Resurrecting The Scrap

Discussion in 'Binder Builds' started by RinTX, May 14, 2017.


  1. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I’ve also worked quite a bit on the inside of the compartment where the fuel tank goes. I replaced all the rusted out metal on the outside of the body. The inside lower sections all were pitted and had some pinholes. I decided rather than cut it out and replace with new metal - I would add a layer of new metal to the inside.
    I cut and fit several pieces.
    0D4874D9-24AD-4B5A-B0B7-3CB8EA91B748.jpeg
    I did the sides first with each having a lower lip and then I cut a floor piece and installed it so the side lips hold it in position. I used 3M body panel adhesive to install all this. Seems very strong - the original metal may continue to rust a bit but there is plenty of new material that should last.
    52789A84-0D9D-4C23-88E0-FB0AA1B6BBC2.jpeg
    That looked pretty messy but I wasn’t done. After letting it cure for a week I went over everything with a 2 part white liner product. (T-Rex; it was fairly cheap and I could buy a single batch - one bottle of liner and one bottle of activator). Rolled and brushed it on.
    6FEC6D04-3189-48D0-B407-DCB490C82B09.jpeg
    AF7D5E88-286A-4284-A9EE-B89D81C161AE.jpeg
    I think it looks pretty darn good now. I plan to clean and wire brush the outside surfaces and coat them with a black liner material. Should last a long time I think.
     
    Bussy and fdydguy like this.
  2. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    Other home projects took priority for a while. Got a few things worked on yesterday.
    The passenger side rear axle got new seals and bearings
    F02A1FAE-21DB-449F-9D8C-08C6A576ACF8.jpeg

    F71C2AF7-AFAF-49AB-858A-D3C5BBA1DBD8.jpeg
    8B18A7FD-82F9-45F3-8852-A62D58C68BCA.jpeg

    6C30D6BF-C099-4752-A264-913EB8299CD0.jpeg
    062DE89C-4F9A-4194-ADB5-E8CD2BDDA5C5.jpeg
    2A506C36-F1EC-4441-9AE2-D7B0A6E545C3.jpeg
    One thing I find a little frustrating- it is impossible to be certain that the bearing and axle are fully seated in the bore. It’s in as far as I could get it to go and the bolts are torqued to 60ft-lbs. It turns smoothly and spins the drive shaft when you turn it.
    11B170C7-B57E-454C-9419-5D9B60A48992.jpeg
    Today I should get the differential cover on and refill the axle as well as put the brake together.
     
  3. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    Been a really long while since I’ve done much on the poor Travelall. Been real busy.
    I do have a new master cylinder and power booster. The first one came with a master cylinder that although it is listed for front disc and rear drums (according to multiple parts sites) it really looks like a drum/drum brake master cylinder. Asked about it in General Tech and most agreed it was wrong one. So I got a correct replacement.
    AC13B295-DE40-4002-AEBE-DB48946C1C91.jpeg 4D0086F6-6596-476B-8B36-FA6C16E069FE.jpeg 8D6F6113-D345-4D99-AA1C-85191ADDE047.jpeg
    I’ve also done a little work on brake lines.
    6F2258BF-9129-4E41-AAD3-1E85DF187199.jpeg 1A2ED626-60B2-439C-AD86-77A17CA177B7.jpeg 1AD88E99-E81F-433A-AC4C-7459466F24BF.jpeg 5F1DD033-ACB4-48A7-9B80-7273AB335A9D.jpeg
    I cut my sections of rock guard too short. Oh well lesson learned.
     
  4. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I also replaced the flexible line in the rear.
    68327353-84B5-4458-8383-F9A11DD86887.jpeg C889ABF1-72F3-4888-90DC-8F259103646B.jpeg
    Also removed existing master cylinder and brake booster...
    8C21AFFA-EC43-4E17-9BA6-A1B0BE3B5E8B.jpeg
    “Sir I think I’ve figured out why your truck won’t stop...”
     
