A 969 rebuild from Downunder.

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kw573
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A 969 rebuild from Downunder.

Post by kw573 » Tue Jan 26, 2010 5:16 pm

I have a Diamond T 969 that I'm repairing. Currently doing a major open cab rebuild due to rust and other abuse. As I wish to rally this vehicle at every opportunity, I am looking to fit a Japanese diesel and gearbox and up the overdrive or diff ratios. Has anyone found a way to up the diff ratios by 20-30%? Are there different ratio bullgear/pinions available (and helical cut as well) that can be purchased and pretty much bolt straight in? Has anyone tried to have gears made? I'm looking to cruise comfortably at 80kph (50mph). I've never done this before and don't know what's available. Help and advice would be greatly appreciated. Sam.

12/2016
I have decided to slowly build a rough contents list of what is on each page as this thread is full of lots of D.T. technical stuff. It will be slow, a work in progress, as I make time. Page numbers may not be exact, but close.


CONTENTS LIST

P.1. Tyre size discussion. Intro to cabin repair/floor panels. Jeffs' truck pics.

P.2. Pressing floor panels. Cabin progress. Screw and toolbox handle questions/pics.

P.3. Cabin repairs. T nuts. Paint prep. Handle ID. Cowl Vent manuf. Wind screen inner repairs.

P.4. Light switch lockout mechanism. Plumbing fittings for air wipers.

P.5. Windscreen frame rebuild. Axle rebuild pics and bearing numbers.

P.6. Brake line tubing. Making hand nuts for windscreen frame. Chassis repair and cleaning. Painting chassis brackets. Repairing rear suspension trunion.

P.7. Bearing prices. Rear spring saddle repairs. Rear Pintle hook repairs. Rear axle rods bush repairs. Rear trunion and saddle assembly fitting. Cabin wiring harness. Rear spring U bolt nut repairs.

P.8. Seal surface repairs on rear axle. Rear diff parts, assembly and adjustment. Fitting rear axle housing axle shaft seals. Fitting diff to housing.

P.9. Brake chambers. Wheel bearing felts. Crane A frame saddles. Hood lip question.

P.10. Windscreen frame repairs. Fitting rear axle housings and torque rods.

P.11. Bumperette repair and manufacture. Front axle housing dis-assembly.

P.12. Front spring shackle bushes. Front springs repair/assembly. CV housing assembly. Front spring fitment. Front diff repairs.

P.13. Front diff repairs. Diff to front axle housing. Front brake drums and wheel studs. Axle shaft seal surface repair. Steering box repairs. Pictures of the Diamond T as found. CV joint repair.

P.14. Bolt reconditioning. Front brakes assembly/adjustment problems. Fit front axle assembly. Drag link repair. Bump rubber manufacture. Fuel filter repair.

P.15. Steering Box. Chassis fuel filter. Double check valve. Radiator. Rear body repairs/blasting.

P.16. Rear body repairs. Air tanks.

P.17. Rear body repairs.

P.18. Rear body repairs. Retrieve original cranes from 'Homebush' truck. Banana Bar mounts. Mudguard straightening and repairs.

P.19. Retrieve original cranes. Tailgate repairs. Fit rear body. Disassemble Holmes cranes.

P.20. Tail gate repairs. Transfer case repairs.

P.21. Transfer case repairs. Cummins flywheel repairs. Chassis repainting. Transfer case fitting to chassis. Hand brake linkage repairs. Cummins flywheel modifications. Clutch fitment to flywheel. Pressure plate re-build.

P.22. Pressure plate re-build. Spigot bearing modification. Clutch throwout bearing setup and fitting. Pressure plate fitting to flywheel. Fitting gearbox to engine.

P.23. Clutch clearance testing. Test fit engine/gearbox to chassis. Design/manufacture engine mounts. Spare Cummins engines arrive. Testing injector pump with air compressor.

P.24. Front winch.

P.25. Front winch. Engine sump.Cummins engine T.D.C. lock/injectors/oil filter/alternator bracket.

P.26. Alternator bracket. Oil fill. Fit injector pump. Assemble/fit gearbox P.T.O./ Start Cummins engine. Extend front engine mounts. Injector pump locking bolt.

P.27. Front winch and drive shaft repairs. Re-fit engine/gearbox to chassis. Gearbox shift boot.

