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Happy Hummer
Decided back about 2 months ago to start a new Extra Heavy Duty rock rail, Step / Slider hybrid project.
There were certain criteria that had to be met as well as basic necessities.
* Myself and my lady friend have parents in there 80's (so a step is a must)
* Both myself and my lady friend have got knee, back, etc. personal issues (so a step is a must)
* I do plowing and trailering in the dead of winter so I need overland protection that is suitable to salt spray and ice chunks
It is absolutely imperative that these steps are capable of keeping large chunks (i'm talking boulder size) of snow and ice out from under the rig and that they are very corrosion resistant. To that end I looked at the peep's manufacturing side steps for H3's and to other companies who may have shown slight interest in doing so.
So, I started researching and developing plans and layouts to come up with what would work for me.
I started by making certain the holes on the frame were clean and free of debris and rust. Lubed them up and ran 10.9 **1.5 pitch by 30mm bolt into each hole. I already had oem side steps so I only needed four extra for the center holes.
I continued on with things and developed some templates for the plates and tubes that would be needed for each leg at all six points. This portion of the project actually has taken some time. The process of fitting each tube and tack welding to test for proper fitment is essential. I've completed the preliminary tack welds to placed some 1/8th" by 1/2" steel on the back side of each rear most plate to offer some offset for the frame and spring perch weld seam.
The actual sliders/rock rails are already done.
The following images are of each mounting point on oem steps. One of the images shows the center mounting point that needed to be cleaned and chased.
083017
I just checked my rock rail sliders for the first time and they bow slightly. To much heat soak from welding is my guess.
090117
I chose to go with approximately 1 1/2" to 2" space between tub and step. NO body lift and 265 75 16 tires. This project is quite interesting to say the least. Allot of measurements and patience are needed.
090217
Worked several hours today on this project.
I was able to weld the tubes to the 3/16" plates fully. I was also able to grind them , wire brush & flap disc em. They are looking good.
I've put a bunch of thought into how to best finish these rock rail slider steps.
Nickle plated in a gun metal smoked antique finish?
Or possibly galvanized coated?
Acid dipping and plating in a distressed copper finish?
090417
Put most of the day in on this project. Again allot of welding and grinding. I've got another pass on the brackets to do with welder and then allot more flapper disc. I've got to still run and get more consumables i.e. Lincoln welding wire and a whole host of other stuff.
Last time I was in a pinch I bought HF wire and boy is that cr@p to say the least. I switched to a new roll of NR211MP. I'm outside doing this so no shielding gas...it would just be a waste because it would blow away. Albeit the flux is messy.
090517
Stopped during biz today to purchase a bunch of supplies. I also ordered more grinding wheels, medium grit & fine grit flapper disc's as well as .030" inner shield wire. Should be here later this week. Today I got the itch and bought a new welding work mate bench. Got a good deal and it of course had cr@ppy Chinese directions translated 10 different ways before English lol!
Took a bit to put it together and some washers were missing per the instructions but all in all not bad looking. Should be able to use it this week.
090717
Got the chance last night to finish the welding of the legs and hit them with a 4.5" spiral twisted grinding wheel. I also tried out the new welding bench. I'm waiting for the flapper disc' to arrive, then I'll do a last 100 grit flapper and done. I'm excited to see how they fit. Lastly I'll be tacking on the tube slider.
091017
Spent a few hours finishing up the support legs today. Went over them with a 27 grinder disc, 60 grit and 100 grit flapper disc and re welded a few areas to fix some flaws. Would love to media blast them before going any further but alas I do not own a blast cabinet at this time.
final pics of the legs from different views.
Drivers rear bracket:
(2" wide x 8" long x 3/16") (3/4" high sides x 3/16th")
As can be seen in this photo the upper most bout of the rear bracket has been fit with 1/2" x 1/8" metal plate to offset for frame welds
I'm only using three mounting points as I saw no need for a 4th.
Did a bunch more work tonight 083017.
Have had to make adjustments and changes as I've gone. The rear support plates have been stretched length wise 1 3/8" and the tubes had to be gradually stepped back between 1/8th & 1/4". The front tube is 5" in length. Center tube 4 7/8" in length. Back tube 4 3/4" in length.