  5. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I’ve been slowly working on the brake system. Lots of other chores have required my time around here (including my transfer case in my Jeep Cherokee crapping out and requiring a rebuild)
    Master and booster installed and plumbed to proportioning valve.
    735415CE-BB30-4A3F-BC78-BA577AA3B9EB.jpeg
    Ran the line to the rear
    5C78862E-A710-4176-ACBC-3D2EC2707469.jpeg 01B4CF52-C0FF-4D49-8467-6ED37BC8605F.jpeg
    Moved to drivers side front. Using info found here on BP I have the seal and bearings to place a Ford rotor on the Travelall spindle.
    D5FE362D-120C-4E62-B5EB-63FD6EEDD83D.jpeg 1FCEB0CB-8598-427D-9891-E39112E55FCB.jpeg A640BCE6-233A-4CD9-9A8B-44880508FE73.jpeg
    E08A16CE-3EC1-4D52-ABDF-10401BBF34EB.jpeg
     
  6. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    The pax side now has a new rotor and bearings
    AF6A62D4-132B-482C-A515-2D460526EA0C.jpeg CAFC63A1-DE24-4D9F-B99F-7B7C691E1F18.jpeg
    This is the bracket that connects the caliper to the front end. I am amazed at how good these 45 year old parts look when cleaned up
    F3B468D8-39BF-4EF5-BF16-7FEF9754CF07.jpeg
    I decided to paint these and the calipers - I’m waiting for the paint to get here. I made 2 “stands” for painting outta stuff I had laying around
    84E70C08-5431-49E6-86FD-AC172E4CD216.jpeg
    While in the pax side wheel well I noticed the steel fuel line in there was really rusty and decided to replace it. I ordered some 5/16 copper nickel and bent a replacement section.
    CD49199F-63F8-4B46-8B2D-72CAD88BCD6C.jpeg
    Here it is installed
    43FF4476-038A-4BB1-BDE3-96C45DC0ED3E.jpeg 8252EB1B-9AFB-41C3-AA7D-AAB45FF3411B.jpeg
     
  7. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I’ve also greased the upper and lower ball joints and all the tie rod ends. I need new boots on the tie rod ends.
     
  8. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    Painted the calipers and brackets today. I know - really not necessary but I wanted to try to prevent them from turning into a big rusty mess (again).
    693DD0C3-2464-4D97-B821-9D67B3463DBD.jpeg 6A015DFC-17EB-4316-9899-EF98EF11A219.jpeg
     
  9. J.J.

    J.J. Y-Block King

    Joined:
    Dec 14, 2003
    Messages:
    3,295
    Likes Received:
    944
    Trophy Points:
    113
    Location:
    Castalian Springs, TN
    Looking good Rick! That has come along ways since you unloaded it off that trailer.

    JJ in TN
     
    RinTX likes this.
  10. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    Thanks JJ
     
  11. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    After poking around the pax side front wheel well I decided now was the time to address the rust through spots.
    I think this rust is pretty typical.
    6FEFAA1D-2FE5-4935-8E65-47845E5248E0.jpeg 8269655D-2BC3-4A81-87A7-594B28AC6C36.jpeg 849D6916-55A2-45F7-8A95-E896D1EC4198.jpeg
    I’ve got to clean it up a bit more but I did construct some panels to patch this
    2F26DFA5-5FB4-4E22-897D-E4B2573CDAD7.jpeg 2A87697C-FDB0-48E1-9706-D33A85869BB1.jpeg AEB00DBB-42D9-4787-B62A-D40B5FD09CF8.jpeg
    They are just held in place with some magnets to take a picture. I’m probably going to us 3M body panel adhesive to install them. First I’m going to go ahead and make mirror images to do the same repair on the drivers side.
    There is also a hole through the inner fender below the battery tray.
    51E4B266-5124-405C-A56C-3586551F0CFF.jpeg
    I’m probably going to just patch that too.
     
  12. J.J.

    J.J. Y-Block King

    Joined:
    Dec 14, 2003
    Messages:
    3,295
    Likes Received:
    944
    Trophy Points:
    113
    Location:
    Castalian Springs, TN
  13. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I will get in those vents JJ. Mine looks very similar to your first 2 pics in your post 36 (almost exactly the same)

    F4B29367-FF1D-42DE-ABB7-C72C296907AC.jpeg
    I’m curious how you are going to deal with the rust along the side of the seat there.
     
  14. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I got the patch parts made for both sides now.
    ADFF4E3D-FA05-4766-B1C7-E74FCBB59A56.jpeg

    Tomorrow I’ll work on cleaning up the wheel well and then install these.
     