P.28. Front winch fitting to chassis. Starter Switch rebuild. Starter motor fit in chassis. Pedal springs repairs. Winch P.T.O. shaft repairs. Air lines fitting/routing in chassis.

P.29. Cooling system elbow. Gearbox to transfer case drive shaft repair. Fit wiring harness to chassis. Repair gearbox and P.T.O. oil leaks. Transfer case front output repair.

P.30. CV felt seal. Gear box drain plug fail + oil leaks. Hand brake linkage repair. Test drive.

P.31. Cowl Modification to fit Cummins engine. Gear shift cluster/radiator top pipe repairs. Horns wiring.

P.32. Circuit breakers. Low air buzzer fitment. Throttle pedal repairs. Oil dump plumbing. Throttle linkage on toe board repairs. Air compressor cooling water plumbing modification. Realign front brake hose. Air cleaner, bracket and pipework. Toe board modifications. Radiator to cowl brace. Finish cowl modification. Turbo oil dump plumbing modification. Engine mount clearance increased. Making air cleaner to turbo pipework. Pedal felts.

P.33. Air pipe. Amp gauge testing. Chassis wiring harness fitment. Firewall insulation. Steering column escutcheon.

P.34. Bowden cable repairs. Paint dash. Fit firewall insulation. Wire up alternator. Pedals escutcheon problems. Air wiper valve. Oil gauge hose. 'Westinghouse' air fittings. Test fit cabin/repair cabin. "Fit" doors to cabin.

P.35. Remove gearbox to fix oil leaks. Stud lengths/magnetized drain plugs. Flywheel teeth modification. Gearbox P.T.O. gear engagement. Rifle bucket bolts modification in cabin. Transfer case oil leak repair. Indicator light options. Battery Box and supports repairs. WW2 oxy gauge.

P.36. Indicators. Air wipers Battery Box. Gauges.

P.37. Accelerator linkage. Accelerator pedal. Battery 'B' gauge. Steering column escutcheon.Steering column fittings. Fuel Filter gasket. Test drive. Battery Box rebuild.

P.38. Battery Box and clamp rebuild. Battery Box repairs. Front P.T.O. oil leaks.

P.39. PTO oil leaks. Battery Box. W45 U blots + A frame. Fuel tank repair. Fan fitting.

P.40. Fan. Fan Guard/cowl/hub. Front winch overrun brake. Bonnet (Hood) center strip. Cummins tacho drive. Choke cable. Fuel Gauge.

P.41. Horns. Firewall air fittings. Rear brake relay valve. Wiper control valves. Gladhands. Accelerator linkage. Fuel tank shield. Original horn button? Foot brake valve repairs. Fan mounting. Cab repairs. Steering wheel repairs. "T.Bag,
(Fowlers' truck). Front P.T.O. oil leak. Passenger side step. Front bumper. Tyres physical size on the truck.

P.42. Front P.T.O. oil leak. Exhaust pipe size. Suitable trailers. Passenger side step. Fire extinguisher bracket and reinforcement. Front bumper repairs. Fuel tank shield straps, scuff plate and side step. Burned fingers.

P.43. Painting cab and front mudguard parts. Test fitting fuel tank, shield and side step. Fitting windscreen glass. Rolling Fuel tank shield and painting it and associated parts. Front winch drive shaft. Front winch overrun brake. Wiper pipe clips. Radiator grille repairs. Front winch cable guard repairs. Front fender and inner guard repairs. Wiper motor repairs.

P.44. Brake foot valve 'O' ring modification. Windscreen wipers. Front bumper repairs. Front P.T.O. leather boots. Air leaks at firewall.

P.45. Front bumper repairs and fitting. Correct front guards (fenders) bolts. Front winch overrun brake problem. Cabin rodent repairs. Modification to rear cabin mount.

P.46. Fuel tank repairs. Air tank drain valve modification. Fitting fuel tank and shield. Tacho repairs. Front mudguard repairs. Bonnet arm repairs.

P.47. Front Mudguard (fender) repairs. Fuel Tank wiring. Fitting cabin rear section. Door catches and handles. Bonnet arms. Adjustments to get the cabin rear to fit correctly. Gear shift escutcheon modifications.

