My 69' Scout 800 Project

[db1115]

I have been tied up constructing my new shop the last few months, so the scout had to take a back seat. But the shop is done and I have the scout project in progress again.

I would like to thank Damian at DandC Extreme for the tons of helpful advice he has given me. The man's knowledge of these things is amazing and I would still be scatching my head if it werent for him. The quality parts he has is awesome, but his advice is priceless.

Here is a few pics of where it is now. It has a long way to go. I will post more as it moves along. If you would like close up specific pics of anything along the way, please ask.

The first ones are the before pics. The first one is of the Scout I will be building/restoring (the one my Dad bought brand new and I was given 25 years ago). It is a 3spd (have a 4spd swap) with the 266 v-8. The other 2 are donors for this project.







The next pics is where it is now. I have cut all the shock brackets, bump stops, and steering box bracket (in preparation for the Scout II power steering box) from frame and gound them smooth. I have installed new shackles, spring bushings, and had the original springs reconditioned. I ground down the housing on the Scout II Dana 44 in preparation for the SOA and have new spring perches ready to be welded on. I will do the cut and turn once I have the axles where I want them.

It turned out taller than I thought it would. I wonder how much the springs will settle?







Once I get the suspension/axles/steering complete, I will start building the front and rear winch bumper along with installing a D&C roll cage. After that will come the complete tear down of the outer body, interior, engine, etc. This might take awhile.

[pweeks3]

Good luck with the build. Nice to have a place to work. That Tahitian Yellow Scout looks pretty good to be a donor. The 2nd one looks about the shape my 800 is in right now.

[dustin howarth]

Looks like a great project - keep the pics coming, they are a great resource for everyone else (as well as great for you to keep and look back on!) Best of luck!

[db1115]

Originally Posted by pweeks3

Good luck with the build. Nice to have a place to work. That Tahitian Yellow Scout looks pretty good to be a donor. The 2nd one looks about the shape my 800 is in right now.

Yea, the yellow scout is surprisingly straight and rust free. It will donate most of the body parts. The only body parts I dont have a good one of, is a couple of good bed endcaps.

The red one is in pretty rough shape...but it has all the running gear and will run. I bought it mainly for the factory pto winch on it. But I have a Thor 9000lb worm gear electric winch I think I will use instead. So I will probably just sell the red one.

Originally Posted by dustin howarth

Looks like a great project - keep the pics coming, they are a great resource for everyone else (as well as great for you to keep and look back on!) Best of luck!

Thanks. I will get some more this week. I didnt have a whole lot of time to work on it this weekend. But I did get a few things done:

1. I got my front axle centered, pinion angle set where I want it, and tacked the new spring perches in place. I need to pull it out now, weld up the perches, and do the "cut and turn" on it.
2. I set the rear axle under it and lowered the weight on it. I havnt set the pinion angle on it yet, I think I need to move the axle 1" to 1-1/2" forward to center the rear tires better in the fender wells. I think I can do this by drilling a new hole in the spring perch and ubolt top plate.
3. I rebuilt the scout 2 power steering gear box with new seals and everything. It is ready to be mounted.
4. I also purchased a manual brake master cylinder for a 1969 corvette. It looks like it will be pretty easy to make work. It measures about an inch longer than my stock one which will require only a small dent to be placed in my fender well just under the battery tray. I am not sure what proportioning valve I will use for it and the manual 4 wheel discs yet. I have the stock one and one off of a power brake scout 2. Maybe one of those will work.

[db1115]

I figured I would do a little update.

I got the power steering box mounted up. I used a piece of 5"x3" angle iron to get it mounted exactly where I wanted it. It took alot of adjusting, but I am happy with it. Basically I picked the box up high enough to just clear the bottom of the frame with the pitman arm and moved as far forward with out interferring with the front shackle when the suspension is at full flex (down).







Next I moved on to the PS pump and bracket. I am using the Scout II pump, bracket, and water pump pulleys so I knew, from reading on here, that I would have to do some fender trimming. It bolted up fine...but sure enough...it had zero play for the belt tension.

So instead of just cutting a hole...I cut the notch across the top and bottom, then heated the metal to form a new notch then welded it back together. It turned out really well and with a little more grinding and messaging, I think I can make it look stock. It was just enough to almost give me full range on the PS pump belt adjustment. Should be enough to get the belt tight.







Lastly I moved the rear end up 1" by drilling new holes in the spring perches. It centered the rear tires much better in the fenderwells.



Thats it for now. I will post up more when I get em. And I am more than open to any questions or suggestions.

[db1115]

I dont have a whole lot to update. But I did get the knuckles cut, turned (6 deg negative), and welded up. It was a little tougher than I thought...but not too bad. I'm glad its finished. Here is a couple of picks. I also replaced the bad ball joints while I was there.





I am waiting on my ubolts, long shock kit, and steering shaft parts to come in from D&C to get it all finished up. Until then I think I will go ahead and put on my new body bushings and repair the crushed body mout on the driver's side.

[Jensers]

Wow - you are doing it right, and doing good work. Should come out great!

[pri]

Nice build!
I do have a couple of thoughts on the plate for the steering gear though. The vertical welds, straight across the frame, may induce cracks in the frame right beside the welds from what I learned over the years. I've always been taught that when welding on a frame, do the welds horizontally or at an angle across the frame. Also when welding across the frame, the welds should be interlaced with unwelded space at about a 50% ratio.

Paul

[db1115]

Originally Posted by Jensers

Wow - you are doing it right, and doing good work. Should come out great!

Originally Posted by pri

Nice build!
I do have a couple of thoughts on the plate for the steering gear though. The vertical welds, straight across the frame, may induce cracks in the frame right beside the welds from what I learned over the years. I've always been taught that when welding on a frame, do the welds horizontally or at an angle across the frame. Also when welding across the frame, the welds should be interlaced with unwelded space at about a 50% ratio.

Paul

Thanks guys. It has a loooong way to go.

And thanks for the advice on the welding. I considered exactly what youre talking about in reference to the vertical welds. But I decided the risk of frame cracking would be minimal for the following reasons. Keep in mind this is my opinion only and I have been known to be wrong before and I will not be held liable for your frame cracking.
1. The scout frame is a "boxed" design, as opposed to a "channel" which shoud give added support to the tempered area at the welds.
2. I used angle iron, for extra strength, and to let the steering box "rest" on. This angle iron had to be raised off the top of the frame in order to give clearance between the pitman arm and the leaf spring. Therefore I couldnt get my welder in there to weld horizontally up top between the angle iron and the frame. I welded horizontally across the bottom of the plate, but that weld alone would have not been enough to hold the torque of the steering box without the vertical welds on the side.
3. Not to mention International welded vertical welds in the same location, plus vertical welds across the top of the frame, when they welded the factory steering box plate to the frame. I personally have never seen the frame crack from the factory welds, but if mine it does, I will reinforce it and weld it back together.

But thanks again for the suggestions and please keep em coming.

[IH64Scout]

nice, lookin good. seeing how high you scout is i can't wait to see my '69 w/ the SOA and 4" CJ spring lift! how long are your shackles from bolt eye to bolt eye? i picked up a longer set off ebay a few days ago. i got the perches and knuckles ground off my rears...fun stuff!

-Jon