Re: Hayes HD Dump Truck - Take II
 

I haven't worked on this truck for months which is not good. Since the weekend was my "B-day weekend":rolleyes: but I still needed to work on customer stuff I decided to work on this. I bought a used foot shear a couple of weeks ago so I have been eager to use it and get the hang of it. I started out by shearing some strips and then bending them into frame rails. I mounted up stock front suspension and chucked in some plastic cross members to get the overall width right. I then started to make my own cross members. I will likely be making my own suspension for both ends of this truck so that it looks more like the 1:1. I also built the front bumper for the truck although the front part of the frame is not cut to length yet.

http://i1293.photobucket.com/albums/...pswniovekz.jpg
http://i1293.photobucket.com/albums/...ps9madlb9u.jpg
http://i1293.photobucket.com/albums/...pschepg7ix.jpg
http://i1293.photobucket.com/albums/...psclquagvb.jpg
http://i1293.photobucket.com/albums/...psq5cozuo4.jpg
http://i1293.photobucket.com/albums/...psixrzmcqi.jpg

Thanks for looking

Re: Hayes HD Dump Truck - Take II
 

Way to go Reg! Soon you will be making everything!
Cheers, Neil.

Re: Hayes HD Dump Truck - Take II
 

I'm amazed thanks mike

Re: Hayes HD Dump Truck - Take II
 

Reg,

Very cool! Any tricks to making the matching dies? Do you just turn the second one to match the dimensions of the first, less the amount of allowance for the stock to be stamped?

And, would you mind posting a picture of the modified end mill you use to make the oval holes? I'm not sure I understand how you are doing that.

Thanks for all the info!

Jim

Re: Hayes HD Dump Truck - Take II
 

Reg

You might try a little cutting lube or cool mist to keep the heat down on your tooling. Sometimes just step in and out also. The heat and friction is causing the gaulding. The truck is looking great. Did you press stamp the center part of the wheel or spin form it?

Re: Hayes HD Dump Truck - Take II
 

Thanks Neil. I think I am nearly at that point or at least I was with my 850KW. Sometimes it just isn't worth the time to build all your own parts and other times it is. I guess that is determined by the time available and the uniqueness of the parts needed.

Thanks Mike!

Hey Jim, I just machined the dies to be close by eye. I squished out a couple of test pieces and then made some mods. Tried it again and it was good enough I thought. I will post a picture of the endmill later. I just rounded the corners on a regular cutter. Nothing special at all just some trial and error to get the right cut for the oval hole.

I use alcohol now and it works very well. No mess as it evaporates quickly and leaves no residue... It also makes me feel like I'm doing a better job when I'm half cut.lol Just kidding.

Re: Hayes HD Dump Truck - Take II
 

It's been months since I've worked on this and I need to get moving on it so this afternoon I made some parts for the front end of the frame. I am going to add more detail to this truck than I did on my own. I want the frame to look less Tamiya and more mini Hayes HD so I have a lot of machining to do yet just to mount the front axle.

http://i1293.photobucket.com/albums/...ps3qqqyunh.jpg
http://i1293.photobucket.com/albums/...pskii8un5m.jpg
http://i1293.photobucket.com/albums/...psanpiv655.jpg

Re: Hayes HD Dump Truck - Take II
 

Nice metal work, looks really good. By your You-Tube videos, you have plenty of work for this truck to do.

Chris

Re: Hayes HD Dump Truck - Take II
 

Thanks Chris. This one isn't for me. I am building it for a friend of mine. His Dad bought the real truck new in 59' and it is in the process of being restored. The one I am building will be it's little brother.

A bit of an update from today. I built the front spring mount cross member today. It is held together with 0-80 bolts. I am amazed with how strong this is now! It doesn't flex at all up front and I still have more holes to drill and tap further along the frame.

This isn't Scale Art quality but it will be more detailed than the Hayes I built for myself.

