Project First Degree

[Dirk Kolnsberg]

Spent two days of this long weekend, Sunday and today, on the Terra and managed to get some work down but also managed to break some things that I really didn't want to break.

Sunday was spent wrapping up the transmission reseal as last week the new pump gaskets arrived. The transmission was on it belly and I was applying the service book's recommended torque to the pump bolts and it cracked. So I pulled the pump off of another transmission and this time, with the case vertical and turning the output shaft every once and a while, I was working in a circular motion applying about 1/4 turn per bolt to work it down it cracked too. Then about 30 seconds later the screw I had used to secure the transmission to the saw horse through one of its bolt holes broke and the transmission fell and cracked the lower indexing bolt hole ear off ... nice!

So now both transmissions (the one from the Terra and the 2 wheel drive one from a Travelall I had pulled the pump off of) will be dropped off at the tranny shop to have it rebuilt and the cases swapped to make one good 4x4 version. That still doesn't account for the cracked pump, I hope the shop has a good line on one so this doesn't end up costing way more than I already don't want to spend.

After that debacle I moved on to the 392 engine. During a wrench day it had been gone through and resealed / gasketed and then sat in a corner of the garage. I drug it out into the driveway and hosed it down with degreaser and let it soak, then power washed and scrubbed it with Dawn dish soap. After it dried it was painted a universal red (no high temp IH red in the three stores I went to) and then the bracket cleaning and painting started.

Overall this isn't the best clean and paint job but it is 'good enough' and looks good from fender distance away - mostly anyway. After the paint was dried on went an RPT aluminum manifold and fancy coated goodies scored off of the BP classified a year or two ago along with a Truck Avenger carb bartered for last year. There are still some final touches and more brackets to clean, paint and install but for the most part it is done. Now that it looks this good I am having a hard time not wanting to clean the frame and paint it as well so it has a nice home to sit in.

Today the axles were tackled and the rear was first until I realized after pulling the old inner seals out that I didn't have new ones ... on to the front. Old knuckles from JPEater were intalled that have newish ball joints and have already been drilled for 3/4 ton tie rods that sit on top of the arm. To tie the two knuckles together and handle steering duties a tie rod and drag link assembly ordered from Parts Mike was used.

All new seals and bearings were installed in the hub assembly and the axle u-joints were replaced with Alloy USA heavy duty versions. The long side went smoothly but the short side is still waiting because the ears were tweaked just enough to cause the cap to bind and split itself in two (problem when using a 40 ton shop press, you don't have a good feel for that sort of thing like with a bench vise). Some creative use of the press and the ears are back to where they need to be so now just have to order another u-joint and the short side will be complete. Also installed JPEater's old Warn external hubs to finish off the front (one side at least).

Overall got some stuff done but didn't reach my goal to have it sitting on its wheels by the end of the weekend. I guess there is next weekend though.

Here are some pictures.

[sullyscout77]

Great progress Dirk! Good to see you getting after it. Unlike you, I can't seem to get my sh@t together enough to establish a plan. The 392 is coming together nicely! Still
three months before NATS, you'll make it, no sweat! You know where you can get help, when needed.

[scoutpappa]

Ditto on the help brother. I owe you one and after the rebuild class I'm sure a couple of good size boys can get things where they need to be. Let me know. We have the camping trip this weekend but if a all out wrench day is needed the following weekend I know we can get something done. Maybe we can set it up where the wives and kiddos hit the pool while we we wrench. Let me know.

Nick

[Dirk Kolnsberg]

Originally Posted by sullyscout77

Still three months before NATS, you'll make it, no sweat! You know where you can get help, when needed.

Originally Posted by scoutpappa

Ditto on the help brother. I owe you one and after the rebuild class I'm sure a couple of good size boys can get things where they need to be. Let me know. Let me know.

Nick

Thanks for the offers for the help, I am sure there will be ample opportunities before Nationals, particularly once the weather warms up a bit .

Saturday was spent getting the front axle finished and bolted on top of the springs using new u-bolts and new-to-me u-bolt skid plates from Holt.

Today John gave me a call with an offer to come over an do a little wrenching and I caved in right away. It was perfect timing as we got the engine, transmission, transfer case and front drive shaft bolted in and also filled everything with fuild and reprimed the engine before stabbing the distributor.

Here are a few pictures of the progress, with the first a picture showing the notches ground into the knuckles to allow the grease fittings from the Alloy USA u-joints to fit through.

Once again thanks for the help John.

[sullyscout77]

Great Progress Dirk! You'll be cruising in no time!

[Dirk Kolnsberg]

Overall a good wrenching weekend. Saturday installed new Alloy USA rear axles, bearings and seals, cleaned up the drums and painted them with high temp caliper paint to keep the rust off. Installed some old but little used Rancho 9000 shocks, amazing part is that it has been about 10 years since I bought them and the poly bushings are now crumbing into powder. The rubber bushings from the original shocks are in great shape so they were pressed out and into the 9000's.

