[firestopper]

Set up outside to cut the 1/4" plate and radius the corners and edges.
The pressure vessel to the left of the Hypertherm has 10 pound of desiccant to pull any moisture from the air. I normally don't fire up the refrigeration air dryer when cutting by hand as the air compressor doesn't run like it does when CNC cutting. For those not familiar with plasma cutters, clean dry air is required for the longevity of the torch consumables.

After dressing up with a 60 grit flap wheel the edges are softened.

Test fitting and marking the locations for some angle clips to secure the top.

The clips are welded along the inside perimeter of the cart top frame allowing it to be lowed and stay in place without sliding. This also allows the top to be pulled off without the use of fasteners (plate is upside down).

Here you can see the plate held in place looking from the bottom.

Overall shot of the cart with the top in place and lined up to the iron worker.

The handle was made from 12 gauge X 1" tubing. The XXX represent were I plan to knurl.

It was knurled on the lathe prior to bending providing a nice medium knurled grip. This required a follow rest on the lathe carriage.

Piece ready for bending.

Bending the handle. The handle had to be a bit long for the bending to take place. Honestly I could have cut it a
little shorter to not waste as much.

More to follow...

 

[firestopper]

Cutting the handle to size and also cutting a 30º angle for a slight kick up.

The angle.

Tacking in. The level should always match the top plate surface in the event the floors not perfectly level.

Welded in.

A top surface view.

The money shot! the heavy break can now be slid in and out without any back strain.

The other tooling on the top is for converting over to punching holes.

A detailed view of the alignment. The die/tooling cart can be pulled away after a tooling swap.

This is one of my favorite additions to the shop.

 

[firestopper]

Wow.... Very impressive.

Thank you Rusty,
I don't specialize in any one thing so when I do work in gun-smithing, I get some pleasure out of it.

 

[firestopper]

Three years after the horrific attacks on the World Trade Center The Tucson Fire Department had embarked on developing a Metropolitan Medical Response System (MMRS) with the help from federal grants. This meant ordering new dedicated box trucks and medical supplies to respond to mass casualty incidents. Tucson would respond to any natural or man made disaster within the entire South West portion of Arizona. This meant assembling teams cross trained in Haz-mat and Technical Rescue disciplines. Also purchased were specialized rigs and equipment that could detect Nuclear, biological, and Chemical WMD's as well as other equipment to support Building Collapse, Trench Rescue, High Angle rescue, Low Angle Rescue, Tower Rescue, Confined Space Rescue and Swift Water Rescue. Some of us also went across the country for more specialized education such as IED bomb making, Nerve agent training, and Live pile training. What was not available in the market was a simple litter (cart) that could be used to transport injured individuals to an appropriate triage (Green,Yellow, or Red) treatment area. I was asked by an assistant Chief to design such a cart. I came up with a prototype during my six day break. The prototype required a couple of tweaks and the department ordered 6 to go into the MMRS box trucks. I took those proceeds and hired a patent attorney to begin the process.

Over the next several years, We were blessed to build and sell 300-350 units per year. Mostly to fire departments starting their MMRS programs. The patent was finally awarded in 2005 and I still build and sell the litters today. The name of this company is RescuExpress inc. We offer three different variations of the litter with the most popular being the urban 10" wheel model. We most recently sold four Rough Terrain (16" tires) versions to the north slope of Alaska. To date we have over 1900 units across the US and a couple in Canada. The sad truth is the the department has dismantled the program due to budgetary constraint and lack of interest from the Feds. Now I sell to mining operations, Airports and some military bases.
Sorry for the long explanation but I felt it was important to understand the following photos of the production process.
The following photos are the last production run of 35 units. Nine of these units went to Honolulu International Airport. The remainder are inventory.
The first day is spent cutting (gang cutting) all the tubed parts on the band saw followed by de-burring and any machining. The components made from flat bar are sheared on the Iron worker.
The dedicated jig table has several stations to build individual components such as frames, axel assemblies, toe plate and kick stands.
Here were notching corners to create a radius end.

