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Old 01-09-2018, 08:34 PM
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MetalShaper of the Month March 2018, August 2021,November 2023
 
Join Date: Jan 2018
Location: Hector, MN
Posts: 294
Default Chassis plumbing

This will be a fairly long post with a pile of pictures focusing on mainly the "plumbing" of the chassis: Brake lines, fuel line, air lines, emergency brake cables, air system components, etc.\
I bent up a removable transmission crossmember mount. If you look you can see the flange with two bolts. Unbolt each side from the frame and the crossmember drops out.

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View of the transmission mount from the bottom.

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Here I've started routing the individual emergency brake cables (temporarily held with zip ties while I work on it). I inserted a curved tube inside each frame rail that softly routed the cable through each rail nicely without kinking it at all.

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A close up of the cable exiting out the passenger frame rail and is held into a "split" clamp that I welded to the frame that lines it up with the brake caliper.

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I fabricated internal structure inside the frame rail in order to securely mount the sway bar through the frame itself. (The frame is upside down on a rotisserie in this picture)

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Close up of one of the sway bar frame "caps" unbolt this and you gain access
to the actual mounting hardware of the sway bar itself.

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This picture shows more components mounted to the chassis along with the maze of stainless lines! The passenger rail is fuel line as well as individual lines going to the front air bags and a supply line coming from the tanks.

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This view shows the dual air tanks and compressors and also the solenoid block for the air ride as well as more individual lines going to each rear air bag.

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Another view help showing the lines and the bends required to route them nicely. I fabricated the clamps on the frame that separate them and hold them in place. All lines were flared stainless with AN fittings.

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The driver side showing all the brake lines and components (the blue items above the master cylinder and booster are residual valves) Again these are all stainless with AN fittings.

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This close up shows the adjustable proportioning valve for the brakes. Also shows how I fabricated the air tank mounts. This side wasn't as involved, but the mounts on the passenger tank also align and clamp the stainless lines in place correctly.

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Here we are jumping back to show how the pair of emergency brake cables were mounted to the outside rail and connect into the adjustable "Y" block that brings it down to a single cable that routes into the cab to the emergency brake handle.

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This last picture shows the fabricated body mounts (That were drawn up and laser cut out earlier)

Here you can also see by this time I had fully welded the new frame rails and boxing plates.

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