63' Scout 80

[ihpartsjeff]

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

 

[ihpartsjeff]

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.

 

[ihpartsjeff]

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.

 

[ihpartsjeff]

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).

 

[ihpartsjeff]

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.

 

[ihpartsjeff]

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.

 

[ihpartsjeff]

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

 

[ihpartsjeff]

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

 

[ihpartsjeff]

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

 

[ihpartsjeff]

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

 

[ihpartsjeff]

Bilstein shocks were mounted front and rear.

 

[ihpartsjeff]

The Scout nearing completion.

 

[ihpartsjeff]

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.

 

[shane]

I didnt catch what kind of wiring kit you used. Was it a premade kit?

 

[ihpartsjeff]

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.

 

[ihpartsjeff]

After two years this little Scout came back to us for some more upgrades. When it left it had a half cab top and since then the owner had a full travel top installed.

First up on the Scout was having a spray on liner applied to both the hard top and front cab area. We called in Brian at rockliner coatings and had him spray in a nice thick coat of vortex liner.

 

[ihpartsjeff]

A basic stereo and speakers were installed to make the long trips to death valley that Tom the owner plans a little more pleasurable.

Darren fabricated a custom fuel tank for the Scout that bolts in behind the rear axle.

Inside the tank a baffle was installed along with the lines for the fuel filler and vents.

So that the tank can properly ventilate without passing gas fumes a charcoal canister was installed under the quarter panel and a shield to keep dirt/rocks away was added. A custom fuel filler neck and main vent was fabricated next.

The fuel filler neck and vent line had to go thru the frame so a hole was bored and sleeved for both lines.

With the hole cut in the quarter panel for the fuel filler it actually looks nearly like a factory install.

 

[ihpartsjeff]

With mock up of the fuel tank complete it was removed and finish welded.

Once tested for leaks the tank was painted and reinstalled.

With the tank completed we moved next onto the steering. One day as we were moving the Scout around the yard under no power the lower steering column joint was trying to pop out of the lower 'bell joint'. As a major safety issue we decided to modify the steering column with a borgeson kit that we put together.

The outer steering column itself was cut down, sleeved and welded back together.

The inner column was cut down and a collar was machined to hold the lower bearing into place.

Next a 3/4" dd was machined into the shaft and a borgeson universal joint was installed.

 

[ihpartsjeff]

A steering wheel adapter and a smaller more stylish steering wheel was installed.

A firewall mount was purchased and slightly modified to hold the lower column in place.

With another borgeson steering joint on the steering box and a collapsible steering shaft the column was now complete.

With a set of bcb gas tank flanges we were able to install a matching pair of modern style gas caps.

 

[Michael Dimock]

Dang, nice to see an 80 build coming from you guys! This Scout is a nice one and I can see that someone keeps it on the road driving. love the original dash with all it's faded glory!