Forklift completed lots of fab work.

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Well for those who have been asking about my old forklift project I'm happy to say that I got it completed. This ends a very long rebuild for me with this old forklift. I purchased it around this time last year and started in to rebuild it shortly after. I wanted it to be a fun project and to a point it was only for all the hard long hours it took to get it to this point. Basically everything had to be done. I had to remove all the paint, rust and crap others had done with it over the years before I could even begin to start the rebuild. the first thing I had to do was build a new engine hood for the beast. Toyota wanted over $3000. just for the hood so I fabricated the one you see on it now out of 1/8th plate. This one will be awhile before it rusts out.Basically I went right through the complete machine. New rings, bearings, lapped the valves and installed new valve stem oils seals. I rebuilt the mast. all new bearings in it as well and had to rebuild some of the hydraulic cylinders because they were leaking. Some of them had to even be re-chromed due to the pitting on them.After all that was done I sand blasted, primed and painted it. I fabricated the custom stuff such as the headlamp guards. Custom built the rear light bar and all the lights you see in it are strobes. I built sun visor as well and added some more aluminum plate to the sides to pimp it out a bit. The top have a plexy glass top in it now. I added all new gauges and even fabricated new sections of the dash because it was in pretty bad shape. It even has air horns now along with chrome duel exhaust stacks. I had to design some custom adapters to get them to work on the lift but they sound nice so it was worth it.I removed the old Toyota charging system and it's external voltage regulator and installed a GM alternator with a built in regulator. Of course that's harder than it sounds because I had to make up new brackets to get it to fit. I also added a cool hook up to the engine cover that I can just plug my booster cables into so I don't have to pull up the lid to do it.Anyway there's much more to this story but I'm sure you'll see by the pictures there was a lot of work involved. One thing I did learn out of this. Never try and rebuild a forklift unless you have a forklift to help. These buggers a very heavy. I'm happy with the outcome. It's runs like new and will come in handy around the shop. Here's some photo's.New charging system installed:Some of the old wiring I removed:Booster cable hook up:Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Completed:Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Beautiful job!!  What a difference!!"Good Enough Never Is"MIller AC/DC  ThunderboltHobart HH180, 125EZRiland Cut 40 Plasma oxy/act  outfitTons of "stuff", all treasures to me!
Reply:That is a massive project.  Great job.  Love the diamond plat and the stacks, cool touch.  Just curious, what did that rear counter balance weight weigh?
Reply:Hello Paul,               Top class job,(no less than than we all expected from "the master"  Rebuilt by Paul Short says it all !  Huge task with no detail too small to be overlooked. every man on this forum would be proud to turn out projects that even approached your standards..P.S do you do all the graphics as well, or get them custom made,Congratulations once again 10/10.  Cheers from across the pond.  Gordon.Last edited by gordon stephenson; 05-17-2009 at 09:19 AM.Lincoln SP-170 MigHypertherm powermax 45Lorch T220 AC/DC TigButters FM 215 synergic MigKemppi 180 adaptive mig RULES ARE FOR THE OBEDIENCE OF FOOLS AND THE  GUIDANCE OF WISE MEN.
Reply:thats one bad@$$ forklift! nice work-NateMiller Trailblazer 302gMiller Spoolmatic 30aLN-25 x 2Idealarc SP200Hypertherm Powermax 600
Reply:Originally Posted by JC'sWeldingThat is a massive project.  Great job.  Love the diamond plat and the stacks, cool touch.  Just curious, what did that rear counter balance weight weigh?
Reply:Nothing to say but a beautiful piece of work, you should be proud.....Mike
Reply:Great job, im sure its better than new by a long shot.  However i just cant wrap my head around the stacks, and the diamond plate looks good but doesnt fit with the rest of the machine.  To each his own I guess.Have we all gone mad?
Reply:Originally Posted by gordon stephensonHello Paul,              P.S do you do all the graphics as well, or get them custom made,
Reply:The jumper cable q/c should be standard equipment.  No more leaning the seats up to get at the batts.  Would be really handy out on a cold whse dock.