Both ends. Each unit will utilize two of these pieces. The final dressing to create the radii is done on a 12" sand disc.

Those pieces then get broken to 90º.

All the pieces are loaded onto the jig table cart making it fast to load for welding.
The table itself is made from 3/4" plate to ensure no warping.

Another view of the table shows the axel jig portion. The axel jig can be modified to weld axels for larger tires using the threaded holes.

A detail of the axel jig welding up an axel. Modified clamps index the 5/8" CR axel onto the jig while the axel sleeves
are welded to the 1/4" x 1' axel assemblies.

A close up of the hot weld joining the 16 gauge tubing to the flat bar.

Once all the axels are welded, then we move onto another component (different part of the table) until they are all done
and start another component.

The kick stand being welded. This piece is comprised of two 14 ga. x1" x 1" welded to a piece of 3/8" x 1" flat bar.

Photo limit...

 

[firestopper]

The toe plates are made from 1/8" x 7" flat strap and are sheared to 14".

The shear can handle up to 1/4" X 14" wide or 5/8" x 6".

The individual pieces then get two corners sheared at 45º.

The second to last step in creating the toe plate is a 1" 90º return followed by a de-burring.

Back on the jig table the main frames get welded and two cross members added.

Another view.

A detail of the end section that lock the folding handlebars open.

With the main frames welded they get stacked onto another jig table for minor cleaning. In the back round you can see an R/T (rough terrain) version fully assembled with the handle bars stowed.

The ends get de-burred as they will have a telescopic toe plate inserted.

The precut sections of tubing will be bent into offsets to serve as handlebars. The digital Ercolina ensure a repeatable
bend every time. Here you can see the settings set to 50º with a spring back compensation of 3.

More to go...

 

[firestopper]

Making progress on the bender.

The bent sections are loaded on a different jig to create the handlebar assemblies. The same jigs is used to drill
The holes for the bolts for the bars to rotate out. The jig utilizes drill bushings for accurate straight holes as this is done by hand.

The cross bar is welded followed by drilling.

A close up the the drill bushings that align the brill bit. These bushing are made of real hard martial and can be sourced from McMaster-Carr.

The handle Bars are stacked onto a transport jig to be sand blasted and powder coated.

The toe plate assemblies are also welded on a different portion of the jig table.

The joint to be burned in.

A stack of toe plates.

The main frames are now ready for the axel and kick stand assemblies to be welded on. For this two small jigs are used to index the pieces for welding.

 

[firestopper]

With the kick stands and axels welded on the frames get stacked on a special transport jig for blasting and powder coating. You can see the indexing jigs still on the frame. These ensure the litters built today are the same
as the predecessors from seventeen years prior.

The transport jig can safely hold up to 40 main frames.

The goods ready for the 30 mile trip to the finisher.

Another view.

With about a week for the carts to be ready for pickup, I start building the custom pallets and pre-cut all the crating material.
The large jig table is converted to a cut station. The table has tapped holes to secure the compound saw.

This small cradle will capture the assembled litters wheels and is nailed to the main pallet.

The almost complete pallet. This design allow a fork lift to purchase from either end.

One down five to go.

With the pallets done and all the crating pre cut it's the to take a breather (after a shop clean up).

More to follow...

