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Upgrades and Repairs to the 1477 Forklift


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#1 WrenchinOnIt OFFLINE  

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Posted June 27, 2020 - 06:23 PM

Decided to install a NOS PS unit I’ve had laying on the shelf. I knew I’d have to remove the roll cage and pedal engagement mechanism to get the fender pan off , a further challenge was the forklift seat support and the pump brackets were in the way so I had to make new hard lines had the 3/8” tube in 304 SS so used it. I also needed to shim out the rear mount as the vertical seat support covers one of the bracket mounting holes. Tight quarters behind the engine fire wall and steering cowl ,ended up freeing up the steering cowl ( unbolt and tilt back ) and disconnect the steering shaft from the steering bridge to access the flow diverter port and be able to fit a wrench in there to work on the valve. Upside it will make it easier to change out the back engine mounts. Changed the tie rod ball joints while I was at it. Pleased with the results.

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Edited by WrenchinOnIt, June 27, 2020 - 07:42 PM.

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#2 WrenchinOnIt OFFLINE  

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Posted June 27, 2020 - 06:33 PM

Been very dissatisfied with the tires those skinny fronts (rears ?) sink sink sink once off the hard pan , my buddy Rick Show ( blackjackjake) found me some of the wider 10” wheels so into the blast cabinet they went , gave the inside some POR 15 , decided on Carlisle Industrial 20x10x10’s. Mounted them up. Like it a lot better now.

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Edited by WrenchinOnIt, July 28, 2020 - 03:45 PM.

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#3 WrenchinOnIt OFFLINE  

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Posted June 27, 2020 - 06:36 PM

Front (rear?) Motor mounts replaced. WIP on the other two

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#4 WrenchinOnIt OFFLINE  

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Posted June 27, 2020 - 06:40 PM

Rears (fronts?) not a R4 fan. Wanted USA made and something that looked like it belonged on a GT. Decided on the new Goodyear R14’s. Need to clean and paint the duals and mount them up. Thinking I’m going to add another set of weights to it.

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Edited by WrenchinOnIt, June 27, 2020 - 07:18 PM.

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#5 kjmweld OFFLINE  

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Posted June 27, 2020 - 07:27 PM

What a game changer on those front Carlisle's, those really set it off as "tall & proud." I'm sure they'll make a huge difference as well. Super nice clean install on those lines you made up. Pictures make it look easy, but I know that wasn't an easy task to pull off. Awesome upgrades Kevin, I love it 👌👍
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#6 JohnWR OFFLINE  

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Posted June 27, 2020 - 08:34 PM

Looks amazing Kevin, everything you do is just pure perfection.
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#7 Austen OFFLINE  

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Posted June 27, 2020 - 09:53 PM

Some large frame action from Kevin, what could be better, this evening got a lot whole more interesting! :) Great upgrade, I'll bet you wonder how the previous owner lived without PS before. I suppose, though, that in this setup unlike your other one (formerly Dave's) that the weight is over the backend so steering may not be as heavy as you might think, or even lighten up some with heavy loads. In any case, forklift duties usually include constant maneuvering so PS is an obvious upgrade anyway you look at it. That's so cool you had an early system, color period correct, that you could add to it. :thumbs:

 

Thanks for walking us through the process too. Making those lines and everything would take a lot of time and precision. As mentioned in your other thread, I like the look of your new front tires. The wider style I think goes better on a forklift. I remember when you added the duals, that was a fitting addition to it as well and makes an already very unique machine even more more to look at. Please post some updated pics once you get the new shoes mounted up on the rear.

 

How tall is the cage? It looks tall but hard to get perspective without seeing in person.

 

post-8592-0-23707700-1593300771.jpeg

 

BTW, there's just something about this pic. It looks frame worthy.


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#8 nkaust OFFLINE  

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Posted June 28, 2020 - 05:21 AM

man that thing looks mean, hard to beat the old bolens lol


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#9 firedudetl1 OFFLINE  

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Posted June 28, 2020 - 09:59 PM

looks great - nice job - how difficult is it to bend that ss tubing? I see one handle in the vise and I'm wondering if you've got a "cheater" on the other handle to bend it? I've got some lines to replace on my old Bobcat 371 and you've given me some guidance, so thanks for that

again great job!


