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Old 01-21-2014, 11:02 AM   #1
ihpartsjeff
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Default Steve's Expedition Scout Traveler

We started this build over two years ago and as it nears completion I thought it was time to put together a build thread. Our customer Steve has always had a vision of traveling to exotic places with an expedition type vehicle. IHPA was given the task of building the base vehicle so that Steve could then outfit the rig to his particular needs.

To begin the build we started with two different 118" wheelbase Scout Travelers. Steve already owned one, a tired and rusty diesel powered 1980 that had seen many a miles up in Alaska. Beat and used up this Scout Traveler still ran(although not well) and the body was done but since we were sticking with the Nissan sd33t engine and keeping a manual transmission some of the parts off this vehicle would be needed. This second Scout Traveler Steve purchased off the internet and was a gas powered Midas edition that looked to have a very good body.

The plan for the project was to keep with as many parts as possible that can be found abroad. So with that in mind the Nissan SD33T turbo diesel was kept for the power plant as versions of this engine are found in Nissan Patrol's and industrial equipment like forklift's all over the world. To fuel the engine a 33 gallon fuel tank was installed in place of the factory 19 gallon as well as a secondary heated tank set up to hold filtered waste oil. A NV4500 5 speed overdrive transmission with one of our CPT NV4500 to IH V8 Adapter Kits Was chosen for its strength followed by a Jeep version of the Dana 300 transfer case.

For axles the stock Dana 44's were to be retained with 4.09 gears and Eaton E-lockers. The front brakes were to be upgraded to our GM disc brake conversion kits And for the rear one of our TSM Scout II rear disc brake kits. And to boost the stopping power a CPT hydroboost kit would be installed. Suspension was to be kept mild with 2 1/2" spring lift, a CPT reverse shackle kit with CPT sway bars Both front and rear.

For the interior a custom roll cage would be built with the ability to hold a roof rack through and above the factory traveler fiberglass hardtop. Corbeau seats and a Tuffy lock box center console Would be fitted to the cage and a AMA air conditioning kit would be installed to keep the interior temperature comfortable on the warmer days.

The 1976 Midas Traveler


The 1980 turbo diesel powered Traveler(with 1976 front sheetmetal/grill). We had already begun the teardown when this picture was taken.
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Old 01-21-2014, 01:25 PM   #2
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Default Re: Steve's Expedition Scout Traveler

The Midas Traveler arrived to us first.



It was a typical smogged down 345 with a 727 auto transmission.




The worn interior was sporting a round gauge instrument panel.


And had the typical 70's style midas interior.




A 33 gallon tank Was already installed as well as a 2.5" Rough Country lift kit.


The Scout was fairly clean underneath and sporting newer mufflers.


The overworked and bent down rear bumper will end up getting reused.


First thing to start the build process was to remove the hard top and gut the interior.




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Old 01-21-2014, 01:52 PM   #3
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Default Re: Steve's Expedition Scout Traveler

Once Darren and Michael had the Scout's interior stripped the tub was cleaned and evaluated for rust.







Overall the both the front and rear floors looked real good with the exception of an abundant amount of holes due to the Midas interior.


Unfortunately we did find that the quarter panels had succumbed to rust and would have to be replaced.


Darren began the process began by drilling out all the spot welds and cutting the front of the quarter panel off.





Once off you can see how much more rust there actually was.






With the quarter panel off the inner wheel well lip which was also rusted was removed.
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Old 01-21-2014, 02:23 PM   #4
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Default Re: Steve's Expedition Scout Traveler

The driver side quarter panel had the same problems and thus got the same treatment.







The inner wheel well lip was rusted away just like the passenger side was.


New inner wheel well lips were welded back into place.




Lots of clamps are needed in order to make sure the replacement parts goes right back into place correctly.


At this point with the amount of surface rust that was on the tub itself and the additional rust that we were finding we decided to have the tub sand blasted before any more additional metal work would be performed.


So the tub was removed from the frame.




Once removed the gas rolling chassis was set off to the side.
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Old 01-21-2014, 02:57 PM   #5
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Default Re: Steve's Expedition Scout Traveler

With the tub off the frame the remaining front body parts were removed.



Then the body tub was set on a temporary rolling chassis.



The diesel powered Scout was then brought in as a few key parts were going to be needed for the build.


One thing that we needed was the brake/clutch pedal assembly as the midas Scout was an automatic yet we were going with a manual transmission.


So that the drivetrain could be removed we lifted the body off of the frame.


With this much rust you could see why this body was not going to be used.


Certain parts were going to be needed from the existing diesel powertrain hence why we needed to remove it.


With the rusted out body back in place the gas powered chassis was rolled in so that its powertrain could be removed as we decided to also send out the frame that we were going to use for sandblasting.




Before being loaded onto the trailer for blasting each part was given a quick power washing.


Once washed all parts were loaded onto the trailer.



Then taken over to the sandblaster where everything was unloaded and left for a few days.




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Old 01-21-2014, 03:28 PM   #6
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Default Re: Steve's Expedition Scout Traveler

After a few days the tub, frame and other remaining parts were picked up from the sandblaster.



With the frame and tub back from the sandblaster Darren got right to work in modifying the frame and installed a CPT reverse shackle kit.



Other parts of the frame were rewelded and gussets added in key places.



Then some additional rust repair that surfaced with the sandblasting was performed on the tub.















With some known wiring changes coming some of the old electrical firewall holes were welded up.





Other parts of the tub such as the inner quarter panels and floor were patched up as well.





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Last edited by ihpartsjeff; 01-22-2014 at 11:46 AM..
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Old 01-21-2014, 03:43 PM   #7
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Default Re: Steve's Expedition Scout Traveler

Before things could get back to rusting a good coating of primer was applied to both the frame and body tub.







