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Old 05-06-2016, 05:01 PM   #1
Rustbucket
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Default New old scout 800 project

This is my Scout 800. I bought it years ago for the grand total of $100. I think that May be what it was worth in scrap, mostly rust. I bought it not running and have picked away at it s-l-o-w-l-y over the years. I want to drive it this summer. I do not plan on it being perfect. I just want it to move around under its own power. Things I have done; got it running (using a soda bottle gravity fill system to feed the carb gas; see: no gas tank), switched to pertronix ignition, fabbed cross over steering for the 27 (po had performed spring over and instead of steering it would just bend the tie rod when turning steering wheel, doh!), started aggressively attempting to repair rust (maybe a little too aggressively).... This is where I am at. I plan on doing a cj7 gas tank swap, replacing brake lines, shoes, cylinders, master cylinder, and gas lines,creating ds floor, rocker panel, rocker backer, body mount under ds floor, and creating removable door hinges. It's a tall order. I will post all the pictures I have to date and try to post as I do things. I messed up and the pictures at the bottom are the older ones, the ones at the top are newer.Name:  IMG_4212.jpg
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Last edited by Rustbucket; 05-07-2016 at 09:05 AM..
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Old 05-06-2016, 05:16 PM   #2
Rustbucket
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Default Re: New old scout 800 project

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Here's where I think I went wrong, I should not have removed the fender.... Crap. That is a lot of rust. These photos also explain why I have to lift up my door to close it. Why the floor is unsteady (notice the body mount channel and the 1/8" thick steal floor?)

so, I fabbed a new bottom hinge bracket. Turned out pretty good. About this time (in the photos), I purchase a hf press brake, shear, and roller. If I had to do it again... I might have gone with northern tools version. It is only slightly more expensive, but black Friday would have made it easily the same price and they would have delivered it to my house.

Last edited by Rustbucket; 05-07-2016 at 09:06 AM..
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Old 05-06-2016, 05:28 PM   #3
Rustbucket
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Default Re: New old scout 800 project

So, time line wise, things happened in between these photos. I moved. I did some other little things which I will cover in the next post. Thank god someone else was as crazy and stupid as me and has already done this panel replacement before (and posted with photos). I would be lying if I said I wasn't a tad bit frightened by taking this panel off. The real problem is, I remove something... I find more rust. I remove that piece and I find more rust. This is obviously my kick panel. The only part not rusted was the piece with the most holes.... I was able to save the vent louvres.

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Last edited by Rustbucket; 05-07-2016 at 09:08 AM..
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Old 05-06-2016, 05:49 PM   #4
Rustbucket
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Default Re: New old scout 800 project

After I moved, I decided I could not take not being able to turn the Scout from the cab. I had to use a long pry bar and turn the wheels form the front prying against the leaf springs before I pushed it around the yard. Side note: no driveshaft in yet because I have no brakes. I'm that rare breed that believes a vehicle should stop first and go where you steer it before it moves under its own power. Anyway, I decided it needed to steer. So, I researched a lot. I learned no one makes a good kit that keeps the drag link and tie rod parallel (which is very important in removing bump steer). I looked at other vehicles and what they used and how they did things for cross over steering and they mostly stick to the same design. Connect the drag link to an arm that is attached to the top of the steering knuckle/ball joint/kingpin on the opposite side and the arm should be the same length as the one below that the tie rod is attached to. I took some measurements. Calculated what the sheer tensile strength of the bolts should be according to diameter and thread per inch count, and headed off to a machine shop that dealt with milling and tooling. Here is something I learned after; replacement king pins for the Scout Dana 27 axle are no longer splined. If I had replaced the king pin with the newer style I could have had the machine shop make it in one piece. They could have made a splined one in one piece, but it would have been upwards of $900. I don't have that kind of scratch. I have time and patience. Continuing on, they machined flat the top of the king pin and created me a very heavy thick arm. I can report now, having moved it around, it is easy enough to turn that my 8 y/o son can steer it while I push. Success... Somewhat.
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Last edited by Rustbucket; 05-07-2016 at 09:10 AM..
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Old 05-06-2016, 05:56 PM   #5
Rustbucket
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Default Re: New old scout 800 project

I also got addicted to painting things if I removed them. So I can avoid doing it later. I ordered a rebuild kit for the carb. I rebuilt the carb, these are the results after I soda blasted it, carefully taped, aluminum primered it, then painted it with rustoleum bed liner. I am beginning to like it. I painted my steering box, crossover steering, and front frame horns with it. I really liked how it turned out.
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Last edited by Rustbucket; 05-07-2016 at 09:11 AM..
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Old 05-06-2016, 06:30 PM   #6
Rustbucket
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Default Re: New old scout 800 project

The first photos are not real good, but you can see the floor as I bought it. It was amateur and horrible. Different thickness metals, some arc welded, some brazed, some mig welded... It had to go. I spent a lot of time cutting carefully and grinding away old welds to reveal original paneling (in horrible shape) that I could use as a guide for new stuff. You can see my new body mount channel. It 11g. I have seen on really well preserved scouts how they have the x cross brace on the floors. I wanted to repeat that. I don't want any oil canning. This is my progress to date.

This is where it gets tricky.

