1961 Flying Cloud Frame fabrication and replacement

[RollFast]

I am in the process of refurbishing a 1961 Flying Cloud. It had decent bones to work with when I bought it but was in need of a complete new running gear and frame. It was a project for sure!!!!
I decided to build a new chassis myself and wanted to upgrade it to a new Dexter axle and 5” C-channel while I was at it.
In the process I used (3) 24 foot sticks of 2x5 1/8 wall and (3) 20 foot sticks of 5” C-channel along with 1/4 plate, 14 and 16 gauge plate, 1 1/2x1 1/2X1/4 angle, and a few other odd and ends laying around.
This is what I started with.....stay tooned!!!!

[RollFast]

Making big pieces out of little pieces!!!
Starting with the rear, finding square and level, I fabricated the axle mounting plates and shock locator.

[RollFast]

For the crossmembers, I made an end template to plasma cut them to fit into the C-channel and cut guide for the lightening holes.

[RollFast]

A few more crossmember pics

[Bubba L]

Looks really good. Starting with a great foundation is the way to go. Good luck and keep us posted.

[RollFast]

For the outriggers, I used the same template process as with the crossmembers.
I added some 16 gauge plate over the step opening to keep the road grime and moisture off the plywood in that area.
Mockup started for tank, toilet, and shower placement. I will have to add the rear outriggers in this area after the shell is back on.

[Zcashio]

Looks great! Nice work. Thanks for showing and keep posting!

[RollFast]

Moving onto the front I upgraded to a 2 5/16 coupler.
The forward outriggers are 1 1/2 angle and the lower tongue plate is 1/8.
The forward and aft mount plate is 14 gauge.
Also added in the mix is a receiver hitch for a future bike rack/Honda Trail 70 and stabilizer mounts.

[ddhisself]

Wow! Very very nice work! I wish I was talented instead of being so durned handsome! Oh, well!

[1936RoadWarrior]

YOU ARE VERY SKILLED !! 6 yrs ago I did a complete skin off resto on my 1936 which had the original PIPE frame. My only skill was writing oodles of checks to get it finished.
best money I've ever spent !!!! And my 1936 is not a garage queen. Every year we venture to other states and up into Canada. Even had the restorer put in a small standup shower. Standup is the key word here because if you drop the soap you'd better be able to
do a full knee bend !!

[RollFast]

Gettin good help is worth its weight in gold!
Lightening up the load for the shell swap.

[RollFast]

Sorry for all the directional pictures. They are all in the right direction in my electronic device before I post them.

[RollFast]

Bracing up the shell before I start begging for help!
Added some temporary floor support. I will be adding grey and fresh tanks at a later date once the Black tank is located and secured.

[RollFast]

The help has arrived!!! Now for the floor, tank install, and belly.

[RollFast]

This is the chassis that was hiding under the floor and was replaced. Stay tooned.....

[Bubba L]

RollFast, you’re doing a great job.
Off subject, if you want your 61 FC noted on Captain Jones’ Flying Cloud registry, please let me know and I’ll list it. The Registry goes from 1950 FCs through 1963. It’s a good way to keep up with those who have the same year/model. There are only four 1963s listed.
Keep up the superb progress. Take care

[Streamracer]

Great job! I'm enjoying all the information you are sharing. I can't wait to see the finished product.

[bibbs]

interesting how you didn’t use a gantry Friends are good for something.

[Foiled Again]

Originally Posted by bibbs

interesting how you didn’t use a gantry Friends are good for something.

Which costs more? Lumber or beer?

[RollFast]

Let the noise begin......