The "Re-Roll" Build

[71mtnscout]

Worked on the p/u top again today, I guess I should measure 4 times and cut once.....lol. I was 3/8" short on the top of the roof so I had to improvise, I welded the piece I cut off of the front section back on. After that I cut a notch in it the 2 pieces from the bottom and sawed them out. By having to do this the 2 pieces didn't match up well, the rear section sat 1/8-3/16 below the front section of the roof, if I had cut it correctly the first time I don't think it would have been an issue. Then I had to do a relief cut to the back corners so that I could get the top edges to line up. Got most of it welded together till the wind got to heavy to weld in. I'm by no means a body man, and this will never be a show truck, but.....the top will serve its purpose by keeping me dry and somewhat warm when it needs to.

Its getting closer.

the stitching

the reason for the relief cut

the end of the progress, called, due to wind....I miss a garage!

 

[RMScout]

Clean work. Keep plugging away, you get there.

 

[71mtnscout]

Thanks.......slow and steady.

 

[PaulG]

Looking forward to seeing how the p/u top conversion works out! It's looking good. I'd like to tackle the same project. It looks like you started with a full top, ten cut it down to the size you wanted. Really like the idea of moving the bulkhead back. Would like to see what you do with the sides where the gas tanks are located.
A sliding rear window May be cool to.
Keep up the good work.

 

[71mtnscout]

looking forward to seeing how the p/u top conversion works out! It's looking good. I'd like to tackle the same project. It looks like you started with a full top, ten cut it down to the size you wanted. Really like the idea of moving the bulkhead back. Would like to see what you do with the sides where the gas tanks are located.
A sliding rear window May be cool to.
Keep up the good work.

Yup it was a full top off of an 800B I found in the local jy. If I were to do it again I would add a few more inches to it. I'm going to cut the "step" out of the new claimed space to open up the area more, mine doesn't have the stock fuel tanks so its open behind it.

 

[PaulG]

Yours looks great! I like the thought of an extra few inches and May try that. Saw this Jeep 1/2 cab and May use it as the model. Could retain the 800 full cab window (reduce the length). Our 800's bed will not be that big but for me it's just to throw misc. Stuff back there. Although - I have to find a 800 full cab first.

 

[71mtnscout]

Franken-stitched the rest of the top together today. Its now ready to come off for some final welding and alot of grinding.

Next...........the bulkhead!

 

[71mtnscout]

yours looks great! I like the thought of an extra few inches and May try that. Saw this Jeep 1/2 cab and May use it as the model. Could retain the 800 full cab window (reduce the length). Our 800's bed will not be that big but for me it's just to throw misc. Stuff back there. Although - I have to find a 800 full cab first.
View attachment 27163

Thought about something like that........but not for a trail beater.

 

[71mtnscout]

For the most part the grinding is done...it isn't pretty, and will require some filler to look decent. I did learn a lot about sheet metal though, and I know in the future where to cut and not to cut a full top down to an extended p/u top........lol

 

[71mtnscout]

No real work today, I need to pickup some body filler for the top. I have decided to use paintable bedliner on the inside and out to deaden the "can" sound of the top and it will be white. Something I did address was the seating position. While on my extended test drive the other day it felt like I was sitting to low in the cab, I also found that the Chevy truck bench did not adjust as it was intended. I ended up making a 3/4" spacer under the stock Chevy mounts and that put me in the upper 3rd of the windshield, a much better sitting position. I also reinforced the bolting area with fender washers to spread the load and grade 8 hardware, oh yeah the seat adjusts like it was designed now too.

For those looking for an alternative seat for there 80/800 the 88-95 Chevy truck bench is almost a bolt in deal using the stock Chevy mounts. You need to remove the stock seat mounts and have a flat floor to start, and it needs to be spaced up 3/4-1". Those year Chevy's came with a standard bench, an armrest in the center, and a 60/40 bench with a drivers bucket, and they fit very well. Mine is a little ratty but covers are available and cheap.

 

[71mtnscout]

My hatch cover came in today, its a boat hatch and is rated to walk on, just didn't want an open hole in the bed so.............. I also found out that this filler doesn't work very well, a bunch of dirt and whatever end up in the crack of the lid, then falls into the fuel tank when you open it. So I will be changing it over to a raised filler and add a vent to it.