 

[Ben A Gonna]

The toe plates are made from 1/8" x 7" flat strap and are sheared to 14".
View attachment 640089
The shear can handle up to 1/4" X 14" wide or 5/8" x 6".
View attachment 640090
The individual pieces then get two corners sheared at 45º.
View attachment 640091
The second to last step in creating the toe plate is a 1" 90º return followed by a de-burring.
View attachment 640092
Back on the jig table the main frames get welded and two cross members added.
View attachment 640093
Another view.
View attachment 640094
A detail of the end section that lock the folding handlebars open.
View attachment 640095
With the main frames welded they get stacked onto another jig table for minor cleaning. In the back round you can see an R/T (rough terrain) version fully assembled with the handle bars stowed.
View attachment 640097
The ends get de-burred as they will have a telescopic toe plate inserted.
View attachment 640098
The precut sections of tubing will be bent into offsets to serve as handlebars. The digital Ercolina ensure a repeatable
bend every time. Here you can see the settings set to 50º with a spring back compensation of 3.
View attachment 640096
More to go...

Mr Firestopper
Several questions if you don't mind sir, can you expand any more as to your previous background? How did you acquire all the layout knowledge , and shop experience with the vast array of equipment you have in your shop. Your electrical knowledge for rewiring and altering equipment. Programming the water jet and plasma. I grew up in a time period when computers were not in the shops, all the lathes, mills and such were all run by hand. Wire welding had not been perfected to what it is today.

I program the X Y Z coordinates for my plasma torch into my right hand. Never had a plasma to use when I worked in job shops or fab shops.

I have been certified welder, pipefitter , working gas storage plants & pipeline. Certified structural steel for construction, equipment operator, lucky to be here typing this, spent last 27 years working aircraft production, some military, mostly large commercial aircraft. Happy to say best occupation is retired. So many projects, dont know how I ever had time for a real job.

You made comment about working on submarines, and surface water warships. How the hell did you get them into Arizona.

Thank you Sir
L8R

 

[firestopper]

Assembly day. This actually goes fairly quick. My wife pre-makes all the labels and stickers. The seatbelts and Carefree tires as well as all the hardware required are purchase in bulk so we are ready for orders of up to 150 units.

Staging for assembly.

The press nuts have a grip strength of 1200 pounds and a special tool was turned on the lathe for easy install.

The tool I came upon with is simple with a nice knurl for sweaty hands.

The special stainless push pins are made specifically to my design by Index tool and die Co. They feature a solid stainless button that will prevent collapse.

hey get inserted into the toe plate assembly.

The toe plate telescopes into the main frame and can be deployed by pushing the pin in and pulling the toe plate out. The assembly will automatically catch a second hole on the main frame to lock it in the deployed position.

A detail of the end section with the solid bar welded to the main frame tube.

All crated up and ready for shrink wrapping and shipping labels. Each unit gets a "MADE IN THE USA" sticker.

This is what they should receive if the shipping company does their job.

A link to this company.

RescuExpress Home

rescuexpress.com

Thank for following along.
As always, I hope someone can take away some kind of tip or idea.

 

[firestopper]

Mr Firestopper
Several questions if you don't mind sir, can you expand any more as to your previous background? How did you acquire all the layout knowledge , and shop experience with the vast array of equipment you have in your shop. Your electrical knowledge for rewiring and altering equipment. Programming the water jet and plasma. I grew up in a time period when computers were not in the shops, all the lathes, mills and such were all run by hand. Wire welding had not been perfected to what it is today.

I program the X Y Z coordinates for my plasma torch into my right hand. Never had a plasma to use when I worked in job shops or fab shops.

I have been certified welder, pipefitter , working gas storage plants & pipeline. Certified structural steel for construction, equipment operator, lucky to be here typing this, spent last 27 years working aircraft production, some military, mostly large commercial aircraft. Happy to say best occupation is retired. So many projects, dont know how I ever had time for a real job.

You made comment about working on submarines, and surface water warships. How the hell did you get them into Arizona.

Thank you Sir
L8R

Well Ben, I'll try to keep it short as possible but I have a long work history.
First off please call me Paco.
As a young kid I was not really interested in conventional school work but I was blessed with a hand full of WWII veteran shop teachers that took a shine to me. From the seventh grade I knew I wanted to enlist in the Navy but along the way I took every shop class I could get into. I really didn't apply myself in arithmetic until HS when my machine shop teacher told me I would not get much further in life without advanced math. My drafting and welding instructor echoed the same. I also took sheetmetal, wood shop and auto shop. My machine shop teacher got me a job as a machinist my sophomore year and that took me into my senior year. I don't watch sport and really only read manuals but mostly have failed and learned. I have developed a knack for "Order of operation"when building or repairing and rely mostly on common sense.

So the US Navy was instrumental in honing my fabrications skills and with working shore duty during the Cold War at Pearl Harbor Sub base there was no shortage of Shiftwork that consisted of 12 on 12 off.
At 17 I was exposed to some real machines not the small ones found in my shop. We had a submerged Plasma system that could cut 4" thick HY-80 plate and breaks and shears that could cut or bend with unreal tonnage.
After my time at sub base, I was transferred to a surface ship that was in the middle of dry dock. With my current certifications from sub-base my division officer "volentold" me to work on some items along side of seasoned shipyard workers (civilian). These older fellas took to me much like my shop teachers and they mentored me further plus I'm sure I did some tasks they didn't want to perform hahaha. Once the ship was complete and after sea trials I became disenchanted with ship life and the lack real equipment. We only had stick welding machines and a major amount of work on the superstructure was aluminum. If you're a decent welder and want to get humbled, weld aluminum with a stick machine in the early 80's while pitching and rolling out to sea. We also had a 16x60 lathe and a HD drill press that's it. My job on the ship was boring despite working 12 hours plus a 4 hour watch. I separated when my enlistment was up and moved back to AZ.

After a few months struggling to find decent work I enlisted in the US Air Force to learn a new skillset. I went to Chanute AF base to learn Fuel system, Pneudraulics and schematic for electronics. I worked on C-130's POS A-7's and my favorite warbird the F-16 Fighting Falcon. Keep in mind these F-16 were block 10 so we're taking mid 80's. By 1987 I was married and began side work from my back yard. Any type of fabrication I could bid I did with only a torch, Millermatic 200, two 4" Makita grinders and a Makita 14"chop saw. I decided not to re-enlist and transitioned into civilian life. I worked for a guy off and on but always had a side welding gig. The guy I worked for was into waterworks and in Arizona at the time the Central Arizona Project was taking off. We built 1 million gallon reservoirs, built pumping stations and welded up to 60" pipe all the way down to 1". All field work and GMAW. In his shop he had some worn crappy machines that would drive me crazy and after dealing with empty promises I left for my own full time across the street from him. He was a bit vindictive but I always showed him respect. By 1995 I was in a fire Academy for the city of Tucson and with a firefighters schedule I was able to maintain my rented shop until I built our home and attached shop. It was then that I sold my tired equipment and began over from my home. My son was in sixth or seventh grade when I purchased a new 1440 lathe followed by a 1981 knee mill. I became my sones shop teacher as our public schools no longer offer vocational arts. My son went on to higher learning with a full ride to the US Coast Guard Academy and received a commission. Like his old man he gave them 10 years and moved on. His experience with me and as an officer really opened up some opportunities but like many good success Stories come with a negative, he lives and work 1200 miles away and work long hours so once a year we try to hike the Alpines of Colorado and bag 14ers.
The short answer is I'm blessed plain and simple Ben.
BTW, I don't own or operated a water jet. I built a water table for my CNC Plasma table to cut down on nasty emissions. Lastly, I hate computer CAD work. Its like pulling teeth to me. I do however have a beautiful legit drafting table with a full compliment of tools. I find it therapeutic to spend my evenings playing on it, but honestly most of my shop work is without formal drawings. I do have some client that have stuff engineered and provide me with drawings but I seem to find calculation errors more so than not.
Dang, at 57 I'm getting to sound looooooong winded.
Not sure if I mentioned this but I'm retiring from the Fire Department at the end of the month with 25 years in.
My fabrication and machining are north of 40 years but I'm always learning new exciting things.