Today a big thanks to John and Sully (and Fred for use of the trailer) for going with me to pick up a 71 Scout 800 tub, frame and title and loading everything onto the trailer. We brought them back to the house and surgically removed - with plasma, sawsall, grinder and metal skill saw - the rusty back half off just behind the front doors. The front part including the doors, firewall and inner fender structure was taken over to the storage unit to wait its turn for use on a future project. While there we picked up the tires and wheels for the Terra and brought them back for some test fitting. Back at the house we swapped some engines around on the engine stands and loaded the 345 from the Terra onto the trailer for Fred.

Here are some pictures of the rear axle assembled in the Terra and with the tires installed. The back end is a little high (remember from a few posts back the previous owner had cut them off and rewelded them about 2" lower than normal). I plan on relocation them but need to wait until everything is put back together for a final stance assessment then determine where it all needs to go as I do like the slightly nose down look rather than the dragging rear pre-runner look. Thanks again to the crew for the help!

[txscoutii]

As always happy to help buddy. Here are a few crappy cell phone pictures of today activities.

Don’t forget to lube the transfer case.

John

[sullyscout77]

Always a Good time at Dirk's! Did we mention how Hot it was? And this is only June!
Good to see the progress on the Terra project first hand and glad to reciprocate, at least a little, for his many trips to the Scout Lair!
Rest assured, the pieces you see being removed are being saved for patch panels on future projects, as there were no panels on this beast that were worthy of more than that. Good time with good friends!

[Dirk Kolnsberg]

The heat is getting to be a real joy kill but the work has to go on to make it to Nationals this year with something that has International Harvester in the manufacturer box on the registration.

Saturday the rear driveshaft got new u-joints, it was installed and the rear axle filled with gear oil. For now the booger welded bump stop platforms will stay in place, and to help ensure the rear axle doesn't compress too far some junkyard bump stops were added.

A new IH Only SS extended brake line was bolted in place on the rear axle and to have a better axle vent nipple fixture (not sure that makes sense) I decided to install a 1/8" NPT X 1/4" hose barb in the vent hole and then weld a bracket for the axle end of the SS brake line to bolt to, effectively also making the line a few inches longer. While coersing the hard lines into place the short side line kinked so I will have to go to the parts store and buy another short section. Other than that little piece the rear end is complete.

Also welded on front upper shock mounts to the frame from some old Ruff Stuff Specialties tabs I had lying around. I need new bushings for these shocks as well (poly crumbled) but the old front shock bushings are scrap so it looks like I will have to order some new ones.

Today I only spent about two hours outside cleaning up the old metal brake lines and installing the front IH Only SS brake lines. Also got the new exhaust donuts installed and the flanges bolted up to the manifold.

That will be it for two weeks as next weekend I will be road-tripping with Sully to Nebraska to pick up his new Travelall, it should be a grea trip.

[guidolyons]

Originally Posted by Dirk Kolnsberg

The first step in any multi-step self-help program I believe is to admit that you have a problem ... and I admit it.

I always thought step one was admitting you have a problem...but apparently that doesn't come until step 5, which by then it's waaaay too late.

1. Buy a old Scout 80/800/SII, think it will be a fun, neat little 4x4 to fix up. Find out that rust/old age/Previous Owner hack job have consumed it and that our little quick fixer upper has serious problems.
2. Come to find out there another slightly better/worse Scout that has what you need to restore Scout #1. Buy Scout #2
3. Made a decision keep Scout #2, "just in case"...buy Scout #3 to fix parts missing from Scout #2
4. Made a thorough and searching inventory of the garage, back yard/junkyard in search of "that one exclusive part". Find the diamond in the rough...Scout #4
5. Admit that you have a Scout related problem. Find Scout #5 while on vacation in New Mexico and have it shipped home for 3X what you paid for it.
6. Finally remove all rust from Scout #1. Meanwhile find Scout #6 that has the doors you need for Scout #3
7. Somehow, Scout #3 is now in better shape than Scout #1. Sell Scout#2 for parts.
8. Made a list of all the Scouts that are parked in your back yard, next to the garage, or hidden at the neighors. Trade Scout #1 for Scout #8
9. Made repairs to those Scouts wherever possible, which requires you to buy back Scout#2, and Scout#7
10. Continued to take inventory of Scout parts. Trade Scout #4's Fenders for a windshield frame for Scout#5, tow home Scout#9 from the junkyard...saved from the crusher.
11. Seek out other Scout 80/800 owners, that have similar affliction. Get Scout# 10 and 11, just because...well it was cheaper to buy the whole thing than the rear axle you needed.
12. Having had a Scout awakening as the result of these steps, carry this message to all Scout-o-holics, and to practice these principles in all our affairs. Build Scout #12 from the parts of Scout #2-11

Modified from a slightly better known 12 step program

Great job, the Phoenix rises from the ashes