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#10 firedudetl1 OFFLINE  

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Posted June 29, 2020 - 06:32 AM

just looking again at the tubing pictures - did you do the fittings on the ends or were they purchased w/the fittings - nice neat job of adding them to the system 


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#11 WrenchinOnIt OFFLINE  

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Posted June 29, 2020 - 07:50 AM

What a game changer on those front Carlisle's, those really set it off as "tall & proud." I'm sure they'll make a huge difference as well. Super nice clean install on those lines you made up. Pictures make it look easy, but I know that wasn't an easy task to pull off. Awesome upgrades Kevin, I love it

Thanks Ken, yup line installation had its moments

 

Looks amazing Kevin, everything you do is just pure perfection.

Thanks John, Ha! Too kind , often my expectations surpass my ability

 

Some large frame action from Kevin, what could be better, this evening got a lot whole more interesting! :) Great upgrade, I'll bet you wonder how the previous owner lived without PS before. I suppose, though, that in this setup unlike your other one (formerly Dave's) that the weight is over the backend so steering may not be as heavy as you might think, or even lighten up some with heavy loads. In any case, forklift duties usually include constant maneuvering so PS is an obvious upgrade anyway you look at it. That's so cool you had an early system, color period correct, that you could add to it. :thumbs:
Thanks for walking us through the process too. Making those lines and everything would take a lot of time and precision. As mentioned in your other thread, I like the look of your new front tires. The wider style I think goes better on a forklift. I remember when you added the duals, that was a fitting addition to it as well and makes an already very unique machine even more more to look at. Please post some updated pics once you get the new shoes mounted up on the rear.
How tall is the cage? It looks tall but hard to get perspective without seeing in person.
post-8592-0-23707700-1593300771.jpeg
BTW, there's just something about this pic. It looks frame worthy.

Thanks Austen. Hoping it makes a difference in the steering cause I’m contemplating adding some mass to em.  The cage is slightly over 7’ tall I’ll get you a good measurement when it’s reassembled. Need to get the jack handle outta the pic first tho aye ?

 

man that thing looks mean, hard to beat the old bolens lol

Thanks ! I agree !

 

looks great - nice job - how difficult is it to bend that ss tubing? I see one handle in the vise and I'm wondering if you've got a "cheater" on the other handle to bend it? I've got some lines to replace on my old Bobcat 371 and you've given me some guidance, so thanks for that
again great job!

Not difficult at all, no cheater needed on this. It’s vise mounted just to hold and level it. Much easier when you’re laying out bends based on axis and plane. Also that particular tubing comes in 6’ lengths

 

just looking again at the tubing pictures - did you do the fittings on the ends or were they purchased w/the fittings - nice neat job of adding them to the system

Nut and Ferrell are separate pieces. You should always slide the Ferrell on before flairing if you’ve put a bend in it . Nut will slide past bends Ferrell won’t.

The black bender is a Parker and for 3/8” only. It’s HD , precise and worth the price IMO , flat handles allow for vise clamping. Blue bender is handy for “field” bends on lighter wall tubing. A Hydraulic flare is 37-1/2 degrees ( tools listed at 37) couple flaring tools pictured. The Ridgid is a “wobble” flairing tool and IMO worth the money if your going to use a heavy wall tubing and/or continue to do some installs.

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Edited by WrenchinOnIt, June 29, 2020 - 12:46 PM.

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#12 firedudetl1 OFFLINE  

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Posted June 29, 2020 - 09:55 AM

thanks for the info and extra pictures - someplace in my collection of seldom used tools I have a flare kit. not sure of the brand but I used it years ago to do brake lines for one truck or another. 

If I get to doing the Bobcat lines, I'll invest in the better tools you've listed - thanks again


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#13 WrenchinOnIt OFFLINE  

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Posted June 29, 2020 - 12:31 PM

thanks for the info and extra pictures - someplace in my collection of seldom used tools I have a flare kit. not sure of the brand but I used it years ago to do brake lines for one truck or another. 
If I get to doing the Bobcat lines, I'll invest in the better tools you've listed - thanks again


Just in case it’s needed info : brake lines are 45 degree flare unless AN ( Army Navy) fittings , they like hydraulics are 37 degrees. Also most Brake lines  use a double flare , hydro lines single.


Edited by WrenchinOnIt, June 29, 2020 - 12:39 PM.

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#14 firedudetl1 OFFLINE  

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Posted June 29, 2020 - 12:37 PM

thanks again - will check what flare angles I have in the kit - maybe just the 45s 


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#15 Bolens 1000 OFFLINE  

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Posted June 29, 2020 - 06:56 PM

Very Nice


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