Thank for following along Ben. It sounds like you've also been around the block as well.
God Bless,
Paco

 

[Ben A Gonna]

Paco
I still follow the trade, and from what I read the larger fabrication shops are really hurting as far as finding good help, even after finding some they can train, shortly after the new people go somewhere else for another .25 cents per hour.

Very few will work the hours some of us have. Still a lot of good hard working people out there. With todays steel prices and availability issues, things are not looking good for the smaller shops.

If I may ask how deep are your water wells there in Arizonia.
Paco good luck in the future with your well deserved retirement, keep active, remember a day that you dont learn something new is a wasted day.

Thanks for sharing Paco
L8R

 

[Rusty Scupper]

Paco - Thanks for the write up on yourself. First, thank you for your service and your son's service. Secondly, how did you pack all that in 57 years? Third, Not only are you great at working with metal but your wood work with the shipping crates are second to none. I wish more people would take interest in kids/young adults and find their passions and teach/challenge them. Looks like you had some great mentors and a passion to excel.

I am in the sign/vinyl business and I have a customer that does events. They have a sign frame that they sell but need a new manufacturer. I will PM you and see if you have any interest. With Covid this has been on the back burner so no real rush.

 

[firestopper]

Paco
I still follow the trade, and from what I read the larger fabrication shops are really hurting as far as finding good help, even after finding some they can train, shortly after the new people go somewhere else for another .25 cents per hour.

Very few will work the hours some of us have. Still a lot of good hard working people out there. With todays steel prices and availability issues, things are not looking good for the smaller shops.

If I may ask how deep are your water wells there in Arizonia.
Paco good luck in the future with your well deserved retirement, keep active, remember a day that you dont learn something new is a wasted day.

Thanks for sharing Paco
L8R

Good morning Ben,
Prior to my fire service I had 4 full time employees. I was always worried about running out of work as I felt obligated to keep them employed with 40 hour weeks. The seemed to take more than I could give and my weekend were spent alone in the shop righting wrongs if you get my drift. I was also constantly replacing extension cords and drill bits yada yada yada. In the end two of these guy took my service truck without permission and wrecked it sending a couple of folks to the ER. My insurance was sued and they settled the case and my premiums went up for the fowling five years.
Those two guys that essentially stole my truck quit and went to work for my former employer (across the street). The only lasted a couple of weeks and were fired. The irony of the story I'm sharing is they applied for unemployment insurance and were awarded against my account. The unemployment folks stated that since they were employed by me longer, my account was responsible to pay them. I was so burnt out by this time with the depositions etc. from the law suit I laid down and moved on. I forgave those guys but have never considered hiring anyone again. As for the fuel, steel, insurance and taxes imposed, its getting really hard to make a profit for many out there. It's gonna get worse IMO with the clowns running our Country. The politicians have been slowly killing America for decades to line their own pockets.

On the Aquifer question. The area we live in, it's not unusual to reach a water table at 800' but volume might be questionable. Generally at first signs of water the drill rigs will take it down further. I live in a low density community and we all share a the well. In the City itself, many wells around the airport and older section of the City the wells were condemned but to Trichloroethylene (TCE) levels like many parts of the country. The Central Arizona Project (CEP) was supposed to mitigate the foreseeable water shortage projected back in 1973 when the 336 mile long project was started. One particular Senator became a multimillionaire as he had first hand knowledge of the proposed rout of the canal and purchased up land only to sell it back at a unreasonable profit. The project was finalized and opened in 1993.
The problem got bad for folks using the water as many chemicals used to treat the "potable" resulted in failing pipes in older homes with galvanized piping. In the end the decision was made to use the CAP water to recharge the ground water. The city water was once a standard for most fo the country for pure clean water. Now it taste shitty and requires RO and secondary filtration. Our water here is still good but its inevitable the well owner will eventually sell it to the City of Tucson Water department. They seem to own many sites within the county outside of city limits. It's a huge money maker to say the least. As for other parts of AZ, I'm not sure about water tables.