The tub got one last cleaning before having the primer applied.





Darren applied several coats of the primer.






All coated with a quality primer there were no more worries about rusting.



The tub was then placed back onto a temporary chassis.



Next up was the building of both front and rear axles.



Each axle got a master overhaul kit , Eaton E-lockers and new ring and pinion sets.



With every rear axle build that we do we perform a straightness check. As expected this housing was bent on one side bad enough that it needed to be cutoff and welded back on in order to compensate for the bent axle tube.



With the axle rebuilds complete each housing got painted along with the frame.



With painting chores done on the frame and axles the chassis was now ready for reassembly.

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__________________

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Old 01-21-2014, 04:27 PM   #8
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Default Re: Steve's Expedition Scout Traveler

The transmission, a NV4500 adapted to run behind either an IH or Nissan diesel engine was prepped as well as the Jeep Dana 300.



With the axles built and chassis assembled the tub could be lowered down so that the next round of fabrication could be performed.



The quarter panel end caps were spot welded to the quarter panel.



Since quarter panel's for the 118" wheelbase Scout's are not available a lot of additional work has to be performed in order to add an extra 18" to the standard Scout II quarter panels.














An access hole was cut into each front inner quarter so that additional welding of the quarter panel could be performed.





The driver side access hole will also give access to the waste oil tank's fuel filler which will be fabricated next.

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Old 01-22-2014, 09:38 AM   #9
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Default Re: Steve's Expedition Scout Traveler

With the driver side quarter panel mocked up Darren was now able to locate and trace out the design of each fuel door to be installed.







For each fuel door a box was fabricated to locate and protect the fuel filler itself.





Darren then modified a stock fuel filler neck, welded some mounting brackets and installed it onto the Scout.



Mocked up the whole set up has a nice clean look to it.





The rear fuel filler was shortened and modified to work with a fuel door set up.



With both fuel fillers completed and mocked up the final quarter panel modifications could be performed.

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Old 01-22-2014, 10:02 AM   #10
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Default Re: Steve's Expedition Scout Traveler

With the fitment and fabrication of the fuel fillers and quarter panels complete the tub and related parts were then given a final coating of lizard skin. We like using lizard skin as it is a water soluble product that works remarkably well for reducing not only noise but heat as well.





Both inner and the outer quarter panels got coated.



With the coating completed the Scout was rolled back into the shop so that final installation of the quarter panels could be performed.



Both fuel filler's were installed for the last time.



And then Darren welded everything up.









The custom aluminum fuel tank we ordered finally arrived from grease car.

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Old 01-22-2014, 10:48 AM   #11
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Default Re: Steve's Expedition Scout Traveler

Next up was the fabrication of the custom roll cage.





Some days its best to leave the fabricator alone.



Ihc customs cage dash plates were used in conjunction with a dash bar.



There are going to be two separate tops used on this Scout. One will be for normal daily use but when steve goes exploring this particular hardtop will be installed as it will have provisions for a storage rack to be installed above with all its weight on the roll cage itself.



To make sure the roll cage to storage rack mounting feet lined up through the hard top Darren had to spend some extensive time and creativity getting everything perfect.







With the roll cage complete it was hoisted out of the tub.





By using tube clamps we are able to break down the cage into separate components without sacrificing strength.



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Old 01-22-2014, 11:09 AM   #12
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Default Re: Steve's Expedition Scout Traveler

Custom swaybar setups for both the front and rear were ordered up and with their arrival Darren was able to get both installed.











Darren also fabricated a custom hi-flow exhaust system.



A modern type A/C compressor was installed with a modified version of our CPT A/C compressor retrofit bracket.



Darren prepares for the final installation of the body tub to the frame.



Notes are taken all the time on projects in order to keep track of all time and material spent.



Since the vacuum brake booster is being ditched for a hydroboost unit a standard polished one-wire Delco 10si alternator Was installed along with a PSC power steering pump kit w/ remote reservoir.

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Old 01-22-2014, 11:38 AM   #13
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Default Re: Steve's Expedition Scout Traveler

More Lizard Skin was applied to the various surfaces of the Scout including inner/outer fenders, firewall and hood.









The inside of the tub was also given a coating of skin.



With the front sheet metal and doors installed it was off to the painter.



Additional components needing to be painted were boxed up and stowed in the trailer.

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Old 01-22-2014, 12:48 PM   #14
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Default Re: Steve's Expedition Scout Traveler

After a few weeks we stopped by the painters shop and checked on progress.



Standing on the left is Brent Jackson owner of Brent Jacksons Customs. Brent is a neighbor up the road from our shop who mostly performs paint jobs and restorations to Corvette's and hotrods but was willing to take on the task of painting the Scout.









A few weeks later the Scout was painted and picked up from Brent's shop.





Brent did an absolute fantastic job painting the Scout a pearl blue.



With the Scout back it was time to send out the roll cage and related components to get powdercoated.



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Last edited by ihpartsjeff; 07-28-2017 at 02:57 PM..
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Old 01-22-2014, 01:06 PM   #15
ihpartsjeff
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Default Re: Steve's Expedition Scout Traveler

That same afternoon the cage was coated and picked up.



Darren wasted little time getting the cage installed.



As well as the seat and center console cage mount.



Corbeau seats and a Tuffy lock box center console Got installed next.



Additional parts are laid out in the back of the Scout in preparation for installation.



At the time of this writing the project is continuing on and in process so as pictures are taken they will be posted up.

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Jeff Ismail
IH Parts America - Owner
IH Sierra Fall Rallye Event Coordinator
Binder Books
CPT - Crawler Proven Technology
(530)274-1795

Last edited by ihpartsjeff; 07-28-2017 at 03:00 PM..
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