Custom Cross Member and Transfer Case Skid Plate - Dodge Cummins Diesel Forum
3rd Gen Tech Articles Tech Articles for the 5.9L 3rd Gen Dodge Cummins Diesel...NO ADVERTISING

 
LinkBack Thread Tools Display Modes
post #1 of 7 (permalink) Old 06-20-2008, 12:10 PM Thread Starter
Tech Specialist
 
wildcat's Avatar
 
Join Date: Sep 2007
Location: Black Canyon City, Az
Posts: 2,118
Thanks: 2
Thanked 86 Times in 41 Posts
iTrader Score: 0 reviews
Custom Cross Member and Transfer Case Skid Plate

Lately in my spare time, I’ve been working on a cross member designed for multiple use.
It will be used as a platform for a Transfer case skid plate, a fuel tank skid plate, and possibly down the road as a frame mount for traction bars. As far as the skid plate platform goes, I wanted something a little more durable than the factory offering, since I didn’t think it would hold up to my off road driving in this truck.
First thing I did was define my project goals, which in no particular order were:

Something that would actually hold up to more than one or two high centers without folding up into a twisted pile of metal.

The cross member had to be capable of being a platform for a transfer case skid plate, a Fuel tank skid plate, and possibly later, something I can use as an upper mounting point for traction bars for the rear axle. Strength obviously is a major concern.

It also had to be removable, without any bulky brackets left on the frame, and without any excessive welding to the frame.

I also wanted the cross member to line up with the factory transmission/transfer case cross member and the bottom of the fuel tank, so that simple, removable flat pieces of steel could be employed for the skid plate portion.

As a side benefit I wanted the cross member to add strength to the frame, although the frame is plenty strong as it is, I didn’t want the fabrication of this to weaken that structure.

In summary, I wanted a simple bulletproof structure anyone with some mediocre fabrication skills (Like myself) could build.

If you like the idea, but feel you lack the fabrication skills, you could always print this post out and take it to a fabrication shop in your area. I have no idea how much something like this would cost, however. All you probably need them to build would be the cross member, I think most people could cut their own plates and drill some mounting holes.

This is what I came up with. As always, questions and comments are welcome.


First, in case you haven’t seen the stock cross member and transfer case skid plate, I took a picture of one with my camera phone. I’ll probably edit this post later with a pic from my digital camera of one from the Dodge dealership.



The raw materials necessary for the Cross member I built are:

2”X3”X3/16” rectangle tube.

4”X1/8” flat plate
8- 1 ¼” X ½” Grade 8 bolts
8- ½” flanged metal self locking grade 8 nuts (NOT Nylon lock nuts!)
4- prefabricated tabs (If no one in your area sells them, you could make these out of your leftover flat plate)


The tools required would be:

Wire feed welder (I used a Flux core Lincoln wire feed)
Angle Grinder (Soft grinding pad, knotted cup brush)
Sawsall (14 TPI blades)
Right Angle Drill and Drill bits (A Unibit is a “Nice to have”)
Tape measure
Combination Square
Vise (Not really required, but nice to have)




In this pic, the 2X3 tube has been cut to length and the 4” flat plate has been trimmed down to 3” and tack welded to the tube for test fitting.


After test fitting, the plates are fully welded to the tube, and the welds and spatter cleaned up (Flux core)

A close up of the inner weld.



The cross member was put into place, traced in red permanent marker on the frame. This was to provide a measuring reference for using the stock hole locations as mounting points. Measuring points were then transferred to the plate for drilling. Once the holes were drilled, I found some 3/8” bolts to use to temporarily hold the cross member in place for the remainder of the fabrication.



Here is a pic of the tab that I used for the lower cross member mount.



Since a hole is going to be drilled into the bottom of the frame, and a flanged nut is going to be welded into it, I used a washer to space off the tab from the frame to compensate for the flanged portion of the nut, to get it in the right spot on the cross member, before marking the hole on the frame.



The next step is to tack weld the tabs onto the cross member. I used one of the bolts and a washer (Between the frame and tab, not seen in this pic) to line up the tab on the cross member.



After tack welding, the cross member was removed for welding the tabs. Here’s what it looks like so far







The next step was to enlarge the holes in the bottom of the frame to accept the flanged nuts, and weld them into the frame. Here is what it looks like with them welded in and the surface ground flush.



Here’s what it looks like with the cross member in place.





The upper mounting holes are still 3/8” and are now drilled out to ½” while the cross member is in place. Proper hole alignment is critical. Once the holes are drilled, the cross member is dropped down and the frame holes are enlarged to accept the flange nuts, and they are welded in.

Cross member after painting






Cross member installed and ready to start on skid plate



Skid plate done and installed. From this angle, it doesn’t look like it protects the transfer case, but it does. I’ll have to get another picture from a more rearward angle.