Reply:pardon me but all I can say about that is ........dayum.....Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Originally Posted by sn0border88Great job, im sure its better than new by a long shot.  However i just cant wrap my head around the stacks, and the diamond plate looks good but doesnt fit with the rest of the machine.  To each his own I guess.
Reply:no propane conversion ?insert thoughtful quote from someone else2000 Thermal Arc 300GTSW 3.5 hours1946 Monarch 20 x 54 Lathe1998 Supermax 10x54 Mill2004 Haco Atlantic 1/2" Capacity Lasernot mine but i get to play with it
Reply:Another A+ Thanks for the pics. 9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Really, it's hard to believe it's the same truck.Nice job!I hate to say it, and I don't know the truck's application, but I see a few things that would cause the truck to flunk a certain test.Seat belt - It's a must have.Left fork - The left fork's heel appears to show very heavy wear. The test aside, be careful about lifting max loads.Lift chain - Usually when a chain bleeds rust it won't "gauge" because of wear and stretch.Maybe it's just the pictures, or maybe for the truck's purposes these aren't concerns at all.Good LuckLast edited by denrep; 05-18-2009 at 01:11 AM.
Reply:Wow.Just .... wow.I can't believe the massive amount of work you did to rebuild the forklift - the "before" pictures are absolutely hideous, but the "after" pictures are truly awesome.  I like the diamond plate work you did on the lift, and the plexy roof is a good idea for those days when ya gotta drive in the rain (been there, done that, got soaked).  I do see one very important thing missing on the lift .... the name of the builder (as in YOU) stencilled on the side by the seat.  If you're going to build it, you gotta sign it .....Nice dashboard ....... where's the stereo system gonna mount so you have tunes?
Reply:Originally Posted by chenryno propane conversion ?
Reply:Originally Posted by 4shorts...As for the forks. I looked at much newer trucks and they all looked the same....
Reply:Now if that don't beat all I've ever seen, a pimped out forklift, too cool!I am surprised you didn't put some of that diamond plate on the dash panel around the gages too.I think that would have looked great on there!#1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!
Reply:Looks like something Tim Allen would do for his old show Tool Time. With those exhaust pipes I envision Tim putting in a 350 with all the goodies. And of course seeing Tim Allen doing wheelies across the shows stage floor as he drives it through the stage walls.That forklift looks like something too good to use for work! Looks more like something that would be on the Toyota's showroom floor to get the customer's attention.Good Work,TomCo-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:4Shorts, looks like you did a beautiful job.We have many of those little Toyotas at work and they are incredible machines.When I seen the stacks I hoped to see a little diesel conversion so they could actually roll some coal out of them LOL Thanks for the picsLincoln Squarewave 255Miller Coolmate IIISpeedway 320Lots of melted mess so far
Reply:Well, no one can accuse you of doing things half-way.  What a beautiful machine. I consider it like a custom truck, car, or motorcycle. Yes I understand restoring machinery to it's original condition but customizing is just as good and sometimes better. I think the exhaust stacks are a great addition as is the all the diamond plate. The only thing I would have done different would have been to put a solid top on. The sun gets so hot here that any shade is welcome.
Reply:Originally Posted by Oldtimer The only thing I would have done different would have been to put a solid top on. The sun gets so hot here that any shade is welcome.
Reply:4shorts,Man, that's one tricked out lift.Beautiful work.Put me in the camp that definitely "likes" what you've done.  Great attention to detail.No where close to looking as good as your machine, but thought (for giggles) I'd post up a picture of my "rough terrain tig cart". Attached ImagesSyncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.Originally Posted by SundownIII4shorts,Man, that's one tricked out lift.Beautiful work.Put me in the camp that definitely "likes" what you've done.  Great attention to detail.No where close to looking as good as your machine, but thought (for giggles) I'd post up a picture of my "rough terrain tig cart".