P. 48. Cranes lights wiring. Cabin floor fitting/hole for starter switch. Front winch cable fitting. Turbo pipe beading and fitting. Rear vision mirror arms. Bonnet (Hood) repairs.

P. 49 Fuel Gauge. Gear shift escutcheon. Bonnet repairs. Drag Link repairs.

P. 50 Bonnets centre plate. Bonnets brace repairs. Bonnet repairs. Windscreen hold down catch. Fuel tank filler extension and cap.

P. 51 Bonnet repairs. Air pre-cleaner plumbing. Inner guards/engine side panels repairs and fitting. Throttle cable repairs. Inner guard caged nuts. Instrument panel lights. Oil filter plumbing mods.

P. 52 Front blackout marker lights repairs and modifications. LED lights. Passenger side inner guard/engine side panel. Door handle repairs. Mudguard adjustments. Park lights diode pack. Coolant hose re-route at alternator. Headlight bucket repairs. 'Piggyback' park light bulb holder. Head/park/indicator wiring. Passenger side front mudguard repairs.

P. 53 Mudguard repairs. Headlight repairs and wiring. Scuff pate fitting. Mudguard bracket adjustments. Winch chain manufacture. Blackout headlight repairs and modifications. Steering wheel nut modification. Fitting winch chain. Repair/describe/adjust the horns.

P. 54 Overlooked passenger mudguard hole. Front park lights wiring. Mods to tail light buckets, wiring and inserts. Front wheel alignment adjustments and steering box discussion. Fit Jerry can holders/straps/rivets. Adjusting clutch pedal escutcheon clearance. Missed pictures (front mudguard repairs/cabin fitting/door painting).

P. 55 Start on cranes. Making captured nuts. Steering wheel nut modification. Panel adjacent drivers seat. Rear lights. Hook anchour fabrication. Holmes transmission disassembly/clean/repair. Holmes control lever shaft repairs. Holmes neutral return mechanism. Front and rear number plate mounts. Missed pictures (drag link/door catch mechanism/R.V. mirror arms/burring machine/cleaning bonnet flutes/door striker mod). Trailer plug wiring. Pintle hook chain and pin. Clean/repair Holmes cranes frame and parts discussion. Brass electrical connector ID. Shorten mudguard bolts.

P.56 Holmes worklight mounts. Holmes frame and parts repairs and cleaning. Using Phosphoric Acid. Repair/assemble Holmes transmission parts. Bearing shield discussion. Re-conditioning spring washers. Crane scales. Repair Holmes control lever. Modify Holmes transmission cover to receive common size seal and discussion. Unusual shaft damage. Holmes winch drum and associated parts repairs. Brace leg bracket damage. Topping cable guide and pulley repairs. Drivers seat cushion modification. Indicator switch re-location. Fitting Holmes winch drums and assemble luffing winches. Holmes pin bushes and housing lug repair w/crack picture. Holmes transmission assembly. Luffing winch and winch drum overrun brake repairs. Fitting the Holmes transmission to the crane frame and assembling the control linkages and chain tensioner.

P.57 Luffing winch/Boom pivot repairs. Bolster bolt repair. Booms repairs. W45 throttle linkage/transmission controls/winch drive fitting. Fitting W45 transmission. Rebuilding and fitting W45 over-run control brackets. Disassemble and re-assemble W45 worm wheels. Boom repairs.

P.58 Booms and brackets repairs. Over run brake adjustment. W45 booms lock mechanism repair. Fitting luffing cable. Boom and brackets repair and fitting. Hook cable fittings. Outrigger legs and chain repairs. Added chain brackets. W45 Bolster still leg repairs. Bolster U bolt modification. Test fitting Bolster. Bolster stiff leg bolt repairs. Bolster tie plate manufacture.

P.59 Test fitting Holmes cranes. Modify tie plates. Reposition air tank. Repair front spring shackles. Repair Bolster stiff legs. W45 Transmission drive sprocket. W45 crank handle repairs. W45 Bolster leg chain fitting. New hook cable fitting. Fitting cranes to chassis and connecting them. Sorting W45 control handles puzzle.