Thanks for the retirement well wishes. I'm looking forward to the next chapter.
Paco

Paco - Thanks for the write up on yourself. First, thank you for your service and your son's service. Secondly, how did you pack all that in 57 years? Third, Not only are you great at working with metal but your wood work with the shipping crates are second to none. I wish more people would take interest in kids/young adults and find their passions and teach/challenge them. Looks like you had some great mentors and a passion to excel.

I am in the sign/vinyl business and I have a customer that does events. They have a sign frame that they sell but need a new manufacturer. I will PM you and see if you have any interest. With Covid this has been on the back burner so no real rush.

Good morning Russ,
Sorry for the long reply but even at that I have left out many details that have helped me grow and still grow.
My family has served our country since my Pops served in Korea, two of three sisters served and myself.
To date, I have one nephew that attended USAF Academy, One nice who Attended the Naval Academy and my Son who Attended the Coast Guard Academy. I'm extremely proud of all my nephews and nieces as they have grown to be productive.
At the time, serving your country was normal and many young kids enlisted despite the draft ending.
As a first generation American Citizen, I can tell you from personal experience America has plenty to offer those who work for it. No one owes anyone anything other than what the US Constitution provides. It was my pleasure to serve and I took away knowledge and experiences that have provided for my family well. Thank you Russ!

As for wood working, I'm only conferrable working with rough type of finishes, I'm too impatient when it comes to sanding and finishing. I also don't like the saw dust that comes with that trade. On the pallets/crates. This final design is the fifth generation after failures from rough handling by the freight companies. I now only use XPO Logistics formally know as Con-Way. They have been absolutely reliable and handle my freight with care. They charge the most but you get what you pay for.

On the sign frame, I'll take a look when you send me some photos dimensions etc. I'll PM you my email in a bit.
I hope you know, I'm not trying to drum up work by sharing my projects. My hope is that those following can take away tips and tricks and reach out if they have any questions on how I do things. That said, if I can provide a service, then that's good too. Thanks again Russ.
Paco

 

[Rusty Scupper]

My hope is that those following can take away tips and tricks and reach out if they have any questions on how I do things.

Exactly. That is what is great about this site. The knowledge of the members in all aspects of life (Duramax, projects, shops, etc) is vast and people's willingness to share is awesome.

 

[firestopper]

A few examples of the capabilities of a CNC Plasma table.

This sign measures 4'X8' and the text was cut in cursive. The text was then welded back on for a 3D look.

A vinyl wrap was added to include some crystal work. The rear had thin brackets that secured an LED rope light.
The sign was hung inside a Swarovski Crystal shop in down town.

A retirement gift for one of my favorite bosses.
Made from 1/4" plate. It got hung in his back yard.

My wife's retired now but served over 25 years as a Juvenile Probation Officer. This is a blown up copy of her badge.
I did add her name but the other detail reflects her badge. The center was replaced with a mirror and it hung in her office when she was employed. It was treated with automotive clear coat after rusting and using acid to create the black run stains.

A couple of bed rails also rusted and clear coated.

This is a 30" high by 42" wide piece I made for my wife. It hangs at our home's entry outside the front door. A 1/8' x 1" piece of flat strap was welded on edge to pull it away from the surface. A low voltage light creates some interesting shadows with this mounting application.
It's a rendition of the San Xavier Mission.
Link: History

This lamp dates back to 1989 when I started my business and was broke. It was a Christmas gift to my wife and one year old son, The material used was left over from a job I did. The hanging sections of pipe swing slightly to mimic a wind chime. Those cutouts were hand cut with a torch then heated and bent out slightly. The shadows it casts at night look really cool. When we built our home I was planning on leaving it at out first home but my wife had other plans.
She reminded me I owned a 30# jack hammer and breaking up the 400 pounds of concrete securing it would be "easy"......
I obliged her and now has been in our front yard for the past 23 years. The lamp will turn 32 years this Christmas.