 

[71mtnscout]

It's been awhile since I've done any work on beater, been working on other vehicles getting them ready to sell to make more room and fund other projects. So today I cut out the step behind the seat to add more room in the cab. I have found a set of fuel tank access panels and will be installing and sealing them so that water cant get in to the area from there, I will also weld up all the holes that are in the bottom plate for the same reason. At this point I haven't decided what I'm going to do with the fuel tank area that I've opened up.....make some kind of doors and use it for lockable storage or just leave it open. Either way it made it so I can move the seat back another 2 inches and be able to recline the seats for comfort. I picked up a set of Nissan maxima bucket seats for cheap that I will be mounting to the bench seat base that's in it now


a little more room

useable storage

the new seats

 

[71mtnscout]

Not been playin with beater for a while.............will get back on her this week. Got some parts and seats to do, along with finishing the top. Got a bit side tracked with a new toy;

I've decided to take it back to close to stock..............this is gunna be fun!! And beater will be my foul weather vehicle.

 

[71mtnscout]

It seems like forever since I posted or did anything to beater....I got side tracked when I bought this....

And redid it. Its not really done yet, but is a good driver for now and I will be amassing parts for the next phase.

So with that done for now I will get back on the scouts return to glorious dd status!

 

[punjig]

I guess somehow I missed the update back in June. I love the top and I love the extra storage idea. I can't wait to see more progress.

the little honda bike is awesome. It looks like you got that bike lookin' brand new. Cool, cool!!!

 

[71mtnscout]

Thanks punjig, its a 25 footer, but will be done eventually. :d

 

[71mtnscout]

Soooo beater is going down a different road. I have decided to make a hotrod with a twist Out of it. Going to do a modern 4" drop axle on the front with a disc brake system, and still run the d44 in the rear. I'm going to keep the 196 and have located a t19 2wd trans to replace the stock t90/d18, I have a new sii 196 clutch/flywheel/pressure plate that I've been carrying around for a few years..........I knew I would have a use for it someday!

Stay tuned.................

 

[71mtnscout]

So I finally got around to getting some more work done on the Scout. Pulled the top off and made a filler panel and franken welded it in for the storage door over the passenger fuel tank. Also installed the access panels for the fuel tank areas in the wheel wells. Tomorrow I will start framing in the bulkhead, might even get the partition made.

 

[71mtnscout]

I finished off the door fill and got most of the framework done and welded before I ran out of wire for the mig. I've also mostly fitted the center section for the bulkhead pieces. I still have to do a little trimming on it and fit the side pieces before final welding and sealing.

There is alot of holes that need to be welded up!!!

 

[71mtnscout]

So I picked up some more mig wire and finished the frame and finished the sheet metal work and welded in the sections of the bulkhead. I know, I know its overkill, but it will never come back out.

Need to do some finish grinding and fill more holes before the bed liner spray.

 

[71mtnscout]

For those who were wondering why I went through all this to move the bulkhead on my little s80.....here is the payoff.

seat position before

seat position after

A gain of 4" of legroom..........priceless!

 

[71mtnscout]

Today I finished the metal work for the bulkhead. Added another square tube at the top and fabbed a cap for it to mimic the bed rail. All that's left is to finish dressing the welds, scuff, and paint. 1 task is almost done!

 

[71mtnscout]

I will be going to check out a 2wd t90 I found, should bolt right in, and most likely get it. He was pretty honest about condition and sent a bunch of pics for me to look at. I started the fix for the front top mounts, 90% of the holes are stripped, so I've been using rivnuts for the job. Didn't want to spend the $$$ for the gun so I made a tool to do it with what was around. A vw body washer, an oversized nut, 2 washers, and a c clamp to keep the wrench in place while using the breaker bar.

 

[71mtnscout]

Today I picked up the t90 2wd trans with belhousing. It looks really good inside and shifts and spins in all gears. There is some light surface rust on a few gears, but I will be doing a total inspection, cleaning, and replace the gaskets. I will replace anything that is needed. I need to find a number on the output seal and find a yoke, so I have time on my side.

 

[71mtnscout]

I got the part#'s that I needed and the seal and yoke are on the way. Today worked out pretty good, I got the new engine/trans mounts and the reseal kit for the trans form the big brown truck. I also closed a deal on a set of axles from a 95 zj 2wd, 4 wheel disc brakes, 3.73 limited slip, all the brakes hoses and cables. He May even have a power steering box that will work, but I think the one that works is a later years box. Should be picking up the axles this week and will start putting the trans back together with the new seals and gaskets. Next step.....prepping the axles.