P.60 Rear body mudguard repairs. Exhaust tail pipe adjustments. Re-running W45 winch cable correctly. Rear body toolbox handle fitting. Pioneer Tool Rack fitting. W45 worklights and wiring repair and fitting. Rear body front mudguards brackets fitting. Numbers stamped on Bolster stiff legs. Correct cable/hook storage. Rear suspension 'klunk' remedied. Front tail shaft. Fire extinguisher bracket. Drive to weigh bridge.

P.61 Rifle Bucket repairs/fitting. Rear steps repairs/fitting. Painting stars. Registration problems. First tow job attempt. First event @ Bundaberg. Speedo adapters questions.

P.62 Turntable recovery job. Small extinguisher bracket repairs/fitting. Passenger seat modifications. In yard tow job.

P.63 Injector pump discussion. Original rubbers discussion. Fitting welding bottles and rack modification. Paint repairs. Bonnet (hood) insulation.Oil filter oil leak. Hand brake discussion. MJCQ trip report. Tool strap ball tips. Steering column mount. Experimenting with wheel alignment.

P.64 Handbrake discussion. MJCQ Swap Meet. Sign writing. Boom spreader bar. Extra rear lights. Toolbox chains. A crane job. Flat tyres and lock rim safety.

P.65 Tyre repair. Wheel assembly. Cabin roof canvas support. Front drive flange blanks manufacture and fitting. Canvas attaching points. Front drive flange grease leak. Wheel alignment discussion and trials.

P.66 Air compressor and lift pump oil leaks. Steering caster wedges manufacture and fitting. Front spring center bolt mods. 'O' ring groove for front hub free wheel plates. Front stub axle felt retainer repair and fitting. Sump modification. Transfer case selector oil seal leak repair. Fuel tank leak repair. Test fitting larger tyres. Re-manufacturing custom wheel rims.

P.67 Discussion on cruising speeds and on highway behavior. Holmes throttle control modification discussion. Corowa 2020 trip report. Pulling tree roots and discussion.

P.68 'A' frame tow bar/distance bar repairs. Using the cranes to move a lathe. Modifying the front axle free-wheeling plates. Wheel alignment and oil leaks discussion. Front spring height.

P.69 Annoying rattle. Drive shaft clearance. Shackle questions. Gear box temperature. Windscreen frame seal. Drive shaft straightening. Wiper motor repair. Front diff oil leaks. Front springs repair.

P.70 Fitting reset front springs. Shackle bush problems. ANZAC Day picture. Steering box oil leak repair. Shackle bush manufacture and fitting. Transfer case oil leaks and rattle remedy. Re-fitting steering box. Fitting PTO drain plug and selector shaft boot. Front diff shims sealing, pinion nut spanner manufacture and fitting pinion nut. Fitting pinion nut oil seal. CV Housings seal surface repairs and mounting hole modifications.

P.71 Front spring shackle manufacture. BTTT2021. Tyre issues discussion. At Hall of Fame, Alice Springs.

P.72 At Hall of Fame, Alice Springs. BTTT2021. Fuel Tank leak and repair. Darwin to Childers.

P.73 Adjusting air governor. Tyre wear. Lube leak at left steer wheel. Radiator hose failure. BTTT2021 trip observations. Servicing wheel bearings. Hub slinger repair. Axle cleats de-burr. Backhoe recovery. Clutch adjustment.

P.74 BTTT2021 video links. Recovery job in my own back yard! Replacing rear axle torque rod ends.

P.75 Fuel tank repairs. 200000 views.

.
Last edited by kw573 on Wed Jun 12, 2019 1:44 pm, edited 38 times in total.


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Captain Crank
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Re: Speed up a 969?

Post by Captain Crank » Wed Jan 27, 2010 6:02 am

Sam,

These trucks weren't designed to go fast, stopping is the biggest safety factor.

There's also handling and steering.

Don't butcher it up! You are defeating the whole purpose. (and gonna spend a ton of money)

Keep the original power plant and drive line.

The easiest and most economical way to get a few extra mph is to put larger tires on. It will still look original too.

Also, check your laws down there. The UK requires air brakes to be updated to double circuit for use on the roads.

Cheers,

CC
"Beer is proof that God loves us and wants us to be happy"
Benjamin Franklin

"Life is like a roll of toilet paper
It goes quicker towards the end"
CC

Jeff Jensen
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Re: Speed up a 969?

