The "Re-Roll" Build

[71mtnscout]

The fuel cell is now dry. With that being done I cleaned all the sand, dirt, and left over plastic shavings that was inside the tank. I also readjusted the float level so that it reads truer than it did and started designing the mounting system. I will make a frame that the top will bolt to out of 1.5" angle iron which will be welded to the frame behind the rear axle and will have 2 1" support straps going under the tank to the angle iron structure to help support the weight of the tank. I will be designing the filler assembly in the next few days along with a new fuel pickup......that's all for now.

 

[71mtnscout]

So I've been working on moving the fuel cell to under the bed, behind the axle. I've built the support structure to hang it from the frame using 1/8" x 1.5" angle iron that I had laying around, along with 1/8" x 1.25" straps to help distribute the weight of the 19 gallon tank. Since its a rectangle it hangs a bit low in the back and will require a skid plate to be fabbed to protect it from getting crushed. It will be bolted to 1/8" x 1.5" x 13" angle iron brackets that will be welded to the inside of the frame. I added a few more bolts for the mounting on the support structure and used nylon locking nuts for all the hardware. Wont have pics of the final mounting till at least next week.....waiting for the filler cap to come in.

I was going to build a top fill plate and go with a remote filler, but decided to just add an access hole in the bed floor since its going to be a p/u anyhow. Also since there is a chance of roll-over I went to a flush, vented, dirt track filler with a roll-over flap, so that in the event it does go over it wont spill fuel. It wasn't cheap, but safety is more important.

For the fuel pickup I went with an old Ford diesel trick and did a 60* cut on the end of a hose that is just a tad longer than the height of the tank so that it doesn't move and will pickup fuel down to about 3/8". That should do well at using most of the fuel in the tank.

That's it for this installment.

 

[71mtnscout]

Surprise, surprise, parts came in today so I got back on it. I replaced all the gaskets for the filler and installed the new fill assembly. I also had to change the way I was going to mount the tank. Due to the size of the tank there wasn't really any room to get between it and the frame to mount it, along with there being any room to get to the top of the bracket. So I built a wing for lack of a better term that comes off the side and will be mounted to the bottom of the frame. The tank is just to big for the little Scout, the only way it would work is to mount it through the bed from the top and that aint gonna happen, its about 4 inches to deep in the rear. So in the future I will end up building one for it with a with a built in skid plate using 10 gauge steel for the bottom and half way up the sides to the mounts. The tank fits ok, but the rear needs to be at an angle for better departure clearance. A bit getto, but it will work for now and will make it a driver rather than a sitter and I now have the dimensions needed to build a tank .

I also started the custom p/u top that I have in mind.

 

[71mtnscout]

The fuel tank is done, mounted, plumbed, and wired! Took her out for a little run and all is good....at least for street use and forestry roads...lol. I guess I'm gunna have to make one. This tank is decent size wise, but its shaped wrong for a little 80. I can go 1"-1.5" wider and .5" taller, angle the rear bottom plate to about 30* to make the rear drop about 4.5"-5" total and that should be pretty good at not hitting with a SOA suspension. Just for good measure build most of it out of 1/8" (bottom and sides), buy a half sheet....$40.00....14ga top with all the plumbing and electrics for the fuel cell, I even have enough 16ga to make a few baffles in it. But for now, I have to finish cutting the top up for the p/u top, when that's done, start on the bulkhead.

One more baby step closer to daily driverish. Why cant I just win lotto........haha.

 

[71mtnscout]

No work at the shop today, so I tackled the p/u top today. The sides are burned together and its bolted down, I have to make a filler strip for the roof due to the interference of the brace that I didn't take into account. Shouldn't be a problem and I should get it done this weekend. I like the look and the added room behind the seat.

 

[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!!!