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Old 12-27-2012, 02:04 PM   #1
ihpartsjeff
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Default Jim's 1968 Scout 800

This build originally started as a mild drivetrain update to a 1962 Scout 80 to make it more suitable as a daily driver. The original plan was for our customer jim to bring up his already purchased Scout to our shop for a install of a set of modern axles he had purchased from a private party, swap out the 152 4cyl/3speed for a GM 4.3 v6 and 700r4 auto transmission and change out the Dana 18 transfer case for a Dana 300. For suspension a custom variation of our CPT Scout 80/800 suspension kits for some lift and a CPT reverse shackle kit for a smoother ride. While here jim also wanted a custom seatbelt bar fabricated for his half-cab so that shoulder belts could be used. To make things easier to stop and steer a Scout II power steering box and custom hydroboost. And last a modern update to the gauge package and rewire the electrical system.

After the plan was finalized and a date scheduled jim brought up his Scout for us to begin work on it. Upon inspection of his Scout we found that it had a bent frame due to a previous auto accident and severe enough damage to the body itself(the driver door no longer closed properly, major inner fender damage, etc) was enough reason for us to recommend to not build up this Scout. Jim agreed so the search was on for a better Scout to start the project out with.



After checking around for several weeks(and picking up a few parts rigs along the way) we came upon this 1968 Scout 800 that had spent most of its life on a ranch and only had 19000 original miles. The body was in decent shape and overall was a real good Scout to start the build on.




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Old 12-27-2012, 02:25 PM   #2
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Default Re: Jim's 1968 Scout 800

Tear-down of the donor Scout began immediately.





We believe this is to be the original distributor cap as the odometer only showed 19000 miles.



With the bulk of the parts that we we're not going to use discarded and out of the way we were ready to begin the build up.



All brackets and such were cut off the frame that we were not going to be reusing.





The body was moved out back while work on the chassis began.



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Old 12-27-2012, 02:57 PM   #3
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Default Re: Jim's 1968 Scout 800

We started out with three main components - a GM 4.3 v6 longblock, a B&M GM 700r4 transmission and a Jeep version of the Dana 300.



We ordered up an older version of the 4.3 with a mild cam and provisions for a mechanical fuel pump since we were going with a carburetor.



The 4.3 was dressed up with a set of shorty headers, edelbrock intake manifold and a Holley 390cfm 4bbl carb. Advanced adapters motor mounts were used for engine mounting.



A whole slew of parts was gathered up including new leafsprings for front and rear and a CPT reverse shackle kit.



The frame itself was going to need the front crossmember relocated forward so as to give the v6 engine room to fit nicely in the engine compartment.





With the frame back in the shop mock-up of the suspension began.



CPT Scout 80/800 springs from our suspension system were used in the rear of the Scout.



For the front suspension we used some Rough Country 2.5" lift Scout II front springs with a couple of the leafs removed since the GM v6 weighs considerably less than a IH v8 engine.



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Last edited by ihpartsjeff; 12-28-2012 at 11:00 AM..
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Old 12-27-2012, 03:12 PM   #4
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Default Re: Jim's 1968 Scout 800

With the mockup of the basic suspension complete we brought the body back in and removed the front fenders and grill.



Next the front radiator core support was carefully cut out.





Once complete the front support will be moved forward and reattached.



The body was then lowered back onto the rolling chassis.



The engine and transmission combination was readied for install.









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Old 12-27-2012, 03:45 PM   #5
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Default Re: Jim's 1968 Scout 800

With the engine located the front radiator core support is put back in place.



The radiator got installed next.



With the radiator installed the electric fan can then be fitted to check for overall fan clearance.



Next up the interior was going to get refinished so removal of the dash was needed. Upon removal we found some critter had made the Scout home.





Both michael and Darren spent several hours sanding the Scout's interior.





All surfaces that were sanded were then sprayed with a metal primer.





The inner fenders then got sprayed with rubberized undercoating.



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Last edited by ihpartsjeff; 12-28-2012 at 11:02 AM..
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Old 12-27-2012, 04:17 PM   #6
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Default Re: Jim's 1968 Scout 800

The interior was also sprayed with primer after being sanded down.



Taped and all ready to be sprayed with a few layers of liner.



We like to use a product called lizard skin. There are two formulas, one for sound deadening and the other is a ceramic coating. You don't have to apply both but we like to for the best results.



Here you can see Darren applying one of several coats of lizard skin.





Last a top coat of grey paint is applied for the best in uv protection.



The inside of the fenders also get the same royal treatment. Sanding, primer and then undercoating.





Next up was the install of an electric wiper system. All Scout 80 and 800's came with vacuum wipers so this is a huge improvement over stock.



With the dash reinstalled there is ample room for the electric wiper kit.



A new gauge package was also installed to check for fit.

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Old 12-27-2012, 04:40 PM   #7
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Default Re: Jim's 1968 Scout 800

The inside of the halfcab also received several layers of lizard skin.



Next up was dealing with the front shocks and steering.






To make room for a Scout II power steering box the front support had to be modified for extra clearance.



Same with the inner fender. Instead of leaving a gaping hole around the steering column Darren fabricated a nice cover to keep water and mud out of the engine compartment.



A set of bare wheels was installed to check for alignment and for tierod and draglink clearance.





One of the other upgrades jim wanted was a single fuel tank instead of the factory dual tanks that all Scout 80 and 800's had. For the filler it was decided to install it in the rear driver tail cap behind the license plate.



We used a 15 gallon fuel tank and mounted it in the rear of the Scout.



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Old 12-28-2012, 11:29 AM   #8
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Default Re: Jim's 1968 Scout 800

More mockup's of various components continued. Center console, seat brackets, shifters, etc.



A Scout II throttle pedal assembly was modified and installed.



A B&M megashifter was installed to go with the B&M 700r4 transmission.



At the time of this build it seemed to be Scout 80/800 season around here with all the builds!



A simple yet effective front bumper was fabricated for the Scout.







A hydraulic btl hood strut kit from Isa's IH was installed.



Since the Scout had power steering it was decided to go with hydroboost for a very effective braking system.

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Old 12-28-2012, 11:57 AM   #9
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Default Re: Jim's 1968 Scout 800

Darren fabricated a custom headbar that could also support the shoulder type seatbelts.





A multiple holed tab was made so that the overall height of the built could be adjusted if needed.




The stock Scout seat bases had to be modified in order to fit the corbeau seats. You can also see the other half of the seatbelt mounted to the floor.





The driver side seatbase was a little easier to modify due to the way its designed.



Darren fabricated a rear bumper to match the front.



A class 3 trailer hitch was incorporated into the rear bumper.





2" square 1/4" walled steel was mounted deep inside the frame rails for the ultimate in strength.

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Old 12-28-2012, 12:18 PM   #10
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Default Re: Jim's 1968 Scout 800

Back to the shoulder bar with the halfcab removed you can see the additional mount to the bulkhead.







With the bulk of the fabrication done the body was removed one last time to finish up a few things on the chassis and get under the body to wash and undercoat it.









With that complete the Scout was loaded onto a trailer.



And hauled off for a fresh coat of paint.

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Old 12-28-2012, 12:41 PM   #11
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Default Re: Jim's 1968 Scout 800

A short time later the Scout was back from paint.



Wiring was next on the Scout.





At this point lots of little things were being performed on the Scout.





The license plate bracket was a flip design that allowed access to the fuel tank filler.



With the front bumper powdercoated and installed with the hella lights things were really starting to come together.



The overall stance of the Scout looked real good with the new wheels and tires.





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Old 12-28-2012, 12:54 PM   #12
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Default Re: Jim's 1968 Scout 800

First look with the Scout sporting its freshly painted halfcab.



Another view from up above. You can see the guys behind the Scout discussing the tire rack.



With hydroboost for brakes and a remote reservoir for the power steering pump there were quite a few hoses to make for this project.



To keep the hoses from getting baked by the exhaust Darren took the time to fabricate a heat shield.





Wiring, speedo cable, shifters, etc were finished up underneath.





With the shoulder bar freshly powder coated it was installed for the last time.



Speakers were installed into the doors as part of the sound system.



In the midst of stereo equipment being wired up and installed.



For the coldest of days seat heaters were installed and wired into the electrical system.

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Old 12-28-2012, 01:10 PM   #13
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Default Re: Jim's 1968 Scout 800

The next few pictures show how the undercarriage came out once everything was installed.













Some final detail work was performed to give the paint its final polish and a protective wax coating.



Another up above picture of what was in the shop that day.



More wiring of the dash was yet to be completed.



A custom switch panel box was fabricated for the seat heater switch's.



Chad seen buttoning up the transmission shifter.



For easy access the stereo is mounted inside the center console.

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Old 12-28-2012, 01:26 PM   #14
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Default Re: Jim's 1968 Scout 800

Stereo installed.



The gauge panel had a decent length pigtail made for easy access to behind the dash.



And with that jim's Scout was complete. Obviously there were countless hours of work performed that we did not show you but this hopefully gives you an inside look into what it takes to build a custom Scout.























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Old 01-07-2013, 02:21 PM   #15
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Default Re: Jim's 1968 Scout 800

Great looking truck guys! I know its not IH, (or Ford) but I love the modern engine in the truck. What a great way to have a "brand new" 40+ y/o truck. The yellow looks great on this body style!

I do not like diesels, but I have been driving a tata pick up truck with a plucky little diesel in it and have been dreaming about putting one in an 80/800. I'm sure there is a better small diesel engine (Nissan perhaps in keeping with history) that would be better then whoever makes the tata (india it think?)

what do think Jeff? Someone out there must want a modern diesel Scout...
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