  15. J.J.

    J.J. Y-Block King

    Joined:
    Dec 14, 2003
    Messages:
    3,295
    Likes Received:
    944
    Trophy Points:
    113
    Location:
    Castalian Springs, TN
    Hey Rick,
    I am going to hire out. I had purchased on of the SSS floor patch kits several years ago and didn't use all of it. There are sections that should replace this area with some cutting and pasting. My skills are not that great in that area. Mine would have been alright except for the years of mouse nest in the rocker that held the water. Oddly enough it came thru the top, not the sides or bottom. Easier to repair.

    JJ in TN
     
  16. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I did successfully patch the left and right front wheel well rust areas. It won’t win any awards. I’m more concerned about function and it will definitely last a long time. I used 3M body panel adhesive
    . 894C89A9-1AB7-42E7-9AF1-A8DC341E91A4.jpeg
    After struggling with the left side - trying many different ways to apply pressure while the adhesive set up - I added some sheet metal screws to the right side to pull the patch and hold it in position.
    C88BE85C-54F6-4CDD-B22D-AD795730A1FE.jpeg
    Today I did some grinding/smoothing and ground the heads of those screws off. Then I applied a duplicolor rust barrier product. It blended in the patches very well.

    C4953DC4-7BFE-4AF2-9629-1860594BD618.jpeg F108C949-7E42-4984-8FF3-0CC0C6C710B3.jpeg

    Also here is the battery tray patched in the corner where it also ate through the fender.
    FDFC13E6-254C-4649-9BEA-3A3DC15A86B2.jpeg
     
  17. Jeff Jamison

    Jeff Jamison Lives in an IH Dealership

    Joined:
    Oct 11, 2001
    Messages:
    6,198
    Likes Received:
    311
    Trophy Points:
    83
    Location:
    Aliquippa Pa
    Looks good,I usually use rivets to hold things in place,then I drill out and tac with a mig welder
     
  18. J.J.

    J.J. Y-Block King

    Joined:
    Dec 14, 2003
    Messages:
    3,295
    Likes Received:
    944
    Trophy Points:
    113
    Location:
    Castalian Springs, TN
    Looks great Rick!

    JJ in TN
     
  19. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    I now have front calipers
    0AD242FB-B68D-4950-8056-26B20888FCBE.jpeg 01F3C0B3-965F-4E8C-B10C-5D2B992B0D45.jpeg
    It seems a fairly simple design but it was a little troublesome getting everything lined up and getting the guide pins in.
    I also cut and flared and installed front brake lines.
    A8FE859A-2E77-4364-A86E-B8E47319C9B4.jpeg BB8F0873-651D-4419-948B-626E5FF4669E.jpeg 098A92EA-7B8D-4075-B900-F0639F3D7492.jpeg DDF4DA68-3433-498A-BADA-B0EDD5657165.jpeg

    I have “new” front flex/rubber lines that go to the calipers but they are not connected yet. With the front end hanging in the air as it is currently- they seem a wee bit short. I thought that very odd. I must have rechecked the length 4 times with the ones I pulled off - they are a match. So - is something in the front end out of adjustment? If I ever hit full travel it seems the front brake line will be what stops the travel.

    Edit - dang it all - I think I reversed the calipers and that is why the lines seem to short. I’ll check it again in the am.
     
    Last edited: Jun 19, 2018 at 10:47 PM
  20. RinTX

    RinTX High Wheeler

    Joined:
    Jan 19, 2013
    Messages:
    1,042
    Likes Received:
    143
    Trophy Points:
    63
    Location:
    Ft Worth, TX
    Well I sure did put those front calipers on the wrong side. I hate when I have to redo things because of my own stupidity.
    Here they are on the correct side and all hooked up.
    DF258940-07A9-4C5C-8368-4967F96CBF22.jpeg CF079BAA-803D-4CBD-82F1-1CA72309EE28.jpeg
    Had to spend time chasing leaks at bad flares. I think I finally have a brake system, no leaks, and adequately bled. Also verified that calipers are actually engaging. I may bleed again just on principle. It may soon actually move (and stop) under its own power.
     

Share This Page