2007 Dodge 3500 SRW 4X4/5.9L/48RE, KORE, SRT-10 hood, Recon, Isspro, ICEBOX/S&B, Walbro, SMARTY, CFM+, HGD, 5" TBE, TC & VB, SPS 62/71, Head studs, spool aid.
ACDC
wildcat is offline  
The Following 2 Users Say Thank You to wildcat For This Useful Post:
ohv (12-06-2012), rgsauger (03-15-2011)
Sponsored Links
Advertisement
 
post #2 of 7 (permalink) Old 06-20-2008, 12:24 PM
Diesel Head
 
Hot Stuff's Avatar
 
Join Date: Dec 2007
Location: Republic, Ohio
Posts: 3,402
Thanks: 15
Thanked 75 Times in 63 Posts
iTrader Score: 1 reviews
Looks good!

'03 Black 2500 QC/LB 4x4, DRW 6 speed, SB3600DD, Fuel Throttle wheels, 305/70 Terra fronts, 285/75 Terra rears, B&W turnover, air bags, HE351 turbo, 5" pipe, CAI, 2nd gen intake, Pacbrake and Smarty
Hot Stuff is offline  
post #3 of 7 (permalink) Old 06-20-2008, 12:26 PM
Go for Broke
 
Graphic Man's Avatar
 
Join Date: Nov 2005
Location: Mississauga ont. Canada
Posts: 8,061
Thanks: 41
Thanked 122 Times in 88 Posts
iTrader Score: 0 reviews
looks good....nice work :thumbsup

2019 mega cab Laramie
2015 Megacab Laramie 6.7 flame red
SOLD 08 Mega cab 6" lift with long arm kit, 2" leveling, flares, B/M, DPF delete, By-pass oil filter, cold air intake
SOLD01 4X4 Q-cab Sport Monster VP, Redline Injectors, twins 66/S480 with race cover, full billet trans etc,
Special thanks to: Diesel Dr.s
Graphic Man is offline  
Sponsored Links
Advertisement
 
post #4 of 7 (permalink) Old 06-20-2008, 12:35 PM Thread Starter
Tech Specialist
 
wildcat's Avatar
 
Join Date: Sep 2007
Location: Black Canyon City, Az
Posts: 2,118
Thanks: 2
Thanked 86 Times in 41 Posts
iTrader Score: 0 reviews
Thanks guys!

2007 Dodge 3500 SRW 4X4/5.9L/48RE, KORE, SRT-10 hood, Recon, Isspro, ICEBOX/S&B, Walbro, SMARTY, CFM+, HGD, 5" TBE, TC & VB, SPS 62/71, Head studs, spool aid.
ACDC
wildcat is offline  
post #5 of 7 (permalink) Old 07-03-2008, 09:17 PM Thread Starter
Tech Specialist
 
wildcat's Avatar
 
Join Date: Sep 2007
Location: Black Canyon City, Az
Posts: 2,118
Thanks: 2
Thanked 86 Times in 41 Posts
iTrader Score: 0 reviews
Not many views on this, guess no one likes this mod?


2007 Dodge 3500 SRW 4X4/5.9L/48RE, KORE, SRT-10 hood, Recon, Isspro, ICEBOX/S&B, Walbro, SMARTY, CFM+, HGD, 5" TBE, TC & VB, SPS 62/71, Head studs, spool aid.
ACDC
wildcat is offline  
post #6 of 7 (permalink) Old 07-03-2008, 10:47 PM
Only in a HEMI
 
BBRam's Avatar
 
Join Date: Jan 2006
Location: Chelsea MI
Posts: 27,656
Thanks: 1,811
Thanked 1,515 Times in 1,055 Posts
iTrader Score: 13 reviews
And another fine job Bill! Nice work! :thumbsup



100% free webcam site! | Awesome chicks and it is absolutely free! | Watch free live sex cam - easy as 1-2-3

2012 Ram 2500 5.7L HEMI
2012 Dodge Challenger SRT8 6.4L HEMI
2015 Hellcat, and ya, it's got a HEMI
BBRam is offline  
post #7 of 7 (permalink) Old 07-04-2008, 01:24 AM Thread Starter
Tech Specialist
 
wildcat's Avatar
 
Join Date: Sep 2007
Location: Black Canyon City, Az
Posts: 2,118
Thanks: 2
Thanked 86 Times in 41 Posts
iTrader Score: 0 reviews
Quote:
Originally Posted by BBRam View Post
And another fine job Bill! Nice work! :thumbsup
Thanks, Brian.

2007 Dodge 3500 SRW 4X4/5.9L/48RE, KORE, SRT-10 hood, Recon, Isspro, ICEBOX/S&B, Walbro, SMARTY, CFM+, HGD, 5" TBE, TC & VB, SPS 62/71, Head studs, spool aid.
ACDC
wildcat is offline  
Sponsored Links
Advertisement
 
Closed Thread

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Dodge Cummins Diesel Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome