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Old 01-21-2007, 06:49 PM   #1
ihpartsjeff
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Default 63' Scout 80

This 1963 Scout 80 is a recently completed project of ours. We started this build in late November 2006 and finished it 4 weeks later. Aside from starting with a painted body and a rebuilt engine we had to rebuild and assemble everything else from scratch. As the story goes, the owner Tom had this vehicle worked on by several other shops none of which were reliable enough to complete the project. Twice he had a shop bail out on him only to go retreive the Scout and bring it back home. When Tom came to me he was pretty "gun shy' so to speak but I assured him we would not only get his Scout back on the road, but do it in only a short few weeks and have a rig that was better than new. When Tom arrived he had the little green Scout in tow with a pick-up bed full of parts.

So here's breakdown of what was to be done:
inspect and install 152 4 cyl rebuilt engine
rebuild the t90 transmission and Dana 20 transfer case
install rebuilt Scout II Dana 44 axles with 4.27 gears and front disc brakes
install power steering
install Scout II front leaf springs and a CPT reverse shackle kit
all new wiring
reassemble remaining vehicle parts

here are pics at the begining. We had already stripped the Dana 27 axles from the Scout and the leafsprings. The bottom pic shows the freshly built rear Dana 44.

Another pic
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File Type: jpg 100_3085.JPG (116.7 KB, 4265 views)
File Type: jpg 100_3086.JPG (115.3 KB, 3969 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:14 PM..
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Old 01-21-2007, 06:52 PM   #2
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Default Re: 63' Scout 80

Here are all the parts that were brought in for us to use on the project. Unfortunately most were unusable due to being left out in the elements.
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Last edited by ihpartsjeff; 10-23-2013 at 02:15 PM..
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Old 01-21-2007, 06:59 PM   #3
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Default Re: 63' Scout 80

With the old suspension out of the way we started the install of the CPT reverse shackle kit using Scout II leafsprings.

Here you can see the fangs mocked up.

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File Type: jpg 100_3088.JPG (98.0 KB, 3712 views)
File Type: jpg 100_3089.JPG (115.9 KB, 3720 views)
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Old 01-21-2007, 07:02 PM   #4
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Default Re: 63' Scout 80

We rebuilt a Scout II Dana 44 front axle, equipped it with 4.27 gears and new brakes, modified it for use in a Scout 80/800, and then installed it. We also dropped in the engine (after checking it over since we didn't build it).


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File Type: jpg 100_3091.JPG (128.3 KB, 4249 views)
File Type: jpg 100_3092.JPG (108.1 KB, 4780 views)
File Type: jpg 100_3093.JPG (110.6 KB, 4147 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:18 PM..
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Old 01-21-2007, 07:08 PM   #5
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Default Re: 63' Scout 80

We installed new spring bushings in the stock rear leaf springs, hung them under the Scout with new CPT shackles, and bolted in the rear Dana 44 axle.
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Old 01-21-2007, 07:14 PM   #6
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Default Re: 63' Scout 80

Next the Dana 20 transfer case and t90 transmission got completely rebuilt with new gaskets, seals, bearings, and synchros. Once the paint dried they were installed with a new clutch and transmission mounts.



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File Type: jpg 100_3096.JPG (135.2 KB, 4445 views)
File Type: jpg 100_3098.JPG (110.2 KB, 3869 views)
File Type: jpg 100_3099.JPG (101.2 KB, 4078 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:24 PM..
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Old 01-21-2007, 07:18 PM   #7
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Default Re: 63' Scout 80

The mount for the power steering box was fabbed up and box installed. A custom tierod and draglink were built using 1 ton ends.



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File Type: jpg 100_3113.JPG (73.5 KB, 3695 views)
File Type: jpg 100_3114.JPG (69.4 KB, 3761 views)
File Type: jpg 100_3100.JPG (120.7 KB, 4870 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:27 PM..
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Old 01-21-2007, 07:22 PM   #8
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Default Re: 63' Scout 80

New rear brakes and brakelines were installed along with new driveshafts.



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File Type: jpg 100_3101.JPG (120.3 KB, 3687 views)
File Type: jpg 100_3112.JPG (124.6 KB, 3626 views)
File Type: jpg 100_3104.JPG (114.6 KB, 3803 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:29 PM..
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Old 01-21-2007, 07:32 PM   #9
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Default Re: 63' Scout 80

The dash was cleaned up and installed. All new wiring was installed as well.


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File Type: jpg 100_3117.JPG (130.8 KB, 3751 views)
File Type: jpg 100_3124.JPG (105.4 KB, 3945 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:31 PM..
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Old 01-21-2007, 07:35 PM   #10
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Default Re: 63' Scout 80

The engine compartment was buttoned up and a power steering pump mount fabricated.



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File Type: jpg 100_3118.JPG (135.3 KB, 5012 views)
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File Type: jpg 100_3121.JPG (132.2 KB, 3673 views)
File Type: jpg 100_3122.JPG (78.7 KB, 3629 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:34 PM..
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Old 01-21-2007, 07:37 PM   #11
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Default Re: 63' Scout 80

Bilstein shocks were mounted front and rear.
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Old 01-21-2007, 07:38 PM   #12
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Default Re: 63' Scout 80

The Scout nearing completion.

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File Type: jpg 100_3123.JPG (87.1 KB, 3618 views)
File Type: jpg 100_3126.JPG (90.5 KB, 3667 views)
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Last edited by ihpartsjeff; 10-23-2013 at 02:36 PM..
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Old 01-21-2007, 07:43 PM   #13
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Default Re: 63' Scout 80

And heres the completed rig. Turned out quite nice especially for the short time we had with it. Wish we had more pics but towards the end we got pretty busy and thus didn't get many towards the end.





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Last edited by ihpartsjeff; 10-23-2013 at 02:41 PM..
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Old 03-26-2007, 05:59 PM   #14
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Default Re: 63' Scout 80

I didnt catch what kind of wiring kit you used. Was it a premade kit?
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Old 03-27-2007, 05:42 AM   #15
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Default Re: 63' Scout 80

Quote:
Originally Posted by shane View Post
I didnt catch what kind of wiring kit you used. Was it a premade kit?
We use/sell kwikwire wiring kits. This one was an 8 circuit model. Great quality with a great price.
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