Post by Jeff Jensen » Wed Jan 27, 2010 8:30 am

Hi Sam
I have seen pictures of these trucks with super singles, If I find it I will post it.
I have a 969 and drove it around 750 miles one way (41-1/2 mph) 2300 rpm's with 900-20 tires, Truck weighs 22,000 lbs , 6 mpg. I am going to put 11:00-20 NDCC on mine because they are easy to find and much cheaper than buying 10 new 9:00-20's, Do not run 9:00-20 8 plys off 2-1/2 ton 6x6's on the front of this truck they are to light, need to be 10 ply or more.
Keep the gearing original because if something breaks parts can be found and there are no taller gears to put in place, the transmission is all ready 0.768 to 1 overdrive.
The Hercules RXC 529 cubic inch engine is 131.5 HP. torque is 396 foot pounds at 1000 rpm's, You can still today buy a brand new RXC for $2600.00
Some of the guys in Europe have put Cummins diesels in place. I do not know much about Japanese diesel and gear boxes , There is none here in the states that large and you are going to match or have more torque than stated above.
Just remember these trucks are highly collectible and hold a value when original .
Can you post some pictures of what you have.
Jeff

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Re: Speed up a 969?

Post by 40 Chevy » Wed Jan 27, 2010 9:56 am

I concur with what Jeff and Captin Crank have stated, especially on the tire issues that Jeff brought up.
If you are going to play with the BIG toys, they should be maintained and operated as orginally designed, for your enjoyment and safety and those of your fellow vehicle operators.

John Gott
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kw573
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Re: Speed up a 969?

Post by kw573 » Wed Jan 27, 2010 8:48 pm

Thanks heaps for your comments lads. Clearly, I still have heaps of homework to do.
I didn't consider the tyre sizes option much due to appearance, however, as I have a M1A1 heavy wrecker paddock truck with good tyres, it'll be very easy to test out.
Brakes-wise, yes I do need to check local laws. However, as they seem to stop on a dime I didn't forsee problems there.
I certainly won't be butchering anything on what is a fairly good rolling chassis with a blown engine. Photos to come when I work out how! Really, I couldn't afford to rally this truck much at all at 6 mpg. It's about 200 miles to my local city where most of the action is. 750miles! Well done. I'm impressed!
The diesel I'm wanting to use is an Isuzu 6BG1(out of a 13ton gross truck) which revs to 3300. I'll get the torque/power specs when I go home. However, overdrive boxes (21%) for them are scarce. Still looking/thinking. I calculate 53-55mph with this setup. I really am not looking forward to long-haul trucks bearing down on me at 40kph below the speed limit out on the highway.
I'll get some info and pics. Have a nice day. Sam

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Re: Speed up a 969?

Post by Jeff Jensen » Thu Jan 28, 2010 10:31 am

Found it
Image

kw573
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Re: Speed up a 969?

Post by kw573 » Thu Jan 28, 2010 8:37 pm

Wow, that looks real cool!! I presume that they are 11.00 - 20 tyres, but what would the rims be off? Does the offset on the rears put an uneven load on the bearings compared to duals? I suppose that it couldn't have been a real problem since it was done at times evidently.
More pics another day. Thanks for the picture. Sam,
Attachments
KIF_0044 resized.jpg
This is what I've got to work with. It's in generally good order. 15000mls on the clock.
KIF_0044 resized.jpg (225.56 KiB) Viewed 23098 times
KIF_0009 resized.jpg
Rear inside lower corner of the cabin being repaired
KIF_0009 resized.jpg (150.29 KiB) Viewed 23072 times
KIF_0043 resized.jpg
the truck at the moment.
KIF_0043 resized.jpg (218.71 KiB) Viewed 23067 times

Jeff Gordon
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Re: Speed up a 969?

Post by Jeff Gordon » Sun Jan 31, 2010 2:20 am

Hi Sam.
I recon the fact that the Isuzu does 3300 RPM the truck would do 50 MPH using the same gearbox.
The situation here in Australia is much differant to you guys in the States.
Our fuel prices are almost double yours.
We have long distance between towns and poor roads between them. We don't have an interstate and an old highway for slower vehicles. Between where Sam lives and the big smoke is mostly single lane each way and the only road with few places to overtake. It is the main Highway. I would never drive my Diamond T along it for any distance as you hold up too many trucks.
Queensland summer tempretures can get to 42 deg C and 99% humidity in the shade. HXC have over heating and head gaskets problems.
Second hand Japanese Diesels are a dime a dozen and Herc's are rocking horse poo.
I would rather see a Diamond T with a Diesel at a show than not seeing one because it is in the shed and you cant aford to use it.
Original breaks are legal in Oz and are fine.
Super singals would be good with 1200/20 on the beach because duels are useless in soft sand.