I started out with this scrap of 1/2"

http://i1293.photobucket.com/albums/...psivztqidw.jpg

and ended up with this after a couple of hours.

http://i1293.photobucket.com/albums/...pscufhl9ma.jpg

In all I put close to 8 hours into the front end today. It doesn't look like much progress but it takes a while to get things right. Well ALMOST right:rolleyes:. I plan to make the rear hangers next and then will make the axle, spindles and springs.

http://i1293.photobucket.com/albums/...pspw2y2lid.jpg
http://i1293.photobucket.com/albums/...ps8w4z8kcd.jpg
http://i1293.photobucket.com/albums/...psyduzw4xt.jpg
http://i1293.photobucket.com/albums/...psnsvqtbel.jpg

Reg

Re: Hayes HD Dump Truck - Take II
 

Your one of a kind for a friend builds are the best Reg. really looking forward to this one. I'd get some popcorn ready but will probably choke on it as my jaw drops looking at the pics. :)

Re: Hayes HD Dump Truck - Take II
 

Very nice detail. I have used alcohol for a very long time. learned at a machine shop that the alcohol cools better then anything else on aluminum for cutting or drilling milling tapping.

Re: Hayes HD Dump Truck - Take II
 

No choking my friend! My biggest struggle right now is finding good pictures of the pieces I need to make. The real truck is 3 hours away(one way) so I can't just go and look at it. Originally we were just going to use Tamiya running gear so I didn't take very many pictures of the suspension components. I want to create something here that no one else will ever have so I need to make everything I can from scratch. In the end I hope it will turn out well. Fingers crossed!


Yep, it works awesome and evaporates very quickly with no mess. It just makes sense to use it on parts that will be painted, powder coated or glued as it leaves no oily residue. I can see how running coolant on production equipment would be better but for me building small parts it's perfect.

Re: Hayes HD Dump Truck - Take II
 

ONLY 8 hours on the front end parts?? Looks like it should be a lot more to me. Making 1 off parts is a work of art for anyone if done correctly. And you do it RIGHT!!! GREAT job :drool:

Re: Hayes HD Dump Truck - Take II
 

Very mice job Reg looks great keep up the good work.

Re: Hayes HD Dump Truck - Take II
 

Thanks guys. Well another day of my life spent in the shop.lol

After several hours of the day standing half bent over in front of my mill and the other half running over to the shop computer to look at pictures and back again I have this...One custom, hand machined Hayes HD front axle.

http://i1293.photobucket.com/albums/...psfslfudf8.jpg
http://i1293.photobucket.com/albums/...pss7y6ito0.jpg
http://i1293.photobucket.com/albums/...pscrl16qlo.jpg
http://i1293.photobucket.com/albums/...ps5hrdag8p.jpg
http://i1293.photobucket.com/albums/...psjystcn5m.jpg
http://i1293.photobucket.com/albums/...pseuvjteki.jpg
http://i1293.photobucket.com/albums/...psztjaaupi.jpg
http://i1293.photobucket.com/albums/...psjfd1znna.jpg

I like how bead blasting almost makes it look cast.

http://i1293.photobucket.com/albums/...pshxhhszoh.jpg
http://i1293.photobucket.com/albums/...psudl8bwj7.jpg

Re: Hayes HD Dump Truck - Take II
 

That is amazing! Nice work as always Reg:eek::cool::D

Re: Hayes HD Dump Truck - Take II
 

A true fabricator hats off of to you Reg

Re: Hayes HD Dump Truck - Take II
 

This is awesome. Will you be machining drive axles too? I am always impressed by your craftsmanship.

Re: Hayes HD Dump Truck - Take II
 

Thanks a bunch guys. Yes I hope to make the rear axles as well. I am not holding myself to it at this point but I don't think it's worth doing the work one one end and not the other. I started machining parts for the rear suspsension a while back. I also cut the rear springs at that time. Once the front is finished I will do the rear suspension and make a plan from there. I've scratch built diffs before so it's not impossible.

I made the spindles this morning. I had to do some work outside the shop this afternoon so I didn't get as much done as I had hoped but at least the wheels are back on. The spindles aren't all that scale but at least they are setup for the steering like a real Hayes.

I started with this chunk of plate and a crappy outline of what I wanted.

http://i1293.photobucket.com/albums/...psiso46hfk.jpg
http://i1293.photobucket.com/albums/...psqdxpk6kq.jpg
http://i1293.photobucket.com/albums/...psrsznmj1r.jpg
http://i1293.photobucket.com/albums/...psoitwhok1.jpg
http://i1293.photobucket.com/albums/...pswqbku3xy.jpg
http://i1293.photobucket.com/albums/...pssi5kmfrm.jpg

Re: Hayes HD Dump Truck - Take II
 

I made up the new leaf springs yesterday. I have some small pattern nuts coming and a die to cut threads on the U bolts. I will spend more time straightening the U bolts up after they are threaded. I also started to fit the fenders I bent up months ago....

http://i1293.photobucket.com/albums/...psgztof5jf.jpg
http://i1293.photobucket.com/albums/...psxhrt75j5.jpg
http://i1293.photobucket.com/albums/...psgsirm9fm.jpg
http://i1293.photobucket.com/albums/...psw2sqbfyz.jpg
http://i1293.photobucket.com/albums/...pswujrcgzk.jpg
http://i1293.photobucket.com/albums/...psazdd6isz.jpg

Re: Hayes HD Dump Truck - Take II
 

That bolt work is just beautiful.

Re: Hayes HD Dump Truck - Take II
 

Thanks dozerbuilder.

I picked this up again today for a bit. I need to finish off the front suspension before I can do the rest of the body fab on the cab so I spent 3 hours making the rear hangers for the front springs. They are not really true to scale but they resemble the real thing so that will have to do. I made a lot of chips considering how small the end result is.

http://i1293.photobucket.com/albums/...psv2niw0zw.jpg
http://i1293.photobucket.com/albums/...psi1jccg9t.jpg
http://i1293.photobucket.com/albums/...psiwgg4nrw.jpg
http://i1293.photobucket.com/albums/...ps1bqm2hjr.jpg
http://i1293.photobucket.com/albums/...pssx4mm8am.jpg

Re: Hayes HD Dump Truck - Take II
 

Wow nice work Reg great details !! What size are those tiny bolts....yikes almost couldn't see it in place....lol

Re: Hayes HD Dump Truck - Take II
 

Yeah what size, they look like the same ones you put on my dump box. I was thinking of asking you because i doubt i had a wrench that small.

Re: Hayes HD Dump Truck - Take II
 

These are 0-80 bolts. The one in your box are bigger Calvin. I think they are 2-56 or 1-72 I already forget.lol Same size head on either one. 0-80 is much smaller.

Re: Hayes HD Dump Truck - Take II
 

Yeah, doesn't look scale at all ;) Fun to follow this build.

Re: Hayes HD Dump Truck - Take II
 

So perfect I love the work you do is admirable
Cheers....

Re: Hayes HD Dump Truck - Take II
 

Re: Hayes HD Dump Truck - Take II
 

Thanks guys. I appreciate the compliments. BERNA, you set the bar high with the small details!

Here's some progress from today and a picture of my 0-80 socket wrench.lol It's a socket head bolt ground down and TIG welded to a finishing nail. Today I really pimped it out but I forgot to take a picture. I added a purple wire nut to it for a handle. Very stylish....:rolleyes:

http://i1293.photobucket.com/albums/...psfjjmxupx.jpg
http://i1293.photobucket.com/albums/...psed7quljj.jpg
http://i1293.photobucket.com/albums/...psihk35ifn.jpg
http://i1293.photobucket.com/albums/...ps3dltdhcc.jpg
http://i1293.photobucket.com/albums/...psyzmthams.jpg
http://i1293.photobucket.com/albums/...pseiwgak0b.jpg
http://i1293.photobucket.com/albums/...psbeljkkon.jpg
http://i1293.photobucket.com/albums/...pswvcgsfzf.jpg
http://i1293.photobucket.com/albums/...psfg1gr6bk.jpg
http://i1293.photobucket.com/albums/...psvisi7fvc.jpg
http://i1293.photobucket.com/albums/...psivsbcl1r.jpg

Re: Hayes HD Dump Truck - Take II
 

Another awesome build by Sir Alumasticator ! Mike

Re: Hayes HD Dump Truck - Take II
 

lol

Here's a quick video...https://www.youtube.com/watch?v=0SuHko8nCgM

Re: Hayes HD Dump Truck - Take II
 

Nice,really really nice......you have skills fella !!!
(People would pay for such skills...oh ya forgot already are!! Heehee)

Re: Hayes HD Dump Truck - Take II
 

Haha, thanks KP. Let's hope they keep payin!

Another day in the books on this. It's coming along nicely but as always it is time consuming. I ended up soldering some more copper for the light guards. I'm not BERNA that's for sure but there's no way I could weld this thin stuff. Soldering is the way to go. I think I could benefit from a smaller torch as well.

https://www.youtube.com/watch?v=L7I7YJws1xI

http://i1293.photobucket.com/albums/...ps3zjt3epk.jpg
http://i1293.photobucket.com/albums/...psfb9yuuk6.jpg
http://i1293.photobucket.com/albums/...psfkswa6cm.jpg
http://i1293.photobucket.com/albums/...psa9rojgmx.jpg
http://i1293.photobucket.com/albums/...pstrgxb95q.jpg
http://i1293.photobucket.com/albums/...psrbinoufr.jpg
http://i1293.photobucket.com/albums/...pszinmyj1l.jpg
http://i1293.photobucket.com/albums/...pszvptdsi3.jpg
http://i1293.photobucket.com/albums/...pst7eofsvn.jpg
http://i1293.photobucket.com/albums/...psiyxji77m.jpg
http://i1293.photobucket.com/albums/...psafyajn6b.jpg

Re: Hayes HD Dump Truck - Take II
 

Another bit of an update.

https://youtu.be/VpxwZS3KapY

http://i1293.photobucket.com/albums/...ps6t4ezkxm.jpg
http://i1293.photobucket.com/albums/...pszspfxzgm.jpg
http://i1293.photobucket.com/albums/...psauip0qcq.jpg
http://i1293.photobucket.com/albums/...psd00gsdhj.jpg
http://i1293.photobucket.com/albums/...ps9wp1ej3i.jpg
http://i1293.photobucket.com/albums/...psnmoblzb7.jpg
http://i1293.photobucket.com/albums/...psaancg66y.jpg
http://i1293.photobucket.com/albums/...psy2pisebb.jpg
http://i1293.photobucket.com/albums/...ps8pd8k2wp.jpg
http://i1293.photobucket.com/albums/...psnqp89foy.jpg
http://i1293.photobucket.com/albums/...psi6pob9qi.jpg

Thanks for looking.

Re: Hayes HD Dump Truck - Take II
 

Love the verticle headlights behind the grill ! So this truck has 13 speeds forward and forward ?! Mike

Re: Hayes HD Dump Truck - Take II
 

I was looking for the open side hood with a 12V71 under it:D, they're looking good Reg.

Re: Hayes HD Dump Truck - Take II
 

Hey man....this/they look awesome but you need to take a break from building for a while....ummmm which end is the front ?? The two cabs on the same frame facing different directions just looks wrong...heehee....and I'll bet that's exactly why you took those pictures just to mess with us....good laugh!!! But in any case the truck or umm trucks or let's see umm the "it" looks fantastic!!! Lol

Re: Hayes HD Dump Truck - Take II
 

Looking good. I only wish i had just the time to try and build somthing that nice! But i do have a quick question. Are you tig welding the aluminum or a type of solder? Cause i have yet to see if you can solder aluminum with good results!

Re: Hayes HD Dump Truck - Take II
 

Hey reg,

On post 59 you have a pic of a die in the 3 jaw. Are you putting threads on that spindle under power? Does your lathe turn slow enough to do that or are you turning it by hand and just using the lathe to hold everyone square?

Jim

Re: Hayes HD Dump Truck - Take II
 

Haha, it would be cool if those were lights. They'd be nice and bright! She just has a Johnson bar...

No, no. These trucks weren't big enough to have that much power. Usually an old Cummins.... unfortunately...


Thanks KP. I was just trying to fit the panels on both without having two chassis on the bench. It's also a good way for me to see how close or not the two are shape wise. Lou's has the newer style side windows and some other "on purpose" tweaks to separate them but otherwise they are close for hand made. That'll do donkey, That'll do...


Yes it takes a lot of time and patients... I have never used solder on aluminum so I can't say how it would work. I have been tempted to try it but so far I have just stuck to using the TIG.

Hey Jim, in that picture I am just using the lathe to keep everything straight. I don't think that lathe would have the power needed but even if it did, it would just break the die. Turning by hand going ahead but being able to back it up under power is nice on longer threads. I have done some smaller threads under powder when making steering rods but that is only 1/8" aluminum.