along the topside was welded into place before cutting.

 

[Dan]

I ran some tube along the front 3 cross members to make sure everything was in line after the cuts.

Then made a couple plates for the sides that will connect the cross members and hopefully add rigidity. You can see the heat signature where they are welded.

Left a small flange along the perimeter to bolt on a cover. I'll probably add some more welds down the road.

 

[Dan]

Front bed mounts. Top bent piece is 3/16" the rest is 1/8". The tube is 2" and should be strong enough to tie into if needed.

Used part of the old frame to build them on the table.

 

[Dumptruck.the.wookie]

This is so well done, you have talent man.

 

[Dan]

Did some cutting on the bed. I wanted to keep the factory wheel opening shape (or close) so I cut out the opening lip and brought it up a few inches.
Trying to keep this piggy as low as I can.

Looks like about 4" of tire clearance was gained.

These measurements are basically with no weight in the truck and will go down once I start adding some stuff like fuel, winch, etc.