This graduation in length gives a smooth following of the Hummer H3 shape.
The actual process has been tedious to say the least. Measure....cut, grind, weld, cut, weld repeat. The angles changed slightly and the position changed as I moved rearward.
Took the time to install the support legs on the H3 (Happy Hummer).
The pics....
Drivers center bracket:
(2" wide x 6 5/8" long x 3/16") (3/4" high sides x 3/16th")
Drivers front bracket:
(2" wide x 6 5/8" long x 3/16") (3/4" high sides x 3/16th")
Center mounting holes have been shifted 1/2" off center toward the back of vehicle. This facilitates with fitment of parking brake frame mount
Passenger rear bracket:
(2" wide x 8" long x 3/16") (1" high sides x 3/16th")
091417
Spent the better part of the evening and night working on the passenger side slider. Still need to clean up the rock rail and get all the last slag off but coming along decent.
Pic's to follow:
Passenger center bracket:
(2" wide x 6 5/8" long x 3/16") (1" high sides x 3/16th")
Passenger front bracket:
(2" wide x 6 5/8" long x 3/16") (1" high sides x 3/16th")
100817
After countless hours of grinding, flap disc and wire brushes I've gotten them to a level at which the next phase can begin.
The next phase will include another final fitting to H3 and a total recleaning and chemical wash.
Next stop attaching the sliders to the legs. I also need to add a spacer to raise the height of the rear brake cable.
092217
Took some more time to customize the design and to beef up the overall structure of the support legs.
The support legs now have 3/8" on one side from top to bottom for the passenger side. The drivers side has 3/8" both sides of the center support leg. I took 3/16" doubled to make up the 3/8" equivalent.
Also, spent more time doing overall welding and cleanup with both slider steps.
Many hours of behind the scenes clean up, welding, grinding when into these units this past week. I didn't take pictures of any of this though.
100917
Finished the cleanup with grinders, flap disc 60 & 100 + wire wheels and brushes.
Did a preliminary chemical wash and fixed some other items.
They are test fit and waiting for second chemical wash with acetone.
101717
The second round of chemical cleanup has taken place as well as further cleanup and 3 coates of Herculiner urethane spray has been applied. Just waiting for the cure time and then final install.
101817
102117
Wanted to do a wrap up on these rails, sliders, steps.
They're all finished up and mounted ready to go.
Been a long road to hoe and I'm taking a break now.
Kinda of excited about the finish up process.
Before I paint them I'll make certain to do the poser shot of jack my H3 up from each side to prove absolutely nothing lol! J/K....
092617
Wanted to update the page with more current relevant information today. Chose to go with Herculiner spray urethane paint as it was on a good introductory sale locally. Also, after some discussion with lady friend we agree that I should add a plate / step to each area reminiscent of the oem tube steps. I've got a template made yesterday and will probably choose to use 1/4 diamond plate I've got laying around. I might choose to order up some dimple died 1/8" sheet instead but don't know as of yet.
Hoping to get the step plates cut and ready to weld up.
093017
Spent all day working on this project again and I'm pretty sure I'm getting sick of it haha.
Took my template and with my trusty plasma made it become a reality in 1/4" diamond plate. Alot of cutting and grinding. What a mess.
100217
Spent several hours tonight cleaning up the four diamond tread plates. Little bit of welding and a shit load of beveling and shaping. Times four ugh!
Finaly got the first two plates totally welded to passenger side silder step. Little clean up and some gussets all is done. Drivers side needs all the plate welding done and gussets. A whole lot of clean up detail work then insues.
I can say affirmatively costs are running into the stratosphere and it's just getting super heavy. Don't get me wrong I'm grateful to be doing it but wow!
1/4" x 12" x 48" runs about $90 for diamond plate.
Other metals $80 so far
DOM 1/8" 1 3/4" ran $208 for enough + excess
Miscellaneous supplies $250 +
All other $100 +
Just guessing but probably close.
Time.... A whole lot. I mean hours, hours, hours and more hours.
But I'm super picky so that probably accounts for some of the time.
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