Before What we started with...
Before
What we started with Saturday
After What we ended up with...
After
What we ended up with Saturday night
Well, it seems that it's almost impossible to get some free time to work on a second-hand project smack dead in the middle of the show season. But have no fear. We're not giving up just yet! We stole a free Saturday and with the desert heat we decided to just tinker with something simple. There's definitely an energy-draining factor being in 110-degree heat, holding a welder in hand. So we took it easy and decided to just get the fuel cell mounted so we could start to plan where everything, including the air tanks, compressors, and valves, are going to be mounted. After mapping out a plan of attack, we sacked up and built two crossmembers and bent up some tubing to get our fuel cell mounted and to be one step closer to maybe someday finishing this beater and getting her back on the road. For more information, contact the companies in the source box.
1. To mount the fuel cell...
1. To mount the fuel cell and to add strength to our back half, we cut out two crossmembers using the same 2x3.
2. Measure the fuel cell...
2. Measure the fuel cell and place the front crossmember accordingly.
3. Once the crossmember is...
3. Once the crossmember is measured out and squared up it's tacked into place, measured one more time, and then fully welded.
4. For the rear crossmember...
4. For the rear crossmember we kill two birds with one stone by cutting the end piece a total of four inches longer so we can butt it up against the end and smooth everything out.
5. Line up the rear crossmember...
5. Line up the rear crossmember so the two ends butt together and then tack both sides in place. Make sure it's centered; then it can be fully welded on all sides.
6. With both crossmembers...
6. With both crossmembers welded-in the tops and ends can be ground smooth.
7. There she is, the perfect...
7. There she is, the perfect new home for our fuel cell.
8. Now we can use a jack...
8. Now we can use a jack to mock up the fuel cell and take all of our measurements for the tubing that will secure the fuel cell in place.
9. With all of our measurements...
9. With all of our measurements in hand, four pieces of 1-1/2-inch tubing are cut (two long pieces from end to end, and two short pieces to add center strength). The two long pieces are then bent to butt up under the framerails.
10. The tubes are evenly...
10. The tubes are evenly spaced and then tacked into place.
11. We used four simple mounting...
11. We used four simple mounting tabs off the side of the tubing to keep things simple and clean. Bolt them onto the four corners of the fuel cell and line them up to the tubing.
12. With the fuel cell centered,...
12. With the fuel cell centered, the mounting tabs are tacked to the tubing.
13. After the mounting tabs...
13. After the mounting tabs are set up, the center support tubes are notched.
14. Line up the center support...
14. Line up the center support tubes and make sure they are square.
15. Yup, more welding. Weld-up...
15. Yup, more welding. Weld-up the center tubes and we're about set.
16. Bolt-up the fuel cell...
16. Bolt-up the fuel cell and then wipe off the sweat from the desert heat. 16. And there you have it. We're a couple hours closer to wrapping up what should be done in two weeks (yet it's taken us two months LOL).