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Thread: Scout

  1. #21
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    Default Re: Scout

    This is probably the most interesting thing I've every followed on the webs.
     

  2. #22
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    Default Re: Scout

    I'm wondering just how much better than new this Scout will be.
    Dan Fuller, local bicycle enthusiast

  3. #23
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    Default Re: Scout

    Tub flip weekend!

    We used the tractor on one end and the engine hoist on the other and me in the middle.

    IMG_2620.JPG

    We set it down on a rolling table we made last week - a buddy dropped off a bunch of steel box tube he cleaned out of his Mom's place - perfectly timed!

    IMG_2622.jpg

    Here we can see the last of the undercoat and leaky engine/tranny goop. That's about all of the original tub metal left on this thing:

    IMG_2623.JPG

    After some scraping, and then a liberal application of Easy Off oven cleaner and then some more hand cleaning we end up with:

    IMG_2628.JPG

    So now we finish up the welding that we left for "when we flip the tub over" because we didn't go crazy with the overhead welding. Then some more roughing up and then some paint. Meanwhile, now that the chassis and tub are divorced we will turn some attention to the chassis. Also, the boy removed all of the accessories off of the engine in advance of the big clean and painting on that. Things moving along, for sure.

    This has distrated me from cyclocross this year, but after 40 years I've come to know that sometimes I get distracted from cycling and that's ok. Plus our main family catalyst to go to the races is now a freshman at UVM, and really enjoying that. And a proud dad plug: she got selected for the UVM collegiate MTB nationals team. Largely because she went straight to racing with the "A" women and has held her own and she is good at both XC and gravity.

    Thanks for looking! Bob
    Bob Spooner
    Departing from
    East Hampton, CT

  4. #24
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    Default Re: Scout

    Dang good report all around congratulations.

  5. #25
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    Default Re: Scout

    Cleaning, cleaning, cleaning and painting. Not my favorite part of the project. It does make progress more visible. We could work on the tub structure for a couple of weeks and no one but me and Finn could tell that we did anything at all. A few hours of painting and even Mom can see there is progress being made.

    We scrubbed the chassis inside and out. Found and repaired a few cracks and installed some "fangs" on the front which will allow us to put the shackles on the rear of the front springs were they should have been all along. Aside from the cracks and one gaping hole where a shackle hanger had been torn off and re-welded the frame is in good shape.

    Cleaning out the frame:

    IMG_2634.JPG

    Attaching the fangs. We used the TIG as a root pass, so that we could be sure the fangs were fused right to the frame. And then we used the MIG to do a final fill pass. The boy appreciated the heavy metal and just being able to set the TIG to "stun" and make the dimes with the filler instead of the foot pedal.

    IMG_2638.JPG

    All cleaned and ready for paint:

    IMG_2644.JPG

    Painted. So to get to black we painted the inside of the frame with a rust converter paint. We will see how that works - but every little bit helps. When we get the Scout fully assembled we will squirt fluid film into every crack and crevasse we can and that will keep the rust in check. Anyway, green inner-frame paint. Then an Eastwood rust prevention epoxy. Then a chassis black paint. We still have another coat to do on this side, and then flip the chassis for a couple coats on the bottom:

    IMG_2649.JPG

    Meanwhile we did about the same on the tub. Wire wheeling, scrapping, sanding, cleaning, etc. Then the Eastwood stuff. Then we mixed up some DIY lizard skin: we mixed in ceramic mirco ballons in rustoleum satin black. The ceramic balls are used to create an insulating paint. The rustoleum seems pretty low tech, but the real lizard skin uses water-based paint, so it can't be too bad. We painted the whole firewall and the bottom of the tub. It went on easy with a normal spray gu and left a very nice texture - like 160 grit sandpaper. Hopefully it holds up - and keeps the floor cooler.

    IMG_2650.JPG

    A closer look at the texture:

    IMG_2651.JPG

    Fianlly, Finn has the engine torn down and we are waiting on a full seal kit. Might as well replace them all while we are here. Then we will paint the engine,etc. We are coming to the end of the nasty dirty work. We should have our axles done soon, engine/tranny/transfer case done and we can start to put things together. Hoping for another couple of days of warm weather so we can flip the tub back over and weld the rear quarters on and get a coat of epoxy primer on it before the cold sets in.

    Thanks for looking! B&F
    Bob Spooner
    Departing from
    East Hampton, CT

  6. #26
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    Default Re: Scout

    Took advantage of a warm Saturday to stick some roadkill (sound damping sheet) on the bottom of the tub before we flip it back over.

    IMG_2655.JPG

    Then we flipped the tub right-side-up and spent some time hanging plastic sheet to make a DIY paint booth - and also a smaller area we can keep warm as the weather gets cold. It would have been nice to have the tub in epoxy while the weather was still warm, but it is what it is.

    IMG_2657.JPG

    Those front fenders had been hiding behind our pile of doors and we had forgotten just how chewed up they were. The fender lips are basically gone, along with the rockers. The rockers will fix easy enough, but the fender lips will be finicky work. Makes us think that Bushwacker flares might be in our future - we will see how nicely we can repair the fenders.

    Next up, hanging the rear quarters on the tub and prepping everything for epoxy. Also, springs/axles/etc on the chassis and rebuilding the engine. Good day - B&F
    Bob Spooner
    Departing from
    East Hampton, CT

  7. #27
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    Default Re: Scout

    Finishing the tub structure and getting it ready for primer. This past weekend, we finally got the rear quarters finished off - lots of tapping with wierd hammers to get our patches fair with the rest of the panel. Trying to keep the amount of bondo this Scout will have to a minimum.

