Now that the running boards were the right length, we have to mount them. I went over many different ideas but at the end of the day, I decided I didn’t want to drill into the rockers at all so all would have to be supported by the frame channel. So the brackets began:
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Using C clamps, I basically set up the brackets to sit where I wanted while the running boards were supported by the big blue buckets.
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Then did some marking and drilling….
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Then a test fit and all looks good:
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And same for the other side.
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After some testing, I found too much flex in the bracket as I suspected so I made up some little corner supports and TIG’d them into the bracket. You can see the square prior to cutting it corner to corner, and then after it was cut:
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You can see all 6 completed.
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Next was to get the general shape and size of the read mud flap sheet to match the contour of the gen 1 dually fender. So measurements were made and then cut on the band saw. Final cut on the boards themselves to match the flap, and then the flap is cut. Thanks to a buddy I had a second pair of hands for this trimming.
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Frame brackets were cut out of some old steel pipe and then polished prior to powder so the rust would be removed. You can see the amount of rust that came off when polished with emery cloth in a lathe:
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Now there were a few parts from the original running boards that was supplied that I am reusing, so I had to sandblast the old powder off so they would all match. So also spent some time in the booth.
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After many weeks of modifying and fabricating, the brackets are done as are several others for the truck. This is my table of parts to go for powder coating.
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Next task was to make the rear semi Cummins flaps fit. This is what I started with:
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First step was to cut 1” square tubing to size and clamp it to the ¼” plate I machined up to straddle the shock mount bracket reinforcing angle. Then I set it in place, market it, and then got to welding.
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I didn’t want any flex at the welded plate to tube area so I reinforced the top of the flap arm with some angle so it would give extra strength in the area prone to collapse.
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Mud flaps were then cut to size and the parts were ready for powder. The two flat bars sandwich the flap to is is more than just nuts holding it on.
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For the fun of it, I also thought I would do a underbody shot to show what the driveline looks like:
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