Reply:Evening Paul,As always, a Master Class example of Restoration and Fabrication.I cannot think of anything else that has not already been said.Your creations are definitely good advertising for your business, and your abilities.I am a big fan of your work - I believe that I would be incredibly satisfied with the craftsmanship, fit and finish of any project that you worked on for me. Keep up the Excellent Work.Later,Jason
Reply:Maximum awesomeA butterfly without wings, is just an ugly bug
Reply:4shorts,She's an '88 model.  26,000lbs at the boom base.  Have a box beam extension that slides over one fork.  She'll snatch a 2,500 lb diesel engine at the end of the extension and not even grunt.Luckily, my former partner in the yacht sales business also owned the Hyster forklift distributorship for VA, MD, and NC.  This particular lift came off lease and went thru a total refit prior to coming to the yard.  She's gas but she's been a goodie.Got a little palet I threw together for the tig (Syncrowave 250 DX) that I just roll the cart on, strap it down, and away we go with the lift.  Really nice for doing handrails, etc. on the boats.  Machine is right there.  We've got 50A receptacles all over the yard and I just use a 50' boat power cord to supply the tig with juice.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Impressive workMiller Dynasty 200DX Tig Welder
Reply:That forklift is absolutely amazing. I can't believe the transformation this project took. It is just amazing. Have you ever restored any older cars? I would love to see some pics of something like that you completed.Wow, wow, wow!!! Amazing!I need to see more.Jay-O
Reply:I DO SEE ONE MAJOR FLAW!  and one minor one.First the minor flaw is no fire extinguisher mounted on  the lift.  I had to use the one on my 12K Yale this week when the wire for the strobe on the roof shorted out and set the wire loom on fire. thankfully their was ZERO collateral damage to the lift but the smoke definitely puckered my hind quartersThe major problem is it isn't MINE!Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by 4shortsCompleted:
Reply:Very Nice resto. I am in the "I did it my way" camp. Good on you.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Originally Posted by William McCormick JrWhat the heck did that cost you? Ha-ha. It looks unbelievable. Nice work.        Sincerely,             William McCormick
Reply:Originally Posted by 4shortsHa! Ha!. Good thing we don't work together because we would have some wild things done with this project. I told a customer last winter that I was going to put a GPS and a DVD player on it and I thought he was going to die laughing. I think I should have done it  Thanks man. Glad you liked it.
Reply:SpyGuy you have some good ideas there. Some of them I had in mind but being realistic I ended up with what I have now. It will be used but you could sure have fun pimping these things out. I'm surprised I haven't seen more done like that. I have a new seatbelt ordered along with all the warning decals for the little beast and although the photo's I posted before didn't show the extinguisher very well it is there in full view. You got cool idea's my friend!Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:Hey, told ya I could think up some crazy but cool stuff .......
Reply:Originally Posted by SpyGuyHey, told ya I could think up some crazy but cool stuff .......
Reply:Considering I'll be using the lift around the yard either boosting vehicles or even towing them I realized I needed a storage box to put the cables and tow sling in so that's what I made yesterday. I had a bit of checkered plate left so I used that on the project. I also had to decide who I was going to mount the box and not wanting to drill or weld the counter weight I decided to machine a few parts for the lift holes and use two small pieces of threaded rod to hold them in place and then I could just simply  bolt the box on the back and not alter anything. Here's how it ended up.Miller 302 Trailblazer/Custom TrailerMillermatic 350P/Spool gunMillermatic 252Miller Spectrum 875Miller Dynasty200DxHypertherm Powermax 85Tracker CNC 4X8 Pro Table (Down Draft)Visit us @ www.specialtyrepairscustommods.com
Reply:WOW!  Great work.  You're definitely an artist at this.  Too pretty to use though.
Reply:VERY nice!  Good solution for the cable storage.  Throw some ice in there, and a six-pack, and ......... Oh, wait: no drinking on the job - you might spill some.About the only thing I would have done slightly differently would be to mount the extinguisher on one of the vertical cage bars.  That way, you could leave the space open next to you for a clipboard for orders, etc.You've done a great job on "resto-rodding" your forklift.  Professional quality work, all the way.
