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Painstaking measurements and cutting holes in the tunnel over 2 days SWAG circle cutter has come in very handy Shift plate for the Magnum. Added some more nutserts so a person won’t have to try and back up the but side with a wrench under the tunnel

Day project: finish off the tunnel fabrication Mating the old with the new and getting the flange to contour with the floor. Heat, clamp, heat, hammer.... Flange ring is done here Then came a day of contorting myself to weld it. Managed to scorch my armpit and all the pedal work was...

Plugging away. Blasted and primed some setup parts. The knuckles are stock, Reid’s are still in the box but I need studs. Idea is to get this rolling soon Welding the front 5 link up also. #10 FUPA cup from WeldMonger and a gas lens. Triple pass on the .375” wall lowers then run a tap...

Burning in the lower coil mounts Got some different cups and gas lenses from WeldMonger, great stuff. Did all this with a gas lens and a #8 Furick, piece of cake

Wanted to tip the front coils back 10 degrees. Suspension nut is in the way so I ended up notching the bracket Nut welded in place and ran a tap through it

Time to love on the D60 a little bit :D I like REALLY clean parts for welding.... Here’s the GM Bill Of Materials #, comes out to exactly what this had, factory 4:56 Burning in all the link brackets...

Really nice rear departure angle. Not missing that extra 22" of frame at all :yup: And the lower links are so nice and flat. Very little is exposed to hang up on Forward link mounts. This here is where the belly skid plate will end. I like it

Got all 4 tires mounted and the rear links in. I was waiting on a set of left/right taps to chase the bungs after welding them 14” of clearance under the shaved 15B axle And not ridiculously wide compared to the cab

Started welding the rear 4 link bungs in. Got some help to slowly spin the tube while welding so it’s one continuous weld bead. I figure that if that bung separates from the tube at some point, lots of other stuff is going to go well before it Finished welding out all the rear 4 link bungs...

Lots and LOTS of frame plates and filling gaps/holes. Upper link bracket is welded in also Also finished the bracing for the lower links. 2” 3/16 wall square tubing and fish plates on the frame. Should be plenty ridged and capable of handling the push/force of the lower links

Last one. Artec truss and Barnes4WD link brackets Burned through a TON of filler rod, ER70S2

The following contains weld porn. So shoo your kids out of the room :shock: So at least that is done. It’ll still need a few other brackets but those can come later. Truss is a mix of 3/8” and 1/4” plate. Max amperage was 175 and the water cooled torch was such an improvement over air...

TrailReady's are here :clap2: Almost too nice to want to mount them Also swapped out to a different TIG machine. Older Miller Syncrowave but it welds AWESOME compared to the multipurpose machine I was using And this was a long time coming. Spent a full 7 hours in the shop welding out the...

Rear bumper inner reinforcement plate. I want to retain the factory pintle hook, hence the round hole in the center. 1/4" cold roll steel so no need to clean up nasty millscale prior to welding it SWAG circle cutter. Simple and super handy Clamped in place after trimming to fit...

Rearmost plates which are notched to reach the rear bumper I’ll get the inner portion near the rear channel done with MIG, at this point I need one more plate to stiffen across the pintle Both sides are done....and a big stretch after a long hard day

Rough cut-out shape... Cutting it with the plasma, it's 1/4" Mock-up I’m cleaning up the inner frame rails really well (they already got blasted once) then coating with 3M weld through primer And this guy, is growing like CRAZY

Also welded all the brake retainers on the axle tubes. From the factory, they are only about 50% welded Leaky axle tubes on the 15B. While doing the 500 degree pre-heat, ALL the plug welds started leaking nasty old gear oil pretty good. I ended up cleaning them really well and then TIG...

D60.... I did the same 500 degree pre-heat but I decided to TIG the plate. Took probably 5x longer but the end result is at least visually more appealing.

Welding up the shave kits.... This is the 15B. Did pre-heat to 500 degrees and then MIG welded it. Seemed to weld pretty consistently but I just don't care much for the noise and splatter of the MIG process.

Also worked on prepping the passenger firewall so it can be plated. It was fairly bent in places as in "how in the hell is this so hammered?" I roughed up the green paint a bit but I'm not doing to remove it altogether. That was hiding under the ventilation box and is original 68'! Picked up...