Some light switch covers found in our home.

I built two of these tables. They can easily sit 12 folks. The finish has actual copper flakes, then is sprayed with an activator to create a patina, and clear coated after neutralizing the activator. The second table has a different tile color and was Christmas gift to our neighbors.

 

[firestopper]

Modifying an Aluminum radiator for some sort of special application.
The fella needed the corners removed to make this radiator fit. I never asked what the vehicle was or other details.

I laid out the area to be removed and used a 2" die grinder with a cute off wheel. The inside was completely flushed out prior to capping with .100" thick aluminum .

Same on the other end. A total if 1.250" removed from the corner with a 4" taper.

The cuts.

Overall.

The new profile.
TIG welded at 100amp using 1/32' tungsten and 1/32' filler 4043 alloy is a good choice for this application.

 

[firestopper]

I installed a high performance fuel pump and ran new lines as well as a new electrical harness on a 5.9 2500.

It was easier to pull the bed to complete the task. Heavy 4" X 4" cribbing is placed under the fork lift mast as a safety measure. The work was preformed with the bed hovering above allowing for a quick re-alignment when done.

Those fork extensions are made from 6" channel and are handy for the needed reach.

The new Fleece pump assembly carries a lifetime warrantee to the original owner.

After a thorough external cleaning the old pump was removed and the new pump swapped in. New fuel lines ran capping off the original fuel lines and leaving in-place and stashed away. I told the owner it was a nice option in case he wanted to revert back to original some day. I also used a section of clear vinyl hose for added chaff protection. The new wire harness was also ran. The remainder of work took place under the hood.

A new filter added under the hydro-booster. The hoses connected and the electrical tied into the ignition circuit.

All done.

This took about four hours from the time the bed came off to the bed going back on.

 

[OkDually]

Nice work

 

[Pure Diesel]

Firestopper, enjoy your work and posts. Very nice talent that you have. Please keep showing this.
Thank you
Greg

 

[firestopper]

Sometime later the same truck lost a front drive shaft somewhere in New Mexico (hunting). A new shaft was ordered from Denny's driveshafts. Also ordered an upgraded front Spicer yoke replacing the OEM flange yoke, a new pinion seal and new HD spicer front axel shaft U-joints. Since the axel shafts required removing to install the new seal and yoke for proper preload, it was a good idea to replace the U-joints since the rig now has 180K and sees hard service.
With the front brakes removed, the hub nut and hub assembly removed the axel shafts were pulled.

I left all the brake lines intact and components hanging on hooks and bungees

The front diff drained.

Look at that sexy shaft!

With the axel shafts removed it was time to record the pinion gear pre-load using a torsion bar dial torque wrench that measures in IN/LB. The measurement I had was 28in/lb.
Here the pinion nut and flange yoke are removed as well as the old outer seal. These pinions use two seals. A inner seal is on the yoke while the outer seal is on the diff housing.

All the mating surfaces were cleaned and wire brushed followed by some crocus cloth.

The front shafts awaiting new U-joints marinating in penetration oil. You can also see the old OME flanged yoke.

With the splines cleaned and some sealant applied the new yoke has a home. The large pinion nut was also replaced and ran in while checking preload in between. The large flange behind the new yoke has the second seal I mentioned previously.

Here I'm checking the preload. TIP: Remember this needs to be done with the axels removed.
A consistent pass needs to be done a few time the exact way to ensure a reliable reading.
This particular torque wrench employs a sweep needle (black) that requires reset between passes. A very nice feature.

With the pinion nut torqued to correct preload, it was time for the U-joints.

Both axel shafts U-joints complete. I did have some problems with the longer shaft, but a little heat took care if that.
The seal and bearing surfaces were also dresses with ultra fine crocus.

Almost done.