I have a new urethane body mount kit of the Scout.

I have read all over the place the problems people have with hanging doors after doing floors and kick panels and rockers. Mine were already shot to the point that welding a bar to hold it in place would resulted in a larger problem.

So, I have to get the body mounts on the drivers side. The rear body mounts don't exist. There is just flat bar stop steel. (I feel this is a good time to reiterate the $100 price tag) I want to get the body mounts in. Every where I can. Tack the floors and rocker back temporarily. Hang the ds door/fender temporarily. Jack and adjust and tack as needed to get door on straight and body aligned correctly on frame.

This weekend I hope to finish fixing the tranny tunnel where it meets the ds floor. Then I will tack in my new front floor board temporarily. I want to measure and cut the floor board for the ds. Do the cross bracing on it similar to stock.

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Last edited by Robert Kenney; 05-07-2016 at 05:36 AM..
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Old 05-06-2016, 06:38 PM   #7
Rustbucket
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Default Re: New old scout 800 project

Also, how to I get the pictures into my post and not at the bottom?
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Old 05-07-2016, 05:41 AM   #8
Robert Kenney
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Default Re: New old scout 800 project

I did the one above for you.
Pick the post you want to change and click edit. Then find your way to the dialogue in the photo I posted. Place your curser below the last line of typed test so the pictures are inserted at the end and click "insert all"
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People preach " Don't over think life, just go where it takes you". But I can't help but think of the Wise Ancient Mariner who looks toward the horizon for any sign of storm clouds.
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Old 05-07-2016, 09:12 AM   #9
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Default Re: New old scout 800 project

Thank you Robert! That worked great!
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Old 05-07-2016, 11:01 AM   #10
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Default Re: New old scout 800 project

Hey rb, I know the Scout gods are smiling about now. Bringing one so infested with rust back to life, is no small miracle.
good work!
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Old 05-13-2016, 04:58 PM   #11
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Default Re: New old scout 800 project

I have made a little progress. It is slow going with an 8 y/o and a 7 mos/o baby. I got some more rust cut out and new metal welded in place. I have a little bit more to do before I am ready to install the floor. I bough some 14g sheet metal. I did not realize how thick the old floors were until I started cutting them back to good metal! I still have to cut out 4 inches from my bulk head behind the drivers seat, but at least my body mount is still attached and the frame mount for the body mount is not twisted or racked like most of the scouts I see on these forums. Odd, how mine is swiss cheese with rust, but the body mounts are just fine.
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Old 05-17-2016, 02:37 AM   #12
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Default Re: New old scout 800 project

Here are a few more pictures of picking away at the rust around the ds floor. I can say 3 sides done now. I just have to work on the inner rocker and back corner. I will hopefully get to it this weekend. I replaced the body mounts behind the driver and passenger. The picture with the square metal plate is what the prior owner used as body bushings. You can see the rings are all thats left of the original body bushings.
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Old 05-22-2016, 04:07 PM   #13
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Default Re: New old scout 800 project

I made more progress. I burned in the bulkhead behind the drivers seat. I firmly mounted the body mount to the bulkhead as well. I made a small piece to run between the inner rocker panel and the rear bulkhead. I created a raised lip on my inner rocker panels so everything would list flat. I also finally burned in my kick panel that I made. I have been measuring the door and the opening and I am right on so far for the opening. The pictures tell the story so far.
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Old 06-06-2016, 10:06 AM   #14
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Default Re: New old scout 800 project

Its been a week or two since I replied. I have been working on the Scout, but I kind of side tracked to some other problems while I had the floor out. I pulled the t90 tranny and Dana 20 transfer case. My transmission would not shift into gear. I pulled the cover and found that it was full of water and condensation had caused rust on the shifter rails to lock them up. I tore the transmission down and the shift assembly apart. I also received my cj5 gas tank so I thought I would start on the fuel lines and brake lines. And since that wasn't enough, I thought, well, I should paint the transmission case and transfer case while I have them out and the cross members. I am currently still cleaning the transfer case. It is not ready for its photo shoot yet. I welded in the rocker panel, but I have not taken pictures yet. I am working on fixing the door jam that the hinges mount too and working on the removable door hinges. Here are some pictures, but not all of my progress. I also ordered the small parts kit for the t90 and the gasket kit as well. When they arrive I will post the tranny rebuild too.
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This is some rusted metal that I cut out and replaced. I have to get a hole cutter to cut the holes and I have to stop when my 8 month old is napping. My wife gets really upset when I wake her up with the grinding and cutting. (that is also why I am painting things, I can clean/degrease things quietly)

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Old 06-30-2016, 08:32 AM   #15
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Default Re: New old scout 800 project

I haven't posted in a couple of weeks. I have been working on the Scout, I just did not photo too many things. So, I pulled the bell housing, clutch, and fly wheel. I replaced the rear main seal and the freeze plug with a brass one. I also replaced a gasket on the transfer case pan, mated the transfer case to the transmission, mocked up the fuel tank for a hot second, and then proceeded to thrash on my wife's 1991 land cruiser (brakes, shocks, speedo cable, sway bar bushings, fuel press reg, etc...). I did not take too many new photos, but here are some of them to ponder.....

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