You do what you want Sam.
Cheers
Jeff
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kw573
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Re: Speed up a 969?

Post by kw573 » Mon Feb 01, 2010 8:05 pm

Hi Jeff,
Thanks for the clarifications. Isuzu-wise, I have mucked abouts putting different brand engines and gearboxes together before and I ain't goin' there again!!! What a nightmare. So, the Isuzu keeps an isuzu gearbox. the trick is finding one with a suitable overdrive. They are available in .78 (BG6P) or .74 (BG6U). Both are scarce and expensive. I continue to search.


This base has had the bottom 3" of rust replaced.
Drivers seat base.JPG
Drivers seat base, rust removed. Ready for some bog and paint
Drivers seat base.JPG (155.82 KiB) Viewed 22910 times

I began work on this today. It's 3mm plate. Easy to weld but hard to shape.
Drivers seat.JPG
It started on this today. It's 3mm plate.
Drivers seat.JPG (193.86 KiB) Viewed 22905 times




I thought for a long time before deciding to have a go at pressing these floor panels. Most don't seem to worry about it. It took over a week to make the press plates! Photos to follow. They are 1.6mm (16g) sheet and took multipule goes with a 60ton press. I have some softer sheet on order and have been told of a 100 ton press nearby. So maybe the next ones will be even better. These are not real bad at all!
Pressed floor panel.JPG
Pressed floor panel.JPG (150.59 KiB) Viewed 22880 times
Have a nice day. Sam.
Last edited by kw573 on Mon Aug 20, 2018 5:19 pm, edited 1 time in total.

Jeff Jensen
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Re: Speed up a 969?

Post by Jeff Jensen » Tue Feb 02, 2010 8:35 am

Hi Sam
Very nice job.
Yes it can be a nightmare fitting some engines and transmissions unless they have SAE bell housings, then once you find what you want can the original P.T.O. be used.
Some day I will start on my 969, I also have a 981 about 3/4 tore apart.
I think them tires are at least 12:20-20 or larger, I have seen this picture some where else and clearer. The front wheel looks very familiar like on a 5 ton 6x6 and it is off set to be inline with the rear.
The rear looks to have singles but a standard wheel but has to be wider to put 12:00 tires on like the wheel on your Ward.
I have to plow the drive at the shop today, I will stand a 11:00-20 next to it and take a picture.

The other Jeff

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Re: Speed up a 969?

Post by Jeff Jensen » Thu Feb 04, 2010 9:22 am

Here's an 1100 next to my Diamond with 900's on it. There's ice all around so the 1100 appears a bit taller because of that.

Image

kw573
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Re: Speed up a 969?

Post by kw573 » Thu Feb 04, 2010 8:00 pm

Wow! There is a bit of difference there!!! I also notice that there is plenty of room between the two rear axles. I will certainly be having a closer look at this possibility. Thanks for going to the trouble of setting up that pic.
I have recieved a sheet of the more malleable 'bright form' steel to try pressing the drivers side floor panels. More to come. Could you post a couple of pics of your 969? I always like to see anothers' pride/project. Thanks, Sam.

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cessna
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Re: Speed up a 969?

Post by cessna » Fri Feb 05, 2010 8:00 am

I second that request Jeff! By the way, nice towbar!
Brian
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Re: Speed up a 969?

Post by Captain Crank » Fri Feb 05, 2010 10:12 am

Image
Image
"Beer is proof that God loves us and wants us to be happy"
Benjamin Franklin

"Life is like a roll of toilet paper
It goes quicker towards the end"
CC

Jeff Jensen
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Re: Speed up a 969?

Post by Jeff Jensen » Mon Feb 08, 2010 3:41 pm

Thanks for posting the pictures captain.
As you guys can see I us my trucks, This one has payed for its self many times.
Jeff


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