    Checking final fitup - some tweaks to the wheel wells and such. Final sanding/cleaning of areas that will be welded:

    IMG_2669.JPG

    We used 3M panel adhesive on the wheel well/fender lip join and that seems to have worked great. We changed the design of the bed top rails when we made our bedsides. The original design had a trough on the top and a seperate piece of trim was inserted into the trough to create a flat spot for the top to land. The trough was really a result of a spot-weld seam across the top of the bed. As we are TIG welding the quarters on, we didn't need this seam and we could make the top flat. Six lengths of 030 TIG wire and the quarters were welded on. Tricky welding because the flange on the top of the quarter was very thin in spots. But sharp eyes and good coordination make it work:

    IMG_2671.JPG

    This is what the top rail looks like. We installed weld nuts on the top rail in the stock locations. If our measurements were correct then a hard top should bolt right up. We do not plan to ever run a full hardtop, but maybe someone will.

    IMG_2673.JPGIMG_2674.JPG

    Fiannly, I took the day off yesterday and just buckled down the the sanders and got it done:

    IMG_2680.JPGIMG_2681.JPG

    So now the tub is just about ready for epoxy. A quick rub down with etching sauce and then a clean off with acetone. Then we will lay some rust encapsulator on the areas that have and rust remaining - which is only where the remining parts of the tunnel are towards the front. Then we will spray on the epoxy. Then the tub will sit until we install it on the chassis. Final tub finishing - sanding/filling/blocking/paint - will wait until the weather warms back up next year. Meanwhile our attention turns to the chassis/engine/drivetrain. Looking forward to the change. The fabrication has been fun, but putting stuff together and getting the computer to talk to the engine will be cool too. Although there still is plenty of things left to build: exhaust and gas tank will be next up. Thanks for looking! Bob & Finn
    Bob Spooner
    Departing from
    East Hampton, CT

  8. #28
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    Default Re: Scout

    Thanks so much for these pics as I am about 4 wks into a 12 wk shoulder rehab they are inspiring!
     

  9. #29
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    Default Re: Scout

    Quote Originally Posted by Clyde View Post
    Thanks so much for these pics as I am about 4 wks into a 12 wk shoulder rehab they are inspiring!
    Well, I'm glad we can provide some distraction! Good luck with the rehab! B
    Bob Spooner
    Departing from
    East Hampton, CT

  10. #30
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    Default Re: Scout

    Quick turn around - we pushed through final pre epoxy preps so that we could take advantage of a warm day. Epoxy went on yesterday. Now the tub will pretty much get set aside until we place it back on the chassis.

    IMG_2683.JPGIMG_2684.JPGIMG_2685.JPG

    Thanks for looking! B&F
    Bob Spooner
    Departing from
    East Hampton, CT

  11. #31
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    Default Re: Scout

    Meanwhile on the other side of the garage the chassis is all painted and we finished the axle rebuilding and got those hung:

    IMG_2688.JPG

    Next up we have the gas tank - we are building our own tank - the one that was in the Scout was bad. We wanted a little more fuel than the stock ~15 gallons, and we wanted to mount the tank to the chassis. We also did not want to spend $700 on an aftermarket 30 gallon tank. Finally we we needed a tank that was 10" deep and would allow us to use a stock jeep fuel pump/level sending unit. That would just keep things simpler. So, we drew something up and went to the metal store. $100 and we have all the metal we need for the tank. We brought the big sheet to my place of work after dinner one night to use the big brake:

    IMG_2690.JPG

    Here is a view of the interior of the tank showing the baffles - the pump will go in the right front corner:

    IMG_2697.JPG

    I have to show off this weld. The boy is getting tons of practice - with just about everything but especially his welding - on this project and I can see his skills improve constantly. It really is cool - and I'm grateful for this time with him. This weld is a series of linked 1" tacks. We left the sides proud for the weld, and will trim them down later. We are cutting all this sheet metal by hand and wanted to give us some margin for error:

    IMG_2695.JPG

    Finally, we have started to re-assemble the engine. I think I mentioned above that we are using a 2004 jeep 4.0 engine because it was a much cheaper way to get modern fuel management as compared to installing injection on our old 258. The modern 4.0 shares the block with the 258 and it's not a huge change - except it has 50% more HP than the stock 258. Anyway, we disassembled the engine to check everything out and repace all of the seals and timing gears/chain while we were in there. We got the head pressure checked (some of these heads had a tendency to crack depending on their date of manufacture. Ours was good. We had the sealing surface decked (very slightly) and the valves and valve seats ground and the whole think hot dipped. It's better than new now. Here's Finn trying out his new birthday present:

    IMG_2698.JPG

    Every 15 y/o asks for a torque wrench for his birthday, right?

    Anyway, that's where we are at - feels like we are actually assembling things and boy is it sweet to work on clean stuff! Good day - Bob & Finn
    Bob Spooner
    Departing from
    East Hampton, CT

  12. #32
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    Default Re: Scout

    This thread is amazing. Love it.
     

  13. #33
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    Default Re: Scout

    ^^^^ yes. Thank you, and thank Finn, for sharing!
     

  14. #34
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    Default Re: Scout

    Quote Originally Posted by caleb View Post
    This thread is amazing. Love it.
    Yeah...best thread going right now.
    "I guess you're some weird relic of an obsolete age." - davids

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