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Old 05-11-2019, 08:43 PM   #421
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Congratulations on the new beagle puppy. We got one in October. I hope you are a better dog trainer than I am.

Donít overthink drilling the new axle holes. This isnít your first parade.

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Old 05-12-2019, 04:57 AM   #422
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Whaaat? There was a question about axles?

Those puppy pictures distracted me. Sooo adorable!!!

David and Dan - Thanks for starting my Sunday off with a smile. Congratulations to you both.
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Old 05-12-2019, 07:21 AM   #423
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David. Could not agree with you more about those mounting plates. Dexter should default them as blank. I suggested this to Colin Hyde (whom I purchased through) but they didnít give much of a response. Made me think if they are drilling them maybe there are plenty who use those holes.
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Old 05-12-2019, 01:34 PM   #424
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I must correct myself, the slots are 5/8" wide, not 3/4". Don't believe things you read on the internet!

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Old 05-12-2019, 06:21 PM   #425
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Hole Saw From Hell

TouringDan: You are right. I've done this before, so just go do it and stop whining. I rechecked my measurements and chucked up the new Blair Rotabroach Aerowood recommended.

Broach may be a misnomer. I think of it as a hole saw from hell. It is much easier to use than a twist drill. I think it has maybe 8 cutting edges instead of a twist drill's two. See photo 1

The tool cut very cleanly and created an accurate hole diameter. I found it still takes a strong push on the drill to feed the thing through the steel. I have to hold and push the drill horizontally. I've got eight holes to drill, and I've got two of them done. Never start, never finish.

I had some trouble figuring out how to remove the steel "slug" from the rotabroach. It was stuck in there tight. I had to remove the guide pin and then punch the slug out from the back side. Not real handy. See photo

The rear hole is a "overlapping hole", one hole next to the other. Interrupted cut they call it. The rotabroach handled this operation very well. It would be nearly impossible with a twist drill. See front hole, rear hole photos

Location accuracy is a different story. That's my deal. Trying to layout a location from almost no reference is hard. As explained earlier, I used the bottom edge and leading edge of the stamped Dexter axle mount. My hole locations are about .020" off the slot centerline. Certainly not aircraft quality, but not terrible for hand held tools.

So I have several more hours of pushing this rotabroach through the axle plate and then grinding the holes to fit the slots. At least I'll get my axles up tight against the frame rails and then bolted tight so they don't fall off.

David
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Old 05-12-2019, 09:04 PM   #426
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Glad that you like the Blair Rotabroach. I also remember the difficulty in drilling the holes with a twist drill. I ordered the Blair Rotabroach in anticipation of installing 3 new axles in the 95 34í.

Dan
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Old 05-13-2019, 02:45 PM   #427
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I can't help with the axles but the puppy is adorable!
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Old 05-14-2019, 07:17 PM   #428
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No axle mounting holes drilled today. I had to babysit the new puppy.

I don't think a beagle is trainable. All nose, no brain.

David
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Old 05-15-2019, 06:18 PM   #429
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lol, tough day, eh?
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Old 05-15-2019, 07:05 PM   #430
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Worse, once that pup gets older and smarter heíll find lots of ways to cause trouble. Some Beagles are too smart fit their own good.
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Old 05-16-2019, 06:22 PM   #431
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We have a 10 year old beagle, who suddenly has a little step sister. Not a happy camper. Beagles aren't the smartest dog in the show.

Can't wait until we get them both in the Airstream for the next trip. Might be rather exciting.

No axle holes drilled today either.

David
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Old 05-21-2019, 05:55 PM   #432
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Axle Holes Drilled

Springtime in the Rockies. We had about a foot of heavy wet snow last night.
It's been a long winter. The snow fall is welcome moisture however. The Memorial Day cookout may have to be inside.

I now have all 8 new holes drilled in the axle plate. And I have all 8 new bolts installed. The axles are up.

I elected to install a 1/2" steel bar between the frame rail and the axle bracket. I did this because the original U notches in the axle plate were not deep enough to allow the axle bracket to rest tight on the frame rail. It must rest tight on the frame rail with no weight on the axle bolts. I could grind the U notches deeper, or I could add this steel bar to the frame rail. I felt a 1/2" lift will not significantly upset the balance or the appearance of the Overlander. In fact, it will help a bit here in Colorado campsites. The new beagle puppy approved.

I have the new shocks to bolt up. I can do this with the axles in place. I also have the brake wires to connect and verify they all work as intended.

It will be nice to get the Overlander on its wheels and tires soon.

I still have a quite long list of things yet to complete. I'm many hours from the maiden voyage, but closer than I was a year and a half ago.

David
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Old 05-21-2019, 11:09 PM   #433
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David. We got the same snow last night. And again tonight. Just in time for Memorial Day weekend. Good mod on the gap for the axle mount. Glad you got those holes drilled without injury.

1.5 years. You and I started about the same time. I'm so close to heading out. Just some here and there items left. Good luck
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Old 05-22-2019, 08:11 AM   #434
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Come to Minnesota for Memorial weekend. We're supposed to be in the '70's with possible thunder shower lurking. For us, can't get better than that!

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