Reply:that would have to be the best looking forklift I have seen beautiful work as always Paul Creative metal Creative metal Facebook
Reply:Hey spyguy!This is the 21st century, the age of electronics!Clipboards have been replaced by laptops! #1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!
Reply:Originally Posted by Ken DennisHey spyguy!This is the 21st century, the age of electronics!Clipboards have been replaced by laptops!
Reply:what gave me the idea of the laptop is, after 23 years of driving semi, and going into these warehouses, the old days they recorded the pallets or parts coming and going on clipboards, took maybe a half hour or so to get loaded or unloaded.but now, most warehouses are set up with fork trucks that have a computer on board, and a scanning gun, and all the pallets and parts have a sticker with a bar code attached, a shipper can send the picking order to the fork truck driver and never leave his office, the driver as he picks stuff off the shelves that are listed on his computer screen, scans it in for the shipment, and it is all sent to the shippers computer, where he can print out the bill of lading, or vice versa when something is delivered!This is all fine and dandy, until someones computer crashes or the scanner doesn't recognize a bar code, then everything comes to a screeching halt, of which seems to happen more often than not!The computer was supposed to make this all work faster and easier, but 9 out of 10 times, something goes wrong, and it will turn what should have been a 30 to 45 minute load or unload job, into a 4 hour "Or longer" ordeal, while everyone waits for a tech to fix the computer or while they sort out what or where a pallet of stuff is or came from, cause a bar code doesn't work or is missing!Really frustrating stuff these electronic devices! But the straw that broke the camels back for me and driving truck, was when they put a computer in my truck with a phone/intercom and a GPS tracking device, all of a sudden, I have a supervisor looking over my shoulder at everything I did, calling me while I tried to stop and sleep for a couple of hours, and now, I could no longer drive the route I wanted to drive, I had someone sitting behind a desk, telling me where to turn and what road to take, the problem with that last part is, even though a certain road or route might be shorter, it wasn't always better, it might cut 20 miles off of a 500 mile trip, but add 2 hours to it! OK!I'M done ranting about todays so called "Better" ideas for how things should be done! #1. If you don't like what I wrote, or if it offends you, then don't read it!#2. I am living life the way I see fit, if you don't like the way I'M living, tough sh**!
Reply:But remember, it's just tech.  The most sophisticated electronics can always be neutralized by a good old-fashioned hammer ......  I'll agree that computers have their place, but for just moving stuff around in a warehouse or yard, gimme a clipboard - you can't break a piece of paper by dropping something on it.  I'll do the computer work when I get back to the office .......
Reply:I don't know how I missed this.That lift truck is like a new person.I wish I had the attention for detail, and the ability to do it right.I'm about the worst when it comes to equipment.  I fix it, and get on it and go.  It's a bad habit, and it's getting worse as I get older.Your driveway and apron look to be asphalt.  I'm amazed the truck doesn't cause ruts.  Same when you had the machine, and counterbalance up on jackstands.  It must not get real hot where you are.  A good 90-100 degree day here, and the jackstands would sink right through the blacktop.Back when I drove a truck, I learned a hard lesson.  Never drop a loaded trailer on blacktop.  The landing gear goes in right up to the kingpin  My boss split the wrecker bill with me  Worked better than being yelled at, and I didn't get fired.Another beautiful job"Any day above ground is a good day"http://www.farmersamm.com/
Reply:I saw a Toyota fork lift at the AirGas today. It was already painted orange, but pretty beat up. I thought of this thread immediately, as I tried to explain it to my retirement buddy. It even had the red stuff on the lift chains. 9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by Craig in DenverI saw a Toyota fork lift at the AirGas today. It was already painted orange, but pretty beat up. I thought of this thread immediately, as I tried to explain it to my retirement buddy. It even